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Step #2. There is a ~2cm x ~2 cm tab in the center of the door panel, it has a slot about the size of a a small screwdriver on one edge. Pry it ouy. There is a TORX screw hidden below it. Unscrew this. If you do not, the door panel will break.
Step #1. First, go to your Volvo dealer and buy a handful of the white plastic bayonet fasteners that hold the door on. They are designed to be broken, rather than breaking the door panel. I think I broke about 4 or 5. That's OK as they only cost about $0.50 as opposed to the $400 that the door panel lists for. While you are there in the parts department, also look over the parts guy's shoulder and take a look at the exploded diagram of the door panel.
Step # 1.5. While you are at the dealer also pick up a replacement speaker.
Step #3. Pry the door panel loose. I think I used a couple of putty knives covered with masking tape. The triangular black plastic trim piece over the mirror mount also has to come off. This pulls out. The switches for the mirror controls, power locks, power windows, etc, all unplug. The panel mostly pulls out, but also must be pushed upwards to clear the window lip.
Do NOT try to pry out the speaker grill.
Do NOT ask me why I am SURE that trying to pry the grill out of the door panel is not a good idea.
Do NOT ask me how I know that the inner door panel lists for around $400.
Assembly is the reverse of above. No guarantees!
Good Luck!
-Bill the Cat
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