Volvo 850 Rear Door Replacement

[tailor]

VOLVO 850 REAR DOOR REPLACEMENT 1996 SEDAN TO 1994 WAGON

How to replace a door( in this case rear door, drivers side) in a 1994 850 Turbo Wagon
I was at the U-Pull yard today and good fortune was upon me as I found a 1996 850 sedan that was the same colour as mine and did not have the rust eating away at it, so I grabbed it and made off like man possessed.
There are, as always a couple of caveats, fistfuls of colourful language and the almost inevitable missing socket : (
The door is fairly heavy, it is manageable if you are a single operator, however I would recommend a two man job as the alignment is a little tricky and you do not want to damage the paint on either the door or the car.

Open door.
1)Locate the rubber covering the electrical connection and gently pull the rubber away from the body to expose the connector. There is a single pin that locks everything, depress and coax the two pieces apart.

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2)Find the door strap and remove the torx bolt.

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3) There are 4 bolts that hold the door in place, also two spacers/washers, one under each hinge, take note of the orientation. Break the bolts loose, with a 12mm ratchet, this is when you need help to hold or support the door, as you remove all the bolts.

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4)Installation: Support the door and connect the electrical connector and push it into the pillar. Push the excess wire into the pillar and re-attach the rubber to maintain the protective covering. Ensure you get all the wiring back into the pillar so nothing will be crimped when the door closes.
5)Align the hinges onto the door,put in washers, finger tighten the bolts. Align the door starp and put in the torx bolt.
6) This is when I closed the door and checked the alignment. Look for even space all round the door and for light between the rubber along the top of the door and body. If you see light the door needs to be closer to the body edge of the rubber. If you open the front door the bolts for the rear door are exposed. I had to do a little pulling and pushing and lifting to get the door to where I though it ought to be. Check that it opens and closes with ease. Tighten the bolts to specs.. Gut un tight, in my case.
The front doors will be pretty much the same with the exception of a different electrical connector that will have to be disconnected first .

[matthew1]

Tailor, almost missed this! Outstanding writeup, adding to Repair Database.

What part# is "Bag of Old Clothes"? I'll need to know for when I'm at the dealer parts window.

[tailor]

mostly size 40!

[theador]

Did you have a beautiful assistant to help you get the door back on, or can this be done alone?

[theador]

Ignore that, just read the first bit again... Duh.

[theador]

Haynes manual suggests using a trolley Jack to support the door.

[skloon]

If I told my wife I needed an old bag to work on the car I may go missing
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[boxpin]

I know this is like 6 years later but why didnt you just remove the two reverse torx screws on the hinge and lift the door off. No need to fiddle with the hinges.

[theador]

I know this is like 6 years later but why didnt you just remove the two reverse torx screws on the hinge and lift the door off. No need to fiddle with the hinges.

Yeah that's what I did on both the front and back doors

[MadeInJapan]

If I told my wife I needed an old bag to work on the car I may go missing
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You wife called!