Page 1 2007-2013 VOLVO C30 SERVICE AND REPAIR MANUAL...
Page 2 ENGINE Engine Control - Removal, Replacement And Installation ENGINE Engine Control - Removal, Replacement And Installation ENGINE Engine Control - Removal, Replacement And Installation ACCELERATOR PEDAL REMOVAL AND INSTALLATION Fig. 1: Identifying Accelerator Pedal Courtesy of VOLVO CARS CORPORATION Torque: M6 10 Nm...
Page 3 ALTERNATOR GENERATOR (B5244S4; 2007-11) REMOVAL NOTE: Removal steps in this procedure may contain installation details. Battery, disconnection. See BATTERY DISCONNECTING AND CONNECTING Fig. 1: Identifying Bolts Courtesy of VOLVO CARS CORPORATION Remove the auxiliaries belt. See ACCESSORY DRIVE BELT TENSIONER...
Page 4 2012 Volvo C30 T-5 ELECTRICAL Alternator And Regulator - Removal, Replacement And Installation Fig. 2: Identifying Generator B+ Terminal And Bolts Courtesy of VOLVO CARS CORPORATION Remove the following items: 1. Torque: Generator B+ terminal 15 Nm 2. Torque: M8...
Page 5 2012 Volvo C30 T-5 ELECTRICAL Alternator And Regulator - Removal, Replacement And Installation Fig. 4: Identifying Oil Stick Bracket Bolt Courtesy of VOLVO CARS CORPORATION Fig. 5: Identifying Generator B+ Terminal And Nuts Courtesy of VOLVO CARS CORPORATION Remove the following items: 1.
Page 6 REMOVAL AND INSTALLATION Remove the alternator. See GENERATOR (B5254T3; 2007, B5254T7; 2008-12) or GENERATOR (B5244S4; 2007-11) Fig. 6: Identifying Spanner 9997113 Courtesy of VOLVO CARS CORPORATION see 9997113 see 9997113 CHARGE REGULATOR CHARGE REGULATOR (B5244S4; 2007-11, B5254T3; 2007, B5254T7; 2008-12)
Page 7 2012 Volvo C30 T-5 ELECTRICAL Alternator And Regulator - Removal, Replacement And Installation Fig. 7: Identifying Nuts Courtesy of VOLVO CARS CORPORATION Remove the generator (GEN). See GENERATOR (B5244S4; 2007-11) or GENERATOR (B5254T3; 2007, B5254T7; 2008-12). Fig. 8: Identifying M4 Generator Bolts...
Page 8 Removal steps in this procedure may contain installation details. See SAFETY INFORMATION BATTERY AND CHARGING Fig. 1: Identifying Underhood Torsion Rod, Nuts And Cover Courtesy of VOLVO CARS CORPORATION Torque: M8 24 Nm Fig. 2: View Of Battery And Cover...
Page 9 2012 Volvo C30 T-5 ELECTRICAL Battery And Mounting - Removal, Replacement And Installation Courtesy of VOLVO CARS CORPORATION Perform battery disconnecting and connecting, see BATTERY DISCONNECTING AND CONNECTING Fig. 3: Locating Battery Box And Terminal Connector Bolts Courtesy of VOLVO CARS CORPORATION Fig.
Page 10 2012 Volvo C30 T-5 ELECTRICAL Battery And Mounting - Removal, Replacement And Installation when replacing battery (main battery) function. VIDA (Volvo Scan Tool) is necessary to perform this procedure.
Page 11 NOTE: Removal steps in this procedure may contain installation details. Remove left-hand drive shaft, see DRIVESHAFT LEFT Remove the right drive shaft, see DRIVE SHAFT RIGHT Fig. 1: Identifying M7 Bolts Courtesy of VOLVO CARS CORPORATION Torque: M7 17 Nm...
Page 12 2012 Volvo C30 T-5 TRANSMISSION Manual Transmission Fig. 2: Identifying Hose Strap Courtesy of VOLVO CARS CORPORATION Fig. 3: Identifying Hose Courtesy of VOLVO CARS CORPORATION Fig. 4: Identifying M8 And M10 Bolts...
Page 13 TRANSMISSION Manual Transmission Remove the following items: 1. Torque: M8 24 Nm 2. Torque: M10 50 Nm Fig. 5: Identifying M10 Bolts Courtesy of VOLVO CARS CORPORATION Torque: M10 50 Nm Fig. 6: Removing Bevel Gear Courtesy of VOLVO CARS CORPORATION...
Page 14 2012 Volvo C30 T-5 TRANSMISSION Manual Transmission Fig. 7: Identifying Bevel Gear Courtesy of VOLVO CARS CORPORATION For information about transmission lubricants, see LUBRICANT TRANSMISSION To install, reverse the removal procedure.
Page 15 2012 Volvo C30 T-5 2012 Volvo C30 T-5 HVAC Automatic HVAC System HVAC Automatic HVAC System HVAC Automatic HVAC System HVAC GLOW PLUG FUEL-POWERED PREHEATER NOTE: The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.
Page 16 2012 Volvo C30 T-5 HVAC Automatic HVAC System Fig. 1: Identifying Screws For Cover Over Fan Housing Courtesy of VOLVO CARS CORPORATION Remove the 4 screws for the cover over the fan housing. Remove the cover. NOTE: The nearest connection pipe may need to be adjusted in order to remove the cover.
Page 17 2012 Volvo C30 T-5 HVAC Automatic HVAC System Fig. 3: Identifying Cable Terminals And Cables Courtesy of VOLVO CARS CORPORATION Remove: the cable terminal and cable for the flame sensor in positions 1 and 2 (blue and brown)  the cable terminal and cable for the glow plug in positions 9 and 12 (white and brown).
Page 18 2012 Volvo C30 T-5 HVAC Automatic HVAC System Fig. 4: Identifying Flame Sensor And Pressure Equalizer Courtesy of VOLVO CARS CORPORATION Disconnect the flame sensor (1) and with it the holder for the pressure equalizer (2). Remove: the glow plug ...
Page 19 2012 Volvo C30 T-5 HVAC Automatic HVAC System the flame sensor together with the holder. Tighten  the glow plug. Tighten.  Install the cable terminals and cables in the connectors. - Flame sensor in positions 1 and 2 (blue and brown).
Page 20 LIFTING POINTS FOR LIFTING THE VEHICLE Fig. 1: Identifying Lifting Points Of Vehicle Courtesy of VOLVO CARS CORPORATION When lifting the vehicle, the lifting points indicated in the graphic must be used. The jacking plate must have a rubber pad to prevent damage to the vehicle.
Page 21 NOTE: Some variation may occur. However, the essential information in the graphics is always correct. Fig. 2: View Of Symbol Numbers Courtesy of VOLVO CARS CORPORATION Symbol legend Measurement is given from centre Measurement is given from an edge Measurement is given from a cut marking Fig.
Page 22 ACCESSORIES AND EQUIPMENT Body Frame - Specifications, Mechanical For measuring, the recommendation is to use an electronic measuring device type Alvis Light or similar. A deviation of +/- 2 mm is acceptable. Fig. 4: Identifying Rear Measurements (1 Of 2) Courtesy of VOLVO CARS CORPORATION...
Page 23 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Body Frame - Specifications, Mechanical Fig. 5: Identifying Rear Measurements (2 Of 2) Courtesy of VOLVO CARS CORPORATION SIDE MEMBERS, FRONT NOTE: Some variation may occur. However, the essential information in the graphics is always correct.
Page 24 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Body Frame - Specifications, Mechanical Courtesy of VOLVO CARS CORPORATION For measuring, the recommendation is to use an electronic measuring device type Alvis Light or similar. A deviation of +/- 2 mm is acceptable.
Page 25 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Body Frame - Specifications, Mechanical Fig. 10: Identifying Side Measurements (3 Of 3) Courtesy of VOLVO CARS CORPORATION B6 = 1583 mm B7 = 1421 mm ROOF, WINDSHIELD AND REAR WINDSHIELD FRAME ROOF Fig.
Page 26 Measurement is given from a cut marking Fig. 12: Identifying Symbol Number 3 Measurement From The Bottom Of The Recess Courtesy of VOLVO CARS CORPORATION Measurement takes place from the bottom of the recess. If only a measuring point symbol is shown this applies to both points.
Page 27 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Body Frame - Specifications, Mechanical Fig. 14: Identifying Windshield Frame Measurements Courtesy of VOLVO CARS CORPORATION BODY SIDE Fig. 15: View Of Symbol Numbers Courtesy of VOLVO CARS CORPORATION Explanation of symbols As measured from centre...
Page 28 As measured from cut marking Fig. 16: Identifying Symbol Number 3 Measurement From The Bottom Of The Recess Courtesy of VOLVO CARS CORPORATION As measured from the bottom of the recess. If only one measurement point symbol is shown, it applies to both points.
Page 29 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Body Frame - Specifications, Mechanical Fig. 18: Identifying Body Side Measurements (2 Of 5) Courtesy of VOLVO CARS CORPORATION Fig. 19: Identifying Body Side Measurements (3 Of 5) Courtesy of VOLVO CARS CORPORATION...
