New Exhaust installed on 1990 Volvo 240 wagon.

Here is my new exhaust from the cat converter back.

Door Handle Install on 1990 Volvo 240

Side view inside door. Interior side.

Inside door where handle screws on.

Door lock mechanism.

Door latch actuator rod.

Latch rod and spring.

Old Handle original.

Replaced door hinge and handle on Driver’s side. 1990 Volvo 240.

This past month I had the hinge area cleaned up and re-welded. A new door handle was also installed.
I lubed everything mechanical inside the door. Lastly, I realigned the door to close perfectly and it all works great as it should. I’m happy with it. Here are photos of the work.

Door removed and cables out.

Door off car.

Preparing to weld.

Weld before cleaning and grinding.

Inside door hinge weld and bolted together.

Cracked around hinge into door bracket.

Old hinge and New hinge.

This bracket inside the foot-well is located behind the fuse bus terminal. The lower door hinge is attached to the body from inside here.

Finished Install

Replaced ball joints and anti-sway bar bushings. 1990 240.

Here’s before and after pics.