Tweeter Upgrade For 2005+ S40

Tools Needed:
Screwdriver




s40 volvo door
1. The first thing you need to do is to pull off the black plastic cover on the back of the door handles. They come off pretty easily. I used my fingernails. Pull away horizontally.
plastic door cover

door trim

remove trim
2. Place a flat head screwdriver like so and give a few quick sharp blows to release the clips. Work down the length of this panel.
release s40 door clips
3. The clips, in yellow, are located in 5 places on the rear door handle. Position the screwdriver accordingly.
yellow rear door clips
4. When the panel is released, look under it and disconnect the power window switch. You can set the panel aside.
s40 power window switch
5. You will need to loosen 2 torx screws in these two locations. I'm too lazy to photoshop in the arrows, but you can clearly see the two holes where the screws were.
loosen torx screws
6. This is the most tedious part of the operation - trying to get the panel fasteners to release. I use the same flat head screwdriver to pop the fasteners from the metal door panels. There are a bunch of them around the perimeter of the panel. Since I'm pretty skinny, I only had to release a few and was able to stick my arms into the space between the panel and the door. If you can't do that, then I suggest you remove the entire panel. You can see a fastener in the foreground (blurry) and the hole it had come out from. The fasteners along the top of the door panel are different and much easier to release. You can see 3 of them along the top of this picture.
loosen door fastners
7. Look inside the panel and remove the dummy tweeter bracket. Note the orientation as it will be exactly how you should install your new tweeters. Unplug them. This is the tweeter plug I have between my fingers.
tweeter bracket
8. The Dummy bracket and the actual tweeter.
tweeters
9. I also removed a piece of paper filter over the grilles as they may affect the acoustic transparency. I didn't want to remove my door panels again if they sound 'muddy'.
speaker cover
10. Install the tweeters and connect the wire.
wire speaker back up
11. Confirm that the door handle release cable had not detached itself from the door handle, otherwise you won't be able to open the back doors from the inside.
Door handle release
12. Make sure the door lock pins are through the holes on the panel first before you start banging. When properly installed, the door panel should only have a 2 mm gap, the doors should open from the inside and your lock pins are visible!
lock
13. Reseat the door panel by applying quick sharp blows (with your hand, don't use a hammer!) to the door trim at the location of the fasteners. They should all pop into place.

14. Reverse all the steps. Don't forget the torx screws.
Project S60
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