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Foreword: most of the parts on Volvo are designed for easy assembly and made of inexpensive materials(plastic). However, to remove these parts sometimes causes the plastic parts to bend/stretch/break. Proceed with caution...

Tools Needed for panel: T25 Torx + one small and one large flat-head screwdriver, and plastic putty knife w/ V cut, or professional plastic weatherstrip tool (preferred).

Tools needed for weatherstrips: A very long(12+) and skinny flat-head screwdriver and some soap-water.

Tools needed for removing tint: Razorblade, Isopropyl alcohol(70-91%), terry cloths/towels.

Driver's sidel panel:

Pry off the door-trim piece, using your fingernail on bottom and a small flathead screwdriver from the top. (You must remove this before trying to pull out the keypad)


Pull it out straight towards the panel. If it gets stuck, push back in and try again. DO NOT FORCE IT, or you'll strip/break the plastic.


Next, take your large flat head (or your "proffessional plastic weatherstrip tool")and pry off the keypad. This is the tricky part b/c you could break the plastic clips that snap into panel, so BE CAREFUL. As you can see there's total of 6 clips.(5 on top and one below inside the handle well)



I like to start from this end since it only has single clip in the middle and therefore most likely to break.

You should hear a popping sound as the clips become undone, if it's not going out and making a creaking sound. That means one of the clips is coming out crooked, so you might want to push it back in and try again.


You want to aim in-between those two screws.


Next disconnect the keypad harness.

Press-in on the catch and pull straight out.

Next you want to remove 3 bolts that secure the door panel.

With this tool(T25 screwdriver)

Now comes the fun part

You need to pry off 8 plastic clips that secure the door panel without breaking them or stretching out the plastic on your panel. Here's a shot so you could get an idea where each clip is:

For this I use my plastic putty knife tool, but it doesn't work as well as it seems. You should really get a good plastic weatherstrip tool(the kind that looks like a breaker bar, but flatter and made of plastic) A large flatheaded screwdriver works also, but be careful not to scratch anything.

The putty knife doesn't get the clips undone completely. The best way is to pull one side with your hand, and pry on the other side of the clip w/putty knife.

Sometimes the clips just slide off and get stuck on the door.

This is where you could practice your putty-knife technique




After you get all of the clips un-done, push in the door lock pin...

and pull straight back

Just to give you a better idea how it's secured:
This clip....

... goes in this hole:

Next, undo the speaker clip...


Now you have to disconnect stuff...first would be the speaker cable(not shown). You could see where it connects on the right(that gray connector)

Disconnect the connector for the door lock switch...

... and undo the cable from the door handle.

Here's few pix of the front door speaker(premium sound)

You could see the 4 rivets that secure it.

Now, for the weatherstrips.
Start from the side by the mirror and pull straight up.



Now, to get the other one, you might want to roll down your window to about here. (You could plug in the keypad for the window)

as you can see, this side has a very long weatherstrip. This is where your long screwdriver comes in when you put it back.

Another tip, see that large rubber grommet/cover? You could use that to secure the weatherstrip all the way down. I just realized that myself, after I already installed the panels. Oh well, next time they're off again, I'll secure it better.

Next, is the outside weatherstrip. I usually start at this end(by the door handle), and gently push the weatherstip up. Once again, you don't want to force it or it'll break...


...this clip.

These are not all the weatherstrips, just the one's you need to remove to thoroughly clean your window.

Now, for the tint:
Take a brand new blade(don't want to scratch the window), and peel some of the tint.

I usually start from the middle, and then work my way around

You want it to come off in one piece(instead of a bunch of small pieces)

Next, roll up your window and finish pulling off the film.

You could tell that the tint is old and faded(see the puprle ?)

The reason I removed the weatherstrips/panel, is so I could thoroughly clean the glue from the windows. If you don't do this, chances are the window will have a hard time rolling up/down because of the glue sticking to the weatherstrip.

Here's some helpful tips:
Put some tape(electr./duct) on the screwdriver to avoid scratches.

Next time at the dealership, buy a few extra door clips. They break quite easily, and the last thing you want is to be missing a door clip.

Also, might want to pick up some new door handle trim pieces. They usually wear out after a while, and become loose and rattly.

If you door panel doesn't fit completely flush after you put it back, that means you bent/ stretched the panel during removal. Don't worry, you could take it off and use some weight to stretch it in the opposite direction. That happened to me once, and I thought I would need to buy a new panel. As a last resort, I took it off again and stretched it in the opposite direction, and it worked! The door panel fit flush again http://********************/smile/emthup.gif

Hope this helps someone.

Here's some other random pics.





very easy to put some led's in there





Modified by rushin_max at 9:20 PM 4-18-2008
 

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Re: How to remove front door panels/weatherstrips/tint... (rushin_max)

Wow...First off, that would suck not to be able to have window tint at all on the front windows! And http://********************/smile/emthup.gif to you for deciding to do this yourself! I would have just paid the 60 to get the tint removed at a professional place!
 

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Re: How to remove front door panels/weatherstrips/tint... (rushin_max)

Excellent photo documentation!
 

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Re: How to remove front door panels/weatherstrips/tint... (AutoGeek)

Without words it's like . . . interpretive dancing. I love it!
 

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Re: (chil943)

Quote, originally posted by chil943 »
Great write up, I would like to know how to take off the headlight lens!

Mao's did a writeup. Excellent job with him...
 

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Re: How to remove front door panels/weatherstrips/tint... (rushin_max)

I added this into the sticky thread. There's another one in there already, btw. We have a good library of it all now! Thanks.

Tom.
 

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Great write up

Hello,

This is a really great write, well done! I don't suppose you are going to do one for actually removing the dash itself ? as I am wanting to cutting a hole in the dash above where the central air vents are on the dash to route some cables through, so I would like to get an idea of how to remove the dash and also how much room there is underneath the dash on an '07 S40 facelift

Thanks
Guy
 

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These are not all the weatherstrips, just the one's you need to remove to thoroughly clean your window.


Where can i buy the outside weather strip replacements?
 

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As soon as I was done with the driver window I felt the urge to come back and thank you whoever you are rushin_max.

I'll get the other one done once it's cold enough. Mine had only 2 screws and there was nowhere else to drive a third screw, other than that it was pretty much the same as you described. Thank you so much.
 

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Great Thread, except photobucket, really sucks, I found most of the forum had all the pictures being outdated by Photobucket, which will not happen in google photos!
 

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For Tint removal... by far, the easiest way is to warm it with a heat gun. Just be careful not to get it or the surrounding plastic too hot. If you heat it and work slowly pull it off, all the glue will come off with the tint. You can tell when it is not warm enough because it will start leaving glue behind. Just dont try to rush it.
 
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