Page 30 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Body Frame - Specifications, Mechanical Fig. 20: Identifying Body Side Measurements (4 Of 5) Courtesy of VOLVO CARS CORPORATION Fig. 21: Identifying Body Side Measurements (5 Of 5) Courtesy of VOLVO CARS CORPORATION...
Page 31 REMOVAL REMOVING THE FRONT BUMPER RAIL Fig. 1: Removing Front Bumper Rail Courtesy of VOLVO CARS CORPORATION Remove the front section. See: FRONT END . Remove the bracket for the power steering. It is secured using 4 M8 screws.
Page 32 Support the radiator assembly. Detach the radiator. It is secured using 4 M8 screws. Remove the remaining 6 M8 screws for the bumper rail. Remove the bumper rail. INSTALLATION NOTE: For tightening torques, see: TIGHTENING TORQUE . INSTALLING THE FRONT BUMPER RAIL Fig. 2: Installing Front Bumper Rail Courtesy of VOLVO CARS CORPORATION...
Page 33 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation Install: the bumper rail using the 6 M6 screws. Wait before installing the 2 screws for the servo unit  the radiator using the 4 M8 screws ...
Page 34 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation Fig. 3: Aligning Front Wheel Arch Courtesy of VOLVO CARS CORPORATION Align and secure the wheel arch. See: FRONT END and SIDE MEMBERS, FRONT . Align the bracket on the battery shelf. See the dimensions below.
Page 35 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation Fig. 4: Identifying Welding Locations For Replacement Part Courtesy of VOLVO CARS CORPORATION Weld the replacement part into place. Lens diameter: Ø 4.5 mm. Also, see WELDING, GENERAL .
Page 36 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation Fig. 5: Removing Rear Bumper Rail Courtesy of VOLVO CARS CORPORATION Torque: M8 24 Nm Rust proof. See RUSTPROOFING . Install in the reverse order.
Page 37 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation Fig. 6: Removing Rear Bumper Rail Courtesy of VOLVO CARS CORPORATION Torque: M8 24 Nm For information about corrosion protection, see RUSTPROOFING INSTALLATION To install, reverse the removal procedure.
Page 38 REMOVAL REMOVING THE REAR SIDE MEMBER Fig. 7: Identifying The Cutting Point Courtesy of VOLVO CARS CORPORATION If the entire side member does not need replacing, see the cutting point in the illustration. Drill and grind off the member. Grind clean and apply welding primer.
Page 39 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation Fig. 8: Installing Rear Side Member Courtesy of VOLVO CARS CORPORATION Spot-weld the replacement part. Tip diameter: Ø 4.5 mm. See the illustration for the location of the spot welds.
Page 40 PREPARATORY WORK (COMMON TO BOTH METHODS) PREPARATORY WORK Fig. 9: Identifying Cut Points Courtesy of VOLVO CARS CORPORATION When welding body components, see: WELDING, GENERAL . Remove components. See: FRONT SECTION, EXPOSING . Determine the extent of the damage. See: SIDE MEMBERS, FRONT and FRONT END .
Page 41 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation REMOVING THE OUTER SECTION OF THE LOWER SIDE MEMBER Fig. 10: Identifying Side Member Cutting Area Courtesy of VOLVO CARS CORPORATION If the entire side member does not need replacing, see the cutting point in the illustration. Remove: the support plate ...
Page 42 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation Fig. 11: Identifying Cutting Points Courtesy of VOLVO CARS CORPORATION If the entire side member does not need replacing, see the cutting point in the illustration. Cutting point (1) This cutting point is used in the event of minor damage to the side member.
Page 43 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation Fig. 12: Removing Upper Part Of Side Member Extension Courtesy of VOLVO CARS CORPORATION If the member is cut at cutting point (2), remove the upper part of the side member extension.
Page 44 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation Fig. 13: Removing Outer Part Of Cross Member Cowl Panel Courtesy of VOLVO CARS CORPORATION Remove the outer part of the cross member cowl panel. INSTALLING THE INNER SECTION OF THE LOWER SIDE MEMBER...
Page 45 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation Fig. 14: Installing Inner Section Of Lower Side Member (1 Of 2) Courtesy of VOLVO CARS CORPORATION Grind clean. Apply welding primer. Seam-weld the join.
Page 46 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation Fig. 15: Installing Inner Section Of Lower Side Member (2 Of 2) Courtesy of VOLVO CARS CORPORATION Weld the outer part of the cross member cowl panel. Drill Ø 8 mm diameter holes for plug welds.
Page 47 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation Fig. 16: Installing Outer Section Of Lower Side Member Courtesy of VOLVO CARS CORPORATION Grind clean. Apply welding primer. Spot-weld the replacement part. Tip diameter Ø 8 mm.
Page 48 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation Fig. 17: Identifying Spot-Weld Location Courtesy of VOLVO CARS CORPORATION INSTALLING COMPONENTS...
Page 49 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation Fig. 18: Identifying Seam-Weld Area On Collar Courtesy of VOLVO CARS CORPORATION Seam-weld the collar into place using 8 welding seams each measuring 30 mm. See the illustration. Install: the wheel arch.
Page 50 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation Fig. 19: Removing Outer Section Of Upper Side Member Courtesy of VOLVO CARS CORPORATION Drill or grind out the spot welds. Cut off the damaged section.
Page 51 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation Fig. 20: Removing Inner Section Of Upper Side Member Courtesy of VOLVO CARS CORPORATION Drill or grind out the spot welds. Cut off the damaged section.
Page 52 SPARE WHEEL WELL Remove the outer back piece. See TAIL SECTION EXTERNAL Determine the extent of the damage. See REAR SECTION Welding body components. See WELDING, GENERAL Fig. 21: Removing Spare Wheel Well (1 Of 4) Courtesy of VOLVO CARS CORPORATION...
Page 53 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation Fig. 22: Removing Spare Wheel Well (2 Of 4) Courtesy of VOLVO CARS CORPORATION Fig. 23: Removing Spare Wheel Well (3 Of 4) Courtesy of VOLVO CARS CORPORATION...
Page 54 Remove the rear fender. See FENDER . Determine the extent of the damage. See BODY SIDE . Fig. 25: Removing Rear Wheel Arch (1 Of 2) Courtesy of VOLVO CARS CORPORATION Fig. 26: Removing Rear Wheel Arch (2 Of 2) Courtesy of VOLVO CARS CORPORATION...
Page 55 PRINCIPLES OF JOINING Fig. 27: Identifying Cutting Points For C And D-Posts Courtesy of VOLVO CARS CORPORATION Roof pillars must be joined as shown in the illustration unless otherwise indicated in the method. Cut the different panel sections with a 50 mm offset. This applies when replacing all roof pillars.
Page 56 REMOVAL REMOVING THE CANTRAIL / ROOF SIDE Fig. 28: Removing Cantrail / Roof Side Courtesy of VOLVO CARS CORPORATION Remove components. See: ROOF SECTION, EXPOSING (2007-2009) or ROOF SECTION, EXPOSING (2010-2012) . Pull or press out the damaged section to make it easier to re-align internal components.
Page 57 INSTALLATION INSTALLING THE CANTRAIL / ROOF SIDE Fig. 29: Installing Cantrail / Roof Side Courtesy of VOLVO CARS CORPORATION Install foam rubber replacement at (1). See: BODY SEAL, SEALING DIAGRAM . Secure the replacement part. Saw through the two panels at the cutting points.
Page 58 Remove roof panel. See ROOF PANEL Determine the extent of the damage. See ROOF Fig. 30: Removing Roof Arch Courtesy of VOLVO CARS CORPORATION Seal body. See BODY SEAL, SEALING DIAGRAM Rustproof body. See RUSTPROOFING Install roof panel. See ROOF PANEL...
Page 59 Remove roof section, exposing, see ROOF SECTION, EXPOSING (2007-2009) or ROOF SECTION, EXPOSING (2010-2012) . For information about roof, see ROOF INSTALLATION Fig. 31: Installing Roof Panel (1 Of 8) Courtesy of VOLVO CARS CORPORATION Fig. 32: Installing Roof Panel (2 Of 8)
Page 60 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation Courtesy of VOLVO CARS CORPORATION Fig. 33: Installing Roof Panel (3 Of 8) Courtesy of VOLVO CARS CORPORATION Use: 2-component foam, 3M 08463 Fig. 34: Installing Roof Panel (4 Of 8)
Page 61 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation Fig. 35: Installing Roof Panel (5 Of 8) Courtesy of VOLVO CARS CORPORATION Use: Masking tape, 9511050-8 For information about body sealant, sealing diagram, see BODY SEAL, SEALING DIAGRAM Fig.
