How To Replace Remove Front Door Panel 2003-12 Volvo XC90

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In this video, I'm going to show you how to remove and reinstall a front door panel on this 2004 Volvo XC 90, pretty much the same as any 2003 to 2012. Tools you'll need are a small flat blade screwdriver, a T25 Torx driver and a door panel clip tool or household putty knife.

Start out in this top corner. Just firmly grab it or use a screwdriver and pry it. It comes out. In behind here you have the upgraded stereo. There's a little speaker. Just press on the gray tab and disconnect. Then you're going to use a screwdriver again. Carefully go right under here and there are three tabs. It comes up and lifts up and out. There are two Torx screws right under here. These are T25s so I have a T25 Torx bit. You can use a screwdriver style or this style. It's a socket with a ratchet extension. I'm just going to speed up here while I take those two screws out.

You either want a door panel clip tool or a household putty knife. Either one works. Pull out on your door panel a little bit at the top, put your putty knife in, slide it down until you come to one of the clips, and then just give a good, quick pull. Go down further until you come to one of the clips. You just go right around. Also one good tug can actually bring it out.

Once you bring your door panel out a little bit, you have your door handle cable. You just kind of separate a couple of little clips and pull out on that a little bit. It comes right out. Then there are two connections. I'm not sure if you can see both of them. On this green one, there's buttons in behind. You just reach your finger right in behind, right in the center of this green one and it pulls out. There's the button right there. There's a gray one back here. Do the same thing. You just feel for the little button, push the button, and work the connector out. There's the connector, there's the button. Your door panel comes off.

To re-install your door panel is pretty easy. Just reconnect your harnesses, the green one and the gray one. Take your cable and put it in place. Just do a quick test. Watch the cable and make sure that the handle grabs it.

I'll put it back up in place. Make sure this wire comes up top. Put your lock through. Peek in behind. See the clip. Guide it on. I got that back one first. I'm going to check my front one here. Go right around. Here are my two T25 screws. I'm going to fast forward here as I put those two screws in and tighten them up nice and firm, and then also, you can't see it very well, but up top there I reconnect the speaker and the little upper triangle and snapped that back into place. Then this piece, you have to kind of push in and down and lock it in place in there. Then lock it on.

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