Help, help. My 1990 Volvo 240's driver-side door suffered metal fatigue at the bottom hinge and must be replaced. I've found replacement doors that are 1992 & 1993. Are the wiring harnesses the door and under the dash the same? Can I just cut the wiring at the door end, splice the new door wiring into the wires that come through the door, so I don't have to reconnect wires under the dash? Which years are not compatible?

 

I believe they are pretty much the same wiring for almost every car. I've pulled the doors apart on my '92 and '82 wagons when I had to put in some replacement speaker wires and then add back some stock speakers from a '91 sedan and '92 wagon. I've also added many stock parts and electronics from the 70's, 80's, and 90's 240s with out any modification at all. Anyway, they both had the same exact colored wiring/wires. If you're worried about the wiring that much, why not just take the panel off the door you're replacing and fish the wires back through the little rubber tubing that's between the door and the car, in the middle of both hinges. Install the new door, fish the wires back through, connect them to the power window switch, the speaker, and be done with it? No worries.

 

Yup...the only issue would be if you had power mirrors as those were only available pre 86 and 92 and 93 I believe. As suggested, the simplest course is to pry out the accordion rubber bellows from the old door, remove the power window connectors (yes they will fit one at a time), speaker wires and central door lock wiring. Install new door and shove the wiring back in. Tedious, a knuckle scraper but quite simple. A little liquid dish detergent lubes the rubber boot to re-insert it into the door port.

 

Thanks for assuring me of Volvo's conservative approach to wiring. Sure makes life easier!