Page 62 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation Fig. 37: Installing Roof Panel (7 Of 8) Courtesy of VOLVO CARS CORPORATION NOTE: Make sure that the seal is correctly located. Fig. 38: Installing Roof Panel (8 Of 8)
Page 63 3M 08463 Welding body components. See WELDING, GENERAL . Remove the side section. See SIDE SECTION, EXPOSING . Determine the extent of the damage. See BODY SIDE . Fig. 39: Removing/Installing A-Pillar (1 Of 8) Courtesy of VOLVO CARS CORPORATION...
Page 64 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation Fig. 40: Removing/Installing A-Pillar (2 Of 8) Courtesy of VOLVO CARS CORPORATION Use: Insulation foam, 3M 08463 Fig. 41: Removing/Installing A-Pillar (3 Of 8) Courtesy of VOLVO CARS CORPORATION...
Page 65 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation Fig. 42: Removing/Installing A-Pillar (4 Of 8) Courtesy of VOLVO CARS CORPORATION Fig. 43: Removing/Installing A-Pillar (5 Of 8) Courtesy of VOLVO CARS CORPORATION...
Page 66 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation Fig. 44: Removing/Installing A-Pillar (6 Of 8) Courtesy of VOLVO CARS CORPORATION Fig. 45: Removing/Installing A-Pillar (7 Of 8) Courtesy of VOLVO CARS CORPORATION...
Page 67 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation Fig. 46: Removing/Installing A-Pillar (8 Of 8) Courtesy of VOLVO CARS CORPORATION Install the side door's hinges. See DOOR HALF HINGE Seal the A-pillar. See BODY SEAL, SEALING DIAGRAM .
Page 68 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation Fig. 47: 2-component foam, 3M 08463 Courtesy of VOLVO CARS CORPORATION Use: 2-component foam, 3M 08463 To install, reverse the removal procedure BODY SIDE INNER Welding body components.
Page 69 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation Fig. 48: Removing Body Side Inner Section (1 Of 3) Courtesy of VOLVO CARS CORPORATION Fig. 49: Removing Body Side Inner Section (2 Of 3) Courtesy of VOLVO CARS CORPORATION...
Page 70 Remove. See SIDE SECTION, EXPOSING Determine the extent of the damage. See BODY SIDE . Fig. 51: Alternative Sill Molding Cutting Points Courtesy of VOLVO CARS CORPORATION Alternative sill molding cutting points. Fig. 52: View Of Sill Molding Reinforcement Assembly...
Page 71 A-pillar. See A-PILLAR  Alternative cutting points. Fig. 53: Identifying Body Sill Weld Points (1 of 2) Courtesy of VOLVO CARS CORPORATION Fig. 54: Identifying Body Sill Weld Points (2 of 2) Courtesy of VOLVO CARS CORPORATION Install the following items: B-pillar.
Page 72 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation Rear fender. See FENDER  Seal. See BODY SEAL, SEALING DIAGRAM . Rust proof. See RUSTPROOFING Install the side section. See SIDE SECTION, EXPOSING .
Page 73 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation Fig. 55: Installing Inner Rear Section Courtesy of VOLVO CARS CORPORATION Apply welding primer. Spot-weld the replacement part. Tip diameter Ø 4, 5 mm. Also, see WELDING, GENERAL .
Page 74 Remove the rear section. See REAR SECTION, EXPOSING (2007-2009) or REAR SECTION, EXPOSING (2010-2012) . Determine the extent of the damage. See REAR SECTION Fig. 56: Removing External Tail Section (1 Of 3) Courtesy of VOLVO CARS CORPORATION Alternative cutting points. Welding body components. See WELDING, GENERAL...
Page 75 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation Fig. 57: Removing External Tail Section (2 Of 3) Courtesy of VOLVO CARS CORPORATION Use: Insulation foam, 3M 08643 Fig. 58: Removing External Tail Section (3 Of 3)
Page 76 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation REMOVING THE REAR SECTION SIDE Fig. 59: Removing Rear Section Side Courtesy of VOLVO CARS CORPORATION Joints should be used to limit the painted surfaces on the rear fender. Grind and drill out the spot welds and bead welds.
Page 77 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation Fig. 60: Installing Side Rear Section Courtesy of VOLVO CARS CORPORATION Apply welding primer. Secure the replacement part. Spot-weld the replacement part. Tip diameter: Ø 4.5 mm.
Page 78 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation the rear bumper rail. See: REAR BUMPER RAIL.  parts according to: REAR SECTION, EXPOSING (2007-2009) or REAR SECTION, EXPOSING  (2010-2012) . NOTE: Check the whiplash system in the vehicle, seeCOLLISION PROTECTION UNIT...
Page 79 2-component foam 3M 08463 SEALING PRODUCTS Fig. 1: Using Seal, 1161767 Courtesy of VOLVO CARS CORPORATION 1. Weatherstrip When replacing sheet metal parts, the joints between the different sheet metal parts shall be sealed according to illustration Use: Seal, 1161767...
Page 80 ACCESSORIES AND BODY, CAB Body Frame - General Information Fig. 2: Spray sealant, 1161651 Courtesy of VOLVO CARS CORPORATION 2. Spray sealant The putty can be applied in a bead, be sprayed in a thin layer or brushed on with a paintbrush.
Page 81 Soundproofing foam is installed in hollow spaces to counteract propagation of sound in the body. There are 2 types of approved soundproofing foam: Volvo's soundproofing foam consists of a wax-treated cylinder 50x50 mm. It can be compressed for installation between metal parts. Several cylinders can be used if one is not enough.
Page 82 1161682 Stone-chip protection 1161815 Underbody protection 116 1298 PREPARATION Fig. 5: Cavity protection, 1161682 Courtesy of VOLVO CARS CORPORATION Rustproofing diagram for cavity protection Attach the following items: see 9814075  Use: Cavity protection, 1161682  Cavity protection is used for, e. g., weld seams and areas that have been reworked in other ways.
Page 83 Insert the hose in the cavity and spray at the same time as the hose is pulled out slowly. If repairs are made to the body, the areas marked in the illustrations are to rustproof extra thoroughly. Fig. 6: Identifying Areas Rustproofing Courtesy of VOLVO CARS CORPORATION Fig. 7: Identifying Areas Rustproofing Courtesy of VOLVO CARS CORPORATION...
Page 84 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Body Frame - General Information Fig. 8: Stone-chip protection, 1161815 Courtesy of VOLVO CARS CORPORATION Rustproofing schedule for stone-chip protection Use: Stone-chip protection, 1161815 Apply stonechip protection to the areas of the vehicle marked in blue in the illustration.
Page 85 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Body Frame - General Information see 9814076 SHEET METAL, MATERIAL INFORMATION STEEL, MATERIAL INFORMATION Fig. 10: Identifying Sheet Metal, Material Information Courtesy of VOLVO CARS CORPORATION...
Page 86 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Body Frame - General Information Fig. 11: Identifying Steel, Material Information Courtesy of VOLVO CARS CORPORATION Fig. 12: Identifying Zinc Area Courtesy of VOLVO CARS CORPORATION...
Page 87 ACCESSORIES AND BODY, CAB Body Frame - General Information Fig. 13: Identifying Zinc Area Courtesy of VOLVO CARS CORPORATION HSS (High Strength Steel) is a general term for steel material within a specific strength range. The vehicles are built of different steel material, partly to optimize the body (impact safety, rigidity, fuel economy, etc.) and partly to make it as repair-friendly as possible.
Page 88 It is not possible to galvanized BORON steel during the production process. It is therefore very important to rustproof these components extra thoroughly. CAUTION: BORON steel must not be straightened. Fig. 14: Identifying Plastic, Material Information (Rear View) Courtesy of VOLVO CARS CORPORATION...
Page 89 GENERAL Volvo bodies are manufactured to the highest quality. All bodywork repairs must therefore take place following the same principles. Use light tools. Take care of the surface coating, electro dip (ED) and phosphating. Always use welding primer between welded panel flanges.
Page 90 ASSEMBLY Spot welding is mainly used when the bodies are manufactured, and use of this method should always be aimed for with a repair. CAUTION: Gas welding must not be used on Volvo bodywork. WARNING: Use ventilation / extraction equipment.
Page 91 10 mm or more for thicknesses above 2.5 mm. Fig. 17: Identifying Welding Lens Diameter Courtesy of VOLVO CARS CORPORATION Test weld several test pieces. Break the panels apart and measure the size of the welding lens diameter (A), see...
Page 92 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Body Frame - General Information Fig. 18: Identifying Proper Spot Welds On Both Panels Courtesy of VOLVO CARS CORPORATION NOTE: Use welding primer on all internal flanges. Add filling primer if there is grinding damage.
Page 93 GENERAL Volvo bodies are manufactured to the highest quality. All bodywork repairs must therefore take place following the same principles. Use light tools. Take care of the surface coating, electro dip (ED) and phosphating. Always use welding primer between welded panel flanges.
Page 94 ACCESSORIES AND BODY, CAB Body Frame - General Information Fig. 20: Identifying Welding Symbols Courtesy of VOLVO CARS CORPORATION There are a number of other assembly methods that are illustrated with the following symbols: 1. Spot weld/spot weld with the location of the weld and lens diameter specified with color (may be replaced with 2) 2.
