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After checking both cars I have in my parking lot, I still believe the lock cylinder retaining screw is 5mm x .8mm thread.
Even though the threads may appear to be clean, I suggest you run a thread chaser or tap.
FYI, I did not come to this conclusion easily. The 1st PV door I tried did not have a screw so I tried to install a brand new 5mm x .8mm thread machine screw and it did just as you described, it started and then stopped.
So I moved on to the 2nd car and it had its screw so I removed it and tried the new 5mm screw, but it seemed a little loose so I then tried the new screw in the 1st car and it screwed in a few threads and then it stopped. I tried the used screw from the 2nd car and it too went in a few threads and stopped.
So I checked the thread size and pitch and came to the conclusion that was 5mm x .8mm threads.
So I went back to the 1 car and ran a tap through the hole and it cleared the threads.
What I think happened was the threads in the 1st door were damaged slightly when the original screw was removed and the damaged was caused by the end of the screw which was probably mushroomed from clamping down on the old lock cylinder
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Eric
Hi Performance Automotive Service (formerly OVO or Old Volvos Only)
Torrance, CA 90502
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