Nasty door click when opening is (in order of ease and expense) 1)loose Torx fastener on limiter, 2)broken limiter which you can replace with a good used one or 3) and the most likely culprit, I fear, is limiter strap mount on the body is beginning to tear, and, as has been mentioned, will get worse and more expensive. Welding required. I get about $120 to repair at my indie Volvo shop.

A/C compressor job isn't awful, but will require time and patience. I replace just the clutches at the shop, but it may be easier to replace the whole thing for the DIYer. Essential "trick" to the job is unfastening the engine cradle/subframe at the corner (18mm headed bolt) and maybe the others to gain access. Lower bolts are no problem. Upper bolts also hold the alternator onto accessory bracket. So taking the alternator top bolt loose will help you maneuver. Good luck.

Hi Donny,

When you become sufficiently annoyed with the clunking door hinge, the fix is fairly simple.

If it is merely loose fasteners, have a look here:

http://volvospeed.com/Repair/hinge.php

If the door hinge is making grinding or popping noises, then have a look here:

http://au.geocities.com/ozbrick850/door-stay_fix.html#frank


And here is some forum discussion of this problem and how others dealt with it:

http://www.matthewsvolvosite.com/forums/viewtopic.php?p=26689#26689

As mentioned in the above forum, DO NOT let this problem go on for too long. If the hinge plate fails completely, you may be looking at a costly reweld, rather than a simple "drill and bolt" repair.

Good luck.

I hope you haven't started yet. Compressors normally don't go bad, just the clutch. The evaporator replacement is very lengthy, as the entire dash has to be removed - down to the firewall and the car will not be drivable during the process. Winter is coming, so you might want to wait until spring and look around on the web for lots of pics.
www.volvospeed.com and
www.matthewsvolvosite.com/index.php


The above are good sites to explore for pictures. For "normal" AC fixes, remember that local AC garages can also work on your car. Like professional shimming of the clutch, or replacing the receiver/dryer bottle which can get clogged from repeated charging.



There is also an easy fix for the compressor clutch using bread clips and a little glue on volvospeed. But that means the clutch gap is too large and once the engine gets warm, the compressor fails to engage. You have to figure out what your specific problems are.

The crunch door hinge is an easy fix if it is just a broken door stop strap:
http://volvospeed.com/Repair/850_door_hinge.html

A little harder if the connection to the A pillor has broken:
http://volvospeed.com/Repair/hinge.php
OR
http://au.geocities.com/ozbrick850/door-stay_fix.html

I hope the above supplies some good hints.

Klaus
--
Mistakes make us learn. Beer is for a job well done.