Page 95 10 mm or more for thicknesses above 2.5 mm. Fig. 21: Identifying Welding Lens Diameter Courtesy of VOLVO CARS CORPORATION Test weld several test pieces. Break the panels apart and measure the size of the welding lens diameter (A), see illustration.
Page 96 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Body Frame - General Information Fig. 23: Grinding Properly And Improperly Courtesy of VOLVO CARS CORPORATION Grind down the plug weld. CAUTION: Only grind welds, not the adjacent panel.
Page 97 2012 Volvo C30 T-5 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB General - Removal, replacement and installation ACCESSORIES AND BODY, CAB General - Removal, replacement and installation ACCESSORIES AND BODY, CAB General - Removal, replacement and installation DISMANTLING WORK PRIOR TO BODY REPAIR...
Page 98 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB General - Removal, replacement and installation side door, see SIDE DOOR  Inflatable curtain, see INFLATABLE CURTAIN (2010-2012)  Front fender widener, see FRONT FENDER WIDENER  fender extension rear, see REAR FENDER WIDENER ...
Page 99 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB General - Removal, replacement and installation Inflatable curtain, see INFLATABLE CURTAIN  Glass sun roof, see GLASS SUN ROOF  Wind deflector sunroof, see WIND DEFLECTOR SUNROOF  Windshield, see WINDSHIELD ...
Page 100 NOTE: Removal steps in this procedure may contain installation details. Remove battery. See BATTERY Fig. 1: Identifying Anti-Lock Brakes And Brake Pipe Courtesy of VOLVO CARS CORPORATION Install the following items: 1. Torque: Anti-lock brakes 14 Nm 2. Torque: Brake pipe M12 with wrench size 11mm...
Page 101 INSTALLATION To install, reverse the removal procedure. Order and download software according to 30667171 Calibrate according to VIDA/DIAGNOSTICS/VEHICLE COMMUNICATION/Advanced/BCM/Calibration (only vehicles with DSTC) using Volvo specific VIDA scan tool. ANTI-LOCK BRAKE (ANTI-SKID) (2011-12) HYDRAULIC UNIT BRAKE SYSTEM REMOVAL VEHICLES WITH STABILITY ASSIST...
Page 102 2012 Volvo C30 T-5 BRAKES Brake Control System - Removal, Replacement And Installation Fig. 3: Identifying Hydraulic Unit Brake System Courtesy of VOLVO CARS CORPORATION NOTE: When installing this component, do not download any new software. INSTALLATION To install, reverse the removal procedure.
Page 103 METAL PEDALS METAL PEDALS Fig. 1: Removing Original Covers (Manual Transmissions) Courtesy of VOLVO CARS CORPORATION Graphic above applies to cars with manual transmissions. Graphic below applies to cars with automatic transmissions Remove the rubber covers from the pedals by grasping the upper edge and pulling backwards.
Page 104 2012 Volvo C30 T-5 BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Installation Instructions, Accessories Courtesy of VOLVO CARS CORPORATION Fig. 3: Opening the Tabs Courtesy of VOLVO CARS CORPORATION Take the accelerator pedal's metal trimmed rubber cover from the kit.  Hold as shown and fold out the three tabs.
Page 105 2012 Volvo C30 T-5 BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Installation Instructions, Accessories Fig. 5: Securing New Cover Courtesy of VOLVO CARS CORPORATION Pull the tabs down slightly and check that the edges of the cover surround the pedal edges. Pull the cover ...
Page 106 2012 Volvo C30 T-5 BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Installation Instructions, Accessories Fig. 7: Peeling Protective Film Courtesy of VOLVO CARS CORPORATION Remove the protective film from both covers. Ensure that the surfaces of the pedals are clean.  Fig. 8: Positioning Covers...
Page 107 2012 Volvo C30 T-5 BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Installation Instructions, Accessories Fig. 9: Opening the Tabs Courtesy of VOLVO CARS CORPORATION Take one of the remaining covers from the kit.  Hold as shown and fold out the three tabs.
Page 108 2012 Volvo C30 T-5 BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Installation Instructions, Accessories Fig. 11: Securing New Cover Courtesy of VOLVO CARS CORPORATION Pull the tabs down slightly and check that the edges of the cover surround the pedal edges. Pull the cover ...
Page 109 2012 Volvo C30 T-5 BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Installation Instructions, Accessories Fig. 13: Positioning Spacers Courtesy of VOLVO CARS CORPORATION Position the longer cover, which has markings, in the recess on the brake pedal and press securely. The  thicker part of the cover must point downwards.
Page 110 BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Installation Instructions, Accessories Fig. 15: Fitting the Cover Courtesy of VOLVO CARS CORPORATION Hook the cover onto the right-hand shorter side of the pedal, at the same time hold the tabs and pull to the ...
Page 111 2012 Volvo C30 T-5 BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Installation Instructions, Accessories Fig. 17: Identifying The Pedals Courtesy of VOLVO CARS CORPORATION Sport pedals Equipment Fig. 18: Weatherstrip Tool Courtesy of VOLVO CARS CORPORATION Kit contents...
Page 112 2012 Volvo C30 T-5 BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Installation Instructions, Accessories Fig. 19: Identify the Kit Contents Courtesy of VOLVO CARS CORPORATION...
Page 113 2012 Volvo C30 T-5 BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Installation Instructions, Accessories Fig. 20: Kit for Manual Transmission Courtesy of VOLVO CARS CORPORATION INSTALLATION Fig. 21: Verify Clean Surfaces Courtesy of VOLVO CARS CORPORATION...
Page 114 2012 Volvo C30 T-5 BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Installation Instructions, Accessories Clean the surface. Fig. 22: Removing Original Cover Courtesy of VOLVO CARS CORPORATION Fig. 23: New Cover Fully in Place Courtesy of VOLVO CARS CORPORATION...
Page 115 2012 Volvo C30 T-5 BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Installation Instructions, Accessories Fig. 24: Use Mirror to Check Courtesy of VOLVO CARS CORPORATION CAUTION: Using a mirror check that the pedal rubber covers the edges of the pedal. CARS WITH AUTOMATIC TRANSMISSIONS Fig.
Page 116 BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Installation Instructions, Accessories Fig. 26: Installing New Pad Courtesy of VOLVO CARS CORPORATION Hook the pedal rubber onto the pedal at the lower edge and pull the pedal rubber upward. Fig. 27: Use Tool As Needed...
Page 117 2012 Volvo C30 T-5 BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Installation Instructions, Accessories Fig. 28: Verify With Mirror Courtesy of VOLVO CARS CORPORATION CAUTION: Using a mirror check that the pedal rubber covers the edges of the pedal. CARS WITH MANUAL TRANSMISSIONS Fig.
Page 118 BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Installation Instructions, Accessories Fig. 30: Installing New Pad Courtesy of VOLVO CARS CORPORATION Hook the pedal rubber onto the pedal at the lower edge and pull the pedal rubber upward. Fig. 31: Use Tool as Needed...
Page 119 2012 Volvo C30 T-5 BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Installation Instructions, Accessories Fig. 32: Verify with Mirror Courtesy of VOLVO CARS CORPORATION CAUTION: Using a mirror check that the pedal rubber covers the edges of the pedal. LEFT HAND DRIVE VEHICLES...
Page 120 48 hours after doing the work. APPLIES TO CARS WITHOUT ENGINE BLOCK HEATERS Fig. 1: Prying Off Panel At Lower Edge Courtesy of VOLVO CARS CORPORATION Carefully pry off the panel at the lower edge and remove it. ...
Page 121 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 2: Identifying Left Front Wheel Courtesy of VOLVO CARS CORPORATION Cars with 4-cyl. engines Remove the left front wheel.  Cars with 5-cyl. engines Remove both the front wheels.
Page 122 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 4: Removing Wheel Arch Lining Screws Courtesy of VOLVO CARS CORPORATION Remove the screws and the plastic nut from the left-hand inner wing.  Fig. 5: Removing Wheel Arch Lining Courtesy of VOLVO CARS CORPORATION APPLIES TO CARS WITH 4-CYL.
Page 123 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 6: Pressing Locking Sleeve Over Cable Splice Courtesy of VOLVO CARS CORPORATION Remove the lock sleeve over the joint to the engine heater's cable on the left side by the stay on the sub- ...
Page 124 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 8: Identifying Ground Lead With Screw And Toothed Washer Courtesy of VOLVO CARS CORPORATION Disconnect the ground lead from the outside of the side member. ...
Page 125 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 10: Identifying Locking Sleeve Courtesy of VOLVO CARS CORPORATION Remove the lock sleeve over the joint to the engine heater's cable on the right side by the stay on the sub- ...
Page 126 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 12: Identifying Tie Strap Courtesy of VOLVO CARS CORPORATION Remove the cable tie that holds the cable to the cable harness at the top in the engine compartment. ...
