First of all remove the speaker cover. Insert a flat screwdriver roughly where I have inserted the screw driver and genlty push the clip and lift the cover slightly while releasing the rest of the clips. Underneath the speaker cover there is one screw holding the door panel to the door, that needs to be undone
Remove carefully the trim near the mirror (yellow square). Remove the plastic covers (highlighted in the yellow circles) that are on top of the various screws. Unscrew the screws and take note of which one goes where. Not all are the same size
Remove the window/mirror control unit.You need to lift the rear part first and then pull it gently backwards.
Lift the window/mirror control unit from the panel and unplug the two plugs attached to it. To remove the door panel, pull the bottom part away (it is held by two or three clips) from the door about 30 degrees and then lift the whole thing upwards and it will just come off. This is what your door will look like wih no panel. Be very careful with the plastic mebrane (plastic sheet) as it can rip if too much force is used pulling it. THe membrane is attched to the door with some sticky stuff similar to blue tac but stickier. You can either undo it very slowly by pulling gently, or another way is to use a sharp stanley knife and cut the “blue tac” in half.
Undo that screw which secures the external door trim
Remove both internal and external door trims
Lower the window down until you can see the bolts through those two holes. The window is resting on that piece of metal so you can safely remove the two bolts lift window and navigate it out of the frame.
This is it…..
Follow the same instructions backwards to put everything back together.
This tutorial was contributed to www.volvohowto.com by it’s author “gatos”. Original posted in Volvo Owners Club Forum
The instructions in this tutorial will work in the following models / years:
– 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 and 2004 Volvo S40
– 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 and 2004 Volvo v40