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

Trunk Lid or Liftgate

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REMOVAL & INSTALLATION



2 and 4-Door Models
  1. Open the trunk lid. Have a helper support the lid; remove the retaining clip for the gas shock (which holds the lid open) and disconnect it from the lid.
  2.  
  3. Detach any wiring to the trunk lid at the nearest connector. Make sure the wiring will not bind when the lid is removed.
  4.  
  5. Scribe marks around the hinges to facilitate trunk lid installation.
  6.  
  7. Remove the bolts which hold the hinges to the trunk lid and lift the lid clear of the vehicle.
  8.  

Trunk lids can be easily damaged; take great care not to bend or dimple the trunk lid. Store it on pads and cover it to protect it while off the vehicle.

To install:
  1. Place the lid into position and lightly tighten the bolts until snug.
  2.  
  3. Check the lid-to-body alignment and adjust the trunk lid as necessary.
  4.  
  5. Final-tighten the bolts.
  6.  
  7. Reattach the gas shock to the trunk lid and reconnect the wiring, if any.
  8.  

Wagon (5-Door Model)

Because of the size and weight of the liftgate, this procedure requires 2 people during removal and installation.

  1. Remove the inner cover panel on the liftgate.
  2.  
  3. Detach any electrical connectors within the liftgate. Tag or identify the connectors for ease of reassembly.
  4.  
  5. Pull the harness through the hole in the top of the liftgate.
  6.  
  7. While your helper supports the liftgate, disconnect the gas shock(s).
  8.  
  9. With the liftgate safely supported, remove the liftgate-to-hinge bolts on each side at the top. On the 740, one of the bolts is beneath a rubber plug which must be removed.
  10.  
  11. Remove the liftgate from the vehicle and store it on pads.
  12.  

To install:
  1. Place the liftgate into position and loosely tighten the bolts until snug.
  2.  
  3. Check the alignment of the liftgate in relation to the body, and adjust it as necessary.
  4.  
  5. When the alignment is correct, final-tighten the hinge bolts. Left-right alignment is critical. Take your time and work for an even fit.
  6.  
  7. Connect the gas shock(s) to the liftgate.
  8.  
  9. Feed the wire harness through the hole at the top of the liftgate and into position.
  10.  
  11. Connect the wires to the proper points.
  12.  

ALIGNMENT



All Models

Both trunk lids and wagon liftgates are adjustable on their hinges due to slotted holes. The trunk lids are also adjustable by loosening the hinge-to-body bolts and repositioning the hinge vertically.

Wagon liftgates have additional adjusters on the sides. Loosen their screws a few turns and close the liftgate. The adjuster should seek the correct position for smooth operation. Because of the curve of the body and roofline, the wagon liftgate needs to be checked carefully for alignment to the body. Seams should be straight and even, and panels should be flush with no obvious high or low points.

Final adjustments are made at the latch (on the lid) and the striker (on the body). Each can be loosened and moved on its mounts to control tightness and ease of operation. It is recommended to start by loosening the striker only; close the lid or liftgate and let the striker seek its position. Continue adjusting until the latch has no binding in its operation, the key turns freely and the weatherstrip is evenly compressed around the lid/liftgate.

 
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