Page 127 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 14: Identifying Double Clamp Courtesy of VOLVO CARS CORPORATION Loosen the cable from the double clamp by the brake pipe in the top edge of the bulkhead on the left side.
Page 128 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 16: Identifying Ground Lead With Screw And Toothed Washer Courtesy of VOLVO CARS CORPORATION Disconnect the ground lead from the outside of the side member. ...
Page 129 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 18: Prying Off Panel At Lower Edge Courtesy of VOLVO CARS CORPORATION Carefully pry off the panel at the lower edge and remove it. ...
Page 130 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 20: Cleaning Panel Courtesy of VOLVO CARS CORPORATION Fig. 21: Enlarging Markings On Inside Of Panel Courtesy of VOLVO CARS CORPORATION Enlarge the markings on the inside of the panel.
Page 131 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 22: Drilling Out Holes Courtesy of VOLVO CARS CORPORATION Drill out the four holes according to the markings.  Fig. 23: Cleaning Outside Of Panel...
Page 132 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 24: Identifying Protective Panel Courtesy of VOLVO CARS CORPORATION Remove the protective tape from the new panel.  Fig. 25: Identifying Tape Courtesy of VOLVO CARS CORPORATION...
Page 133 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 26: Identifying Spacer Washers Courtesy of VOLVO CARS CORPORATION Secure the spacer washers around the tree studs on the new panel.  Fig. 27: Inserting Studs Into Panel Courtesy of VOLVO CARS CORPORATION Insert the studs into the new panel in the holes on the old one, and secure.
Page 134 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 28: Identifying Locking Washers Courtesy of VOLVO CARS CORPORATION NOTE: Position the panel on a surface that will not damage it when pressing the locking washers into place.
Page 135 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 30: Inserting Cable Into New Panel Courtesy of VOLVO CARS CORPORATION Insert the cable through to the engine heater. Ensure the connector is turned so that the cover's sides are ...
Page 136 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 32: Installing Cable And Panel Courtesy of VOLVO CARS CORPORATION Insert the cable through the hole for the panel.  Fig. 33: Install Wheel To Wheel Hub Courtesy of VOLVO CARS CORPORATION Reinstall and clamp the loose cables to the heater.
Page 137 Do not wash the vehicle for at least 48 hours after work has been carried out. Fig. 34: Identifying Bumper Casing Courtesy of VOLVO CARS CORPORATION Open the boot lid.  Wash the bumper casing and wipe dry.
Page 138 Take the bumper cover from the kit. Mark the center between the middle ribs using a piece of tape.  Fig. 36: Applying Tape And Marking Center Of Bumper Casing Courtesy of VOLVO CARS CORPORATION Apply a piece of tape and mark the center of the bumper casing as shown. ...
Page 139 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 38: Applying Pieces Of Tape To Mark Out Dimensions Courtesy of VOLVO CARS CORPORATION Apply pieces of tape to mark out the dimensions.  Fig. 39: Cleaning Marked Surface Courtesy of VOLVO CARS CORPORATION Remove the bumper cover.
Page 140 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 40: Identifying Protective Tape Courtesy of VOLVO CARS CORPORATION Remove the protective tape from one side.  Fig. 41: Identifying Bumper Cover Center Marking Courtesy of VOLVO CARS CORPORATION Position the bumper cover center marking and the outer corner on the side that had the protective tape ...
Page 141 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 42: Identifying Bumper Cover Courtesy of VOLVO CARS CORPORATION Press the bumper cover towards the bumper casing over the entire surface.  NOTE: Do not use the vehicle for at least two hours after work has been carried out.
Page 142 The two screws (1) will be reused, place the others to one side.  Fig. 44: View Of Subframe Clips Courtesy of VOLVO CARS CORPORATION Remove the five clips in the subframe and bracket for the radiator. They will not be reused. ...
Page 143 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 46: View Of Covered Engine Bay Courtesy of VOLVO CARS CORPORATION Cover the underneath of the engine with cardboard or similar, so that drilling shavings does not blow up ...
Page 144 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 47: Identifying Tool P/N 9512782 Courtesy of VOLVO CARS CORPORATION Rivet the nuts in the drilled holes. Use tool part no. 9512782 .  Fig. 48: View Of New Protective Plate Screws Courtesy of VOLVO CARS CORPORATION Install the new protective plate for marking and drilling holes for the left front mounting.
Page 145 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 49: View Of Radiator Bracket Drill Hole Courtesy of VOLVO CARS CORPORATION Take a 8.5 mm (21/64") drill bit and drill through the hole in the engine's protective plate and through the ...
Page 146 Remove the cover from under the engine.  Fig. 51: Identifying Tool P/N 9512782 Courtesy of VOLVO CARS CORPORATION Rivet the nut in the drilled hole. Use tool part no. 9512782 .  Remove the three pieces of wood, plastic or metal from the inside of the radiator bracket.
Page 147 The two rear screws must have two spacer washers each between the mounting lug and the subframe as shown. Fig. 53: View Of Washers Between Mounting Lug And Subframe Courtesy of VOLVO CARS CORPORATION Fig. 54: Identifying M8 Screws Courtesy of VOLVO CARS CORPORATION Torque tighten the M8 screws.
Page 148 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 55: Identifying Splash Guard Screws Courtesy of VOLVO CARS CORPORATION Remove the screws for the engine splash guard and remove it.  The two screws (1) will be reused, place the others to one side.
Page 149 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 57: View Of Inner Wing Screws Courtesy of VOLVO CARS CORPORATION Remove the screws at the rear edge of the inner wings on both sides. ...
Page 150 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 59: Identifying Catch Pressed Up Courtesy of VOLVO CARS CORPORATION Press the catch up. Remove the cover. Do not damage the painted surfaces or the washer nozzles. ...
Page 151 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 61: Identifying Locating Lugs Courtesy of VOLVO CARS CORPORATION Pull the bumper cover at the lower edge slightly to access the locating lugs on top of the radiator. ...
Page 152 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 63: View Of Cutting The Left-Hand Side Courtesy of VOLVO CARS CORPORATION shows cutting on the left-hand side.  Fig. 64: View Of Cardboard Covering Rear Edge Engine Bay...
Page 153 Remove the cover from under the engine.  Fig. 65: Identifying Tool P/N 9512782 Courtesy of VOLVO CARS CORPORATION Rivet the nuts in the drilled holes. Use tool part no. 9512782 .  Fig. 66: View Of Splash Guard Center Line Marking...
Page 154 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 67: View Of Radiator Bracket Marking Courtesy of VOLVO CARS CORPORATION Make a longitudinal marking 8.5 mm (21/64") from the front edge and on the radiator bracket opposite ...
Page 155 Do not tighten too hard as the engine splash guard must be adjusted at the front edge according to the made markings. Fig. 69: Identifying Splash Guard Screw And Washer Kit Courtesy of VOLVO CARS CORPORATION Fig. 70: View Of Splash Guard Front Mounting Holes Courtesy of VOLVO CARS CORPORATION Center the engine splash guard's two front mounting holes and the center hole above the made markings.
Page 156 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 71: View Of Left Front And The Center Mounting Hole Courtesy of VOLVO CARS CORPORATION Now take a loose drill bit with the same diameter as the holes in the front mounting holes and rotate to ...
Page 157 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 73: View Of Left-Hand Hole Drill Mark Courtesy of VOLVO CARS CORPORATION NOTE: Use a smooth drill bit head and ensure that the drill bit does not slip off the surface to be drilled, the surface is small in relation to the completed size of the hole.
Page 158 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 74: View Of Right-Hand Hole Drill Mark Courtesy of VOLVO CARS CORPORATION Previous graphic applies to the left-hand hole.  Graphic above applies to the right-hand hole.
Page 159 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 76: View Of Protective Plate Screws Courtesy of VOLVO CARS CORPORATION Install the new protective plate for marking and drilling the three holes in the mounting. ...
Page 160 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 78: Identifying Drill Bit P/N 9814112 Courtesy of VOLVO CARS CORPORATION Install the cover beneath the engine.  Take drill bit part no. 9814112 and carefully drill out the three holes.
Page 161 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 80: Identifying Engine Splash Guard Screws Courtesy of VOLVO CARS CORPORATION Install the engine splash guard using two existing screws and the seven screws with washers from the kit ...
Page 162 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 82: Tightening Splash Guard With Torque Specifications Courtesy of VOLVO CARS CORPORATION Torque tighten the M8 screws.  APPLIES TO THE C30 Fig. 83: Identifying Front Bumper Inner Wing...
Page 163 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 84: Identifying Front Bumper Inner Wing Screws Courtesy of VOLVO CARS CORPORATION Fig. 85: View Of Nozzle Cover Courtesy of VOLVO CARS CORPORATION SIDE SCUFF PLATE (2009-12)
Page 164 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 86: Identifying Ignition Key In 0 Position Courtesy of VOLVO CARS CORPORATION Set the ignition key to position 0 .  NOTE: Wait at least one minute before unplugging the connectors or removing other electrical equipment.
