Volvo 240/740/760/780/940/960 1990-1998

Doors

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REMOVAL & INSTALLATION



The doors are heavy! Provide proper support for the door when removing. Do not allow the door to sag while partially attached and do not subject the door to impact or twisting movements.

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect any wiring harnesses running into the door. This may be done either inside the door (remove the door panel) or under the dashboard, inside the pillar. Make sure the wiring harness will not catch or bind as the door is removed from the vehicle.
  4.  
  5. Scribe marks around the hinges to facilitate door installation.
  6.  
  7. Support the door with a jack. Place a piece of wood on the jack to protect the paintwork.
  8.  
  9. Have a helper support the door, then loosen and remove the hinge mounting bolts and remove the door from the vehicle.
  10.  

To install:
  1. With an assistant, position the door and install the hinge bolts. Do not fully tighten the hinge mounting bolts at this time.
  2.  
  3. Check the door for proper alignment. If required, loosen the mounting bolts just enough to allow the door to be moved into position.
  4.  
  5. Tighten all the hinge bolts and check the final fit.
  6.  
  7. If the door stop bracket was removed, reinstall it.
  8.  
  9. Connect the wiring harness and check the function of electrical components in the door. Install the door panel if removed.
  10.  
  11. Connect the negative battery cable.
  12.  

ADJUSTMENT



See Figure 1

The primary door adjustments are carried out at the hinge bolts at the forward end of each door. Further adjustment for the closed position and for latching smoothness may be made at the latch plate or striker. This piece is located at the rear edge of the door and is attached to the bodywork of the vehicle; it is the piece which the door engages when closed.

Although the striker or latchplate is different on various models, the adjustment procedure is the same:

  1. Adjust the position of the door by moving the striker plate sideways.
  2.  
  3. If further adjustments are necessary, first slacken the upper door hinge bolts, then, if necessary, the lower 2 bolts. Push the door toward the body.
  4.  

Never loosen more than 3 bolts at a time or the door may drop. Do not attempt to correct height variations (sag) by adjusting the striker.

  1. After the striker bolts have been tightened, open and close the door several times. Observe the motion of the door as it engages the striker; it should continue its straight-in motion and not deflect up or down as it hits the striker.
  2.  
  3. Check the feel of the latch during opening and closing. It must be smooth and linear, without any trace of grinding or binding during engagement and release.
  4.  

It may be necessary to repeat the striker adjustment procedure several times (and possibly adjust the hinges) before the proper door-to-body alignment is corrected.



Click image to see an enlarged view

Fig. Fig. 1: Door adjustment points on the front door-700 series models shown, others similar

 
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