Page 165 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 88: Cleaning Door Sill Panels Courtesy of VOLVO CARS CORPORATION Clean the door sill panels where the decor panel's cradle is to sit on both sides using isopropanol. ...
Page 166 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 90: Identifying Screws Courtesy of VOLVO CARS CORPORATION Fig. 91: Identifying Panel Courtesy of VOLVO CARS CORPORATION Remove the panel.  Remove the remains of the rivets.
Page 167 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 92: Identifying Protective Tape Courtesy of VOLVO CARS CORPORATION Take the cradles for one side from the kit.  The cradles are marked out and only fit in one place.
Page 168 Press the middle of the pieces of mounting tape.  Fig. 94: Drilling Out Marked Out Holes In Cradle Courtesy of VOLVO CARS CORPORATION Drill out the six marked out holes in the cradle using a 6 mm (15/64") drill bit. ...
Page 169 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 96: Identifying Protective Tape Courtesy of VOLVO CARS CORPORATION Remove the protective tape from the pieces of mounting tape on the rear cradle.  Fig. 97: Aligning Lugs At Front Edge In Rear Cradle In Holes At Front Courtesy of VOLVO CARS CORPORATION Align the lugs at the front edge in the rear cradle in the holes at the front.
Page 170 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 98: Pressing Holder Onto Pieces Of Mounting Tape Courtesy of VOLVO CARS CORPORATION Press the holder onto the pieces of mounting tape.  Fig. 99: Drilling Out Marked Out Holes In Cradle Courtesy of VOLVO CARS CORPORATION Drill out the seven marked out holes in the cradle using a 6 mm (15/64") drill bit.
Page 171 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 100: Riveting Holder To Door Sill Panel Courtesy of VOLVO CARS CORPORATION Take pop rivets from the kit. Rivet the holder to the door sill panel. ...
Page 172 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 102: Hooking Sill Decore Onto Cradle Courtesy of VOLVO CARS CORPORATION Hook the sill decor onto the cradle. Align the holes in the panel with the hooks in the cradles.
Page 173 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 104: Riveting Mounting Lug To Car Body Courtesy of VOLVO CARS CORPORATION Rivet the mounting lug to the car body with a rivet. Now drill and rivet the holes alternately in front of ...
Page 174 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Remove any shavings.  Fig. 106: Identifying Central Pin Courtesy of VOLVO CARS CORPORATION Fig. 107: Detaching Central Pin From Clip Courtesy of VOLVO CARS CORPORATION NOTE: First detach the central pin from the clip by tapping it in and then pulling it out, but leave it inside the clip a few millimeters.
Page 175 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 108: Cutting Out Panel At Front Mounting Courtesy of VOLVO CARS CORPORATION Cut out the panel at the front mounting.  Fig. 109: Identifying Underside Panel...
Page 176 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 110: Identifying Screws Courtesy of VOLVO CARS CORPORATION NOTE: Do not tighten the clips and screws fully yet. Fig. 111: Identifying Screws And Clips Courtesy of VOLVO CARS CORPORATION...
Page 177 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 112: Tightening Screws And Clips Courtesy of VOLVO CARS CORPORATION Tighten screws and clips.  Repeat steps for the other side.  SKID PLATE, FRONT BUMPER (2009-12)
Page 178  Wipe dry.  Fig. 114: Identifying Air Baffle Center Screws Courtesy of VOLVO CARS CORPORATION Remove the two center screws from the air baffle. They will not be reused.  Fig. 115: Identifying Drilling Template And Skid Plate Courtesy of VOLVO CARS CORPORATION Take the drilling template and skid plate from the kit and press the drilling template into the hole in the ...
Page 179 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 116: Identifying Backing Tape Courtesy of VOLVO CARS CORPORATION Remove the backing tape from both templates.  Fig. 117: Identifying Skid Plate And Screws Courtesy of VOLVO CARS CORPORATION Secure the skid plate using existing screws.
Page 180 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 118: Identifying Skid Plate And Drilling Templates Courtesy of VOLVO CARS CORPORATION Now position the skid plate laterally (1). Ensure that the tape on the drilling templates does not adhere ...
Page 181 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 120: Drilling Out Holes Courtesy of VOLVO CARS CORPORATION Drill out the holes through the taped drilling templates.  Fig. 121: Identifying Drilling Templates Courtesy of VOLVO CARS CORPORATION Remove the drilling templates on both sides.
Page 182 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 122: Drilling Holes Courtesy of VOLVO CARS CORPORATION Drill the holes to 8 mm (5/16 ") .  Remove the shavings and smooth off the hole edges.
Page 183 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 124: Identifying Protective Tape Courtesy of VOLVO CARS CORPORATION Now carefully pull off the protective tape slightly from each piece of tape on both sides and secure on the ...
Page 184 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 126: Cleaning Marked Surfaces Courtesy of VOLVO CARS CORPORATION Clean the marked surfaces for the tape to the skid plate using isopropanol.  Wipe dry.
Page 185 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 128: Identifying Protection Tape Courtesy of VOLVO CARS CORPORATION Hold the skid plate with one hand at the same time as removing the protective tape. ...
Page 186 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 130: Identifying Skid Plate And Screws Courtesy of VOLVO CARS CORPORATION Tighten the skid plate underneath using existing screws.  Fig. 131: Drilling Through Holes In Outer Ends Of Skid Plate And Through Air Baffle Courtesy of VOLVO CARS CORPORATION Drill through the existing holes in the outer ends of the skid plate and through the air baffle.
Page 187 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 132: Riveting Skid Plate In Outer Ends Courtesy of VOLVO CARS CORPORATION Take the rivets from the kit and rivet the skid plate in the outer ends. ...
Page 188 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 134: Tightening Skid Plate Courtesy of VOLVO CARS CORPORATION Tighten the skid plate at the outer ends.  SKID PLATE, REAR BUMPER (2009-12) SKID PLATE, REAR BUMPER Fig.
Page 189 Take extra care not to damage the painted surface of the components. Smooth off the sawn edges with a fine toothed file.  Fig. 136: Sawing Out New Skid Plate Courtesy of VOLVO CARS CORPORATION APPLIES TO CARS WITH PARKING ASSISTANCE Fig. 137: Identifying Sensor Courtesy of VOLVO CARS CORPORATION...
Page 190 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 138: Cleaning Area Using Isopropanol Courtesy of VOLVO CARS CORPORATION Clean using isopropanol .  Allow to dry.  Fig. 139: Applying Layer Of Activator Courtesy of VOLVO CARS CORPORATION Apply a thin and even layer of activator to the cleaned surfaces.
Page 191 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 140: Painting Sensor Courtesy of VOLVO CARS CORPORATION Paint the sensors with color code 426 . Only apply one layer.  CAUTION: Protect the connection's contact surfaces from paint. Too many layers of paint can result in the function partially or totally disappearing.
Page 192 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 142: Drilling Holes Courtesy of VOLVO CARS CORPORATION Drill holes in the centers of the markings using a 3 mm (7/64) diameter drill bit. ...
Page 193 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 144: Cleaning Surfaces Where Holders Are Located Courtesy of VOLVO CARS CORPORATION Clean the surfaces where the holders are to be located using isopropanol and wipe dry. ...
Page 194 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 146: Identifying Holder Courtesy of VOLVO CARS CORPORATION Take the 2 holders from the kit.  Clean the surfaces as shown using a cleaning cloth P/N 9192678 .
Page 195 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 148: Identifying Left Side Wheel Arch Courtesy of VOLVO CARS CORPORATION Fig. 149: Identifying Right Side Wheel Arch Courtesy of VOLVO CARS CORPORATION...
Page 196 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 150: Identifying Bolts And Washers Under Rear Bumper Courtesy of VOLVO CARS CORPORATION Fig. 151: Identifying Rear Sill Plates Courtesy of VOLVO CARS CORPORATION...
Page 197 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 152: Identifying Piece Of Tape On Wind Extender's Rear Section Courtesy of VOLVO CARS CORPORATION Attach a piece of tape to the wing extender's rear section to protect it when removing the bumper cover at ...
Page 198 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Remove the pieces of tape.  Fig. 154: Identifying Connector For License Plate Lighting Courtesy of VOLVO CARS CORPORATION APPLIES TO CARS WITH PARKING ASSISTANCE Fig. 155: Disconnecting Connectors For Center Sensors Courtesy of VOLVO CARS CORPORATION Disconnect the connectors for the two center sensors.
Page 199 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 156: Prying Up Hooks On Each Sensor Holder Courtesy of VOLVO CARS CORPORATION Pry up the two hooks on each sensor holder and carefully pull out the sensors. They are to be reused.
Page 200 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 158: Prying Off Hooks From Mountings In Bumper Cover Courtesy of VOLVO CARS CORPORATION NOTE: Take extra care when working with the bumper cover and Skid plate.
Page 201 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 160: Installing Tape On The Holders Courtesy of VOLVO CARS CORPORATION Attach the tape to the holders.  Fig. 161: Cutting Off Holders With Tape On Both Sides Courtesy of VOLVO CARS CORPORATION Cut off the holders with tape on both long sides so that a result is achieved shown below.
Page 202 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 162: Identifying Result Of Cutting Off Holders With Tape Courtesy of VOLVO CARS CORPORATION Fig. 163: Identifying Centering Tool Courtesy of VOLVO CARS CORPORATION Install the centering tool in the holder as shown.
Page 203 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 164: Identifying Remaining Protective Film Courtesy of VOLVO CARS CORPORATION Remove the remaining protective film.  Fig. 165: Pressing Holders Into Place Using Centering Tool On Bumper Cover Courtesy of VOLVO CARS CORPORATION Press the holders into place using the centering tool on the bumper cover.
Page 204 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 166: Identifying Skid Plate Courtesy of VOLVO CARS CORPORATION Install the new Skid plate. Ensure that all the catches engage.  APPLIES TO CARS WITH PARKING ASSISTANCE Fig.
Page 205 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 168: Identifying Sensors Courtesy of VOLVO CARS CORPORATION Install the two sensors.  Fig. 169: Connecting Connectors To Sensors Courtesy of VOLVO CARS CORPORATION Connect the connectors to the sensors.
Page 206 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 170: Connecting Connector To Number Plate Lighting Courtesy of VOLVO CARS CORPORATION Connect the connector to the number plate lighting and to the parking assistance connector, if applicable. ...
Page 207 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 172: Identifying Screws Courtesy of VOLVO CARS CORPORATION Fig. 173: Identifying Rear Sill Plates Courtesy of VOLVO CARS CORPORATION...
Page 208 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 174: Identifying Left Side Wheel Arch Courtesy of VOLVO CARS CORPORATION Fig. 175: Identifying Right Side Wheel Arch Courtesy of VOLVO CARS CORPORATION...
Page 209 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 176: Identifying VIDA (Service Information) To Program Software Courtesy of VOLVO CARS CORPORATION Download software for the accessory's function according to service information in VIDA (Volvo Scan  Tool).
Page 210 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 178: Identifying Left Wheel Arch Lining And Screws Courtesy of VOLVO CARS CORPORATION Fig. 179: Identifying Bolts And Washers Under Rear Bumper Courtesy of VOLVO CARS CORPORATION...
Page 211 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 180: Identifying Rear Sill Plates Courtesy of VOLVO CARS CORPORATION Fig. 181: Identifying Bumper Cover Courtesy of VOLVO CARS CORPORATION Remove the bumper cover from the body by carefully prying off the ends using a weatherstrip tool. Pull ...
Page 212 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 182: Identifying Connector For License Plate Lighting Courtesy of VOLVO CARS CORPORATION Unplug the connector for the license plate lighting on the left side. If the car is equipped with reverse ...
Page 213 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 184: Identifying Fender Liner With Clips Courtesy of VOLVO CARS CORPORATION Loosen the fender liner with the three clips from the panel's clips by first pressing it in until the three clips ...
Page 214 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 186: Identifying Screws Courtesy of VOLVO CARS CORPORATION Fig. 187: Identifying Front Fender's Panel Courtesy of VOLVO CARS CORPORATION Carefully bend loose the front fender's panel starting at the leading edge and then backward. Bend with ...
Page 215 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 188: Identifying Fender Liner Courtesy of VOLVO CARS CORPORATION Loosen the fender liner with the three clips from the panel's clips by first pressing it in until the three clips ...
Page 216 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories APPLIES TO CARS WITH 4-CYLINDER ENGINE WHERE ELECTRIC ENGINE HEATER IS INSTALLED Fig. 190: Identifying Engine Splash Guard Courtesy of VOLVO CARS CORPORATION Remove the seven screws from the engine splash guard. ...
Page 217 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 192: Identifying Nut Holding Wing Liner At Left-Hand Front Member Courtesy of VOLVO CARS CORPORATION Remove the nut holding the left-hand wing liner to the front member. ...
Page 218 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 194: Identifying Cable Pressed Into Previously Installed Clips Courtesy of VOLVO CARS CORPORATION Loosen the cable from the double clamp (1) at the brake pipe and from clamps along the side member's ...
Page 219 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 196: Identifying Tie Strap Courtesy of VOLVO CARS CORPORATION Cut off the cable tie (1) that holds the cable to the left radiator bracket. ...
Page 220 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 198: Identifying Screws Holding Bumper Cover At Left-Hand Wing Liner Courtesy of VOLVO CARS CORPORATION Remove the left and right-hand front wheels.  Remove the five screws holding the bumper cover in the wing liner on the left and right-hand sides.
Page 221 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 200: Identifying Locking Sleeve Courtesy of VOLVO CARS CORPORATION Remove the lock sleeve over the joint to the engine heater's cable on the right side by the stay on the sub- ...
Page 222 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 202: Identifying Tie Strap Courtesy of VOLVO CARS CORPORATION Remove the cable tie that holds the cable to the cable harness at the top in the engine compartment. ...
Page 223 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 204: Identifying Double Clamp Courtesy of VOLVO CARS CORPORATION Loosen the cable from the double clamp by the brake pipe in the top edge of the bulkhead on the left side.
Page 224 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 206: Identifying Ground Lead With Screw And Toothed Washer Courtesy of VOLVO CARS CORPORATION Does not apply to cars for USA. Loosen the ground cable from the leading edge of the side member's outside.
Page 225 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 208: Identifying Clips And Screws Courtesy of VOLVO CARS CORPORATION Push in the center of the five clips (1). Remove the clips.  Remove the two screws (2).
Page 226 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 210: Identifying Catch Pressed Up Courtesy of VOLVO CARS CORPORATION Press the catch up and remove the cover. Do not damage the painted surfaces or the high-pressure washer ...
Page 227 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 212: Identifying Corner Of Bumper Cover Courtesy of VOLVO CARS CORPORATION Carefully pry off the corner of the bumper cover using a weatherstrip tool until the three hooks on the ...
Page 228 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 214: Identifying Screws Courtesy of VOLVO CARS CORPORATION Fig. 215: Identifying Bottom Sill's Panel Courtesy of VOLVO CARS CORPORATION Drive out the center pin in the clips on the underside of the bottom sill's panel. On the two front clips, the ...
Page 229 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 216: Identifying Bottom Sill's Panel Courtesy of VOLVO CARS CORPORATION Remove the bottom sill's panel by carefully bending it loose directly opposite the clips along its entire ...
Page 230  Fig. 218: Bending And Pulling Loose Bumper's Lower Part From Upper Part Courtesy of VOLVO CARS CORPORATION Get help from a colleague for this procedure. Place the bumper casing on a surface that will not damage the painted surface.
Page 231 Do not damage the painted surface on the upper part. Fig. 220: Pressing In Clips For Cable Harness For Reverse Warning In Spoiler's Catches Courtesy of VOLVO CARS CORPORATION Applies to cars with reverse warning Press in the clips for the cable harness for the reverse warning in the spoiler's catches.
Page 232 Fig. 222: Inserting Plastic String For Towing Eye's In Rectangular Hole In Lower Edge Of Opening Courtesy of VOLVO CARS CORPORATION Insert the plastic string for the towing eye's in the rectangular hole in the lower edge of the opening.
Page 233 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 224: Connecting Connector To Number Plate Lighting Courtesy of VOLVO CARS CORPORATION Fig. 225: Identifying Bumper Cover Courtesy of VOLVO CARS CORPORATION...
Page 234 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 226: Identifying Screws Courtesy of VOLVO CARS CORPORATION Fig. 227: Identifying Rear Sill Plates Courtesy of VOLVO CARS CORPORATION FRONT SPOILER...
Page 235 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 228: Loosening Holder From Bumper Casing's Upper Part Courtesy of VOLVO CARS CORPORATION Loosen the holder from the bumper casing's upper part on both sides. ...
Page 236 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 230: Cleaning Areas Underneath Spoiler Courtesy of VOLVO CARS CORPORATION Take the front spoiler from the kit.  NOTE: The unpainted spoiler must be painted first.
Page 237 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 232: Securing Anti-Chafing Protector Aling Edges Of Spoiler Courtesy of VOLVO CARS CORPORATION Position and secure the anti-chafing protector along the edges of the spoiler at the rear edge.
Page 238 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 234: Identifying Protective Tape Courtesy of VOLVO CARS CORPORATION Remove the protective tape from the anti-chafing protector.  Fig. 235: Identifying Anti-Chafing Protector Courtesy of VOLVO CARS CORPORATION Press the anti-chafing protector into place.
Page 239 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 236: Identifying Protective Tape Courtesy of VOLVO CARS CORPORATION Remove the protective tape from the anti-chafing protector.  Fig. 237: Identifying Anti-Chafing Protector Courtesy of VOLVO CARS CORPORATION Press the anti-chafing protector into place.
Page 240 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 238: Identifying Front Spoiler Courtesy of VOLVO CARS CORPORATION Press the front spoiler into the upper section.  Make sure that all catches engage. ...
Page 241 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 240: Identifying Clips And Screws Courtesy of VOLVO CARS CORPORATION Secure the bumper casing with the clips (1) and screws (2).  Fig. 241: Pulling Up High-Pressure Nozzle From Bumper Casing Courtesy of VOLVO CARS CORPORATION Pull up the high-pressure nozzle from the bumper casing and install the covers on both sides.
Page 242 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 242: Identifying Spoiler's Brackets And Baffle's Outer Screw Courtesy of VOLVO CARS CORPORATION Tighten the spoiler's brackets to the baffle.  Tighten the baffle's outer screw on both sides.
Page 243 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 244: Identifying Fog Light Panel (2 Of 2) Courtesy of VOLVO CARS CORPORATION DOOR SILL PANEL Fig. 245: Identifying Bottom Sill Panel Courtesy of VOLVO CARS CORPORATION Get a new bottom sill panel and new clips from the kit.
Page 244 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 246: Pressing In New Panel In Bottom Sill Courtesy of VOLVO CARS CORPORATION Press in the new panel in the bottom sill. Make sure all catches engage. ...
Page 245 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 248: Identifying Clips And Panel Courtesy of VOLVO CARS CORPORATION Get the new panel and new clips for the fender edge from the kit. ...
Page 246 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 250: Identifying Fender Liner And Clips Courtesy of VOLVO CARS CORPORATION Reinstall the fender liner.  Get new clips from the kit and press in to the fender liner.
Page 247 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 252: Identifying Screws On Front Fender Front Edge Courtesy of VOLVO CARS CORPORATION Fig. 253: Identifying Screws On Front Fender Rear Edge Courtesy of VOLVO CARS CORPORATION...
Page 248 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 254: Identifying Screws On Rear Fender Front Edge Courtesy of VOLVO CARS CORPORATION Fig. 255: Identifying Screws On Rear Fender Rear Edge Courtesy of VOLVO CARS CORPORATION Repeat for all wheel housing edges.
Page 249 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 256: Identifying Body Section Courtesy of VOLVO CARS CORPORATION Fig. 257: Turning Wheel Courtesy of VOLVO CARS CORPORATION...
Page 250 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 258: Cleaning Area Where Mudflap Is To Be Positioned Courtesy of VOLVO CARS CORPORATION Fig. 259: Identifying Screws Courtesy of VOLVO CARS CORPORATION...
Page 251 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 260: Identifying Rivets And Panel Courtesy of VOLVO CARS CORPORATION Fig. 261: Identifying Mud Guards, Front Drilling Location Courtesy of VOLVO CARS CORPORATION...
Page 252 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 262: Identifying Body Section Courtesy of VOLVO CARS CORPORATION Fig. 263: Identifying Wheel Courtesy of VOLVO CARS CORPORATION...
Page 253 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 264: Cleaning Installation Area Courtesy of VOLVO CARS CORPORATION Fig. 265: Removing Fender Clips Courtesy of VOLVO CARS CORPORATION...
Page 254 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 266: Installing Rear Clips Courtesy of VOLVO CARS CORPORATION Fig. 267: Identifying Drilling Location Courtesy of VOLVO CARS CORPORATION...
Page 255 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 268: Install Wheel And Tighten To Specification Courtesy of VOLVO CARS CORPORATION MUDFLAPS (2010-12) MUDFLAPS Fig. 269: Identifying Body Section Courtesy of VOLVO CARS CORPORATION...
Page 256 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 270: Turning Wheel Courtesy of VOLVO CARS CORPORATION Turn the wheel.  Fig. 271: Cleaning Area Where Mudflap Is To Be Positioned Courtesy of VOLVO CARS CORPORATION Clean the area where the mudflap is to be positioned.
Page 257 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 272: Identifying Screws Courtesy of VOLVO CARS CORPORATION Fig. 273: Identifying Rivets And Panel Courtesy of VOLVO CARS CORPORATION...
Page 258 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 274: Drilling Hole For Rivet Courtesy of VOLVO CARS CORPORATION Fig. 275: Identifying Body Section Courtesy of VOLVO CARS CORPORATION...
Page 259 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 276: Identifying Wheel Courtesy of VOLVO CARS CORPORATION Fig. 277: Identifying Rivets Courtesy of VOLVO CARS CORPORATION NOTE: These will not be reused.
Page 260 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 278: Identifying Area That Is To Be Cleaned Courtesy of VOLVO CARS CORPORATION Clean the area where the mudflap is to be positioned.  Fig. 279: Identifying Wing Liner Courtesy of VOLVO CARS CORPORATION Fold the wing liner out of the way.
Page 261 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 280: Identifying Clip Courtesy of VOLVO CARS CORPORATION Install the clip.  Fig. 281: Identifying Mudflap Courtesy of VOLVO CARS CORPORATION Fold the inner wing back and install the mudflap.
Page 262 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 282: Identifying Rivets Courtesy of VOLVO CARS CORPORATION Fig. 283: Drilling Hole For Rivet Courtesy of VOLVO CARS CORPORATION...
Page 263 2012 Volvo C30 T-5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories Fig. 284: Install And Tighten Wheel To Wheel Hub Courtesy of VOLVO CARS CORPORATION Wheel to wheel hub tightening torque: Step 1: Wheel to wheel hub, 20 Nm.
Page 264 COVER BUMPER FRONT (2007 - 2011 EARLY) REMOVAL VEHICLES EARLY VERSION Fig. 1: Identifying Bumper Attachment Screws On Front Frame Courtesy of VOLVO CARS CORPORATION Fig. 2: Identifying Bumper Screws On Inner Front Fender Courtesy of VOLVO CARS CORPORATION VEHICLES WITH FRONT SIDE UNDERBODY AIR DEFLECTOR...
Page 265 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 3: Identifying Rear Fender Splash Guard Attachment Screws Courtesy of VOLVO CARS CORPORATION VEHICLES WITH FRONT UNDERBODY AIR DEFLECTOR Fig. 4: Identifying Front Underbody Air Deflector Attachment Screws...
Page 266 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 5: Identifying Rear Bumper Attachment Screws Courtesy of VOLVO CARS CORPORATION ALL VEHICLES Fig. 6: Identifying Front Bumper Removal Points Courtesy of VOLVO CARS CORPORATION WARNING: Be prepared to collect escaping fluid.
Page 267 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 7: Identifying Fog Light Connectors Courtesy of VOLVO CARS CORPORATION VEHICLES WITHOUT UNDERBODY AIR DEFLECTORS Fig. 8: Identifying Underbody Air Deflector Attachment Screws...
Page 268 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 9: Identifying Fog Light Removal Points Courtesy of VOLVO CARS CORPORATION Remove the following items: headlight washers, see HEADLIGHT WASHERS  Front fog lights, see FRONT FOG LIGHTS ...
Page 269 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 11: Identifying Mating Face Courtesy of VOLVO CARS CORPORATION CAUTION: Take extra care not to damage the mating faces. On both sides. Fig. 12: Identifying Bumper Attachment Screws On Front Frame...
Page 270 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 13: Identifying Bumper Attachment Screws On Inner Front Fender Courtesy of VOLVO CARS CORPORATION On both sides. VEHICLES WITH FRONT SIDE UNDERBODY AIR DEFLECTOR Fig.
Page 271 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 15: Identifying Front Underbody Air Deflector Attachment Screws Courtesy of VOLVO CARS CORPORATION VEHICLES WITHOUT UNDERBODY AIR DEFLECTORS Fig. 16: Identifying Under Carriage Bumper Attachment Screws...
Page 272 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 17: Identifying Complete Front Bumper Removal Courtesy of VOLVO CARS CORPORATION NOTE: This step requires the aid of another technician. On both sides.
Page 273 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 19: Identifying Underbody Air Deflector Attachment Screws Courtesy of VOLVO CARS CORPORATION ALL VEHICLES Remove the following items: radiator grille, see RADIATOR GRILLE ...
Page 274 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation REMOVAL Fig. 21: Identifying Mating Face Courtesy of VOLVO CARS CORPORATION CAUTION: Take extra care not to damage the mating faces. On both sides. Fig. 22: Identifying Bumper Attachment Screws On Front Frame...
Page 275 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 23: Identifying Bumper Attachment Screws On Inner Front Fender Courtesy of VOLVO CARS CORPORATION On both sides. VEHICLES WITH FRONT SIDE UNDERBODY AIR DEFLECTOR Fig.
Page 276 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 25: Identifying Front Underbody Air Deflector Attachment Screws Courtesy of VOLVO CARS CORPORATION VEHICLES WITHOUT UNDERBODY AIR DEFLECTORS Fig. 26: Identifying Under Carriage Bumper Attachment Screws...
Page 277 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 27: Identifying Complete Front Bumper Removal Courtesy of VOLVO CARS CORPORATION WARNING: Be prepared to collect escaping fluid. NOTE: This step requires the aid of another technician.
Page 278 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 29: Identifying Underbody Air Deflector Attachment Screws Courtesy of VOLVO CARS CORPORATION ALL VEHICLES Remove the following items: radiator grille, see RADIATOR GRILLE ...
Page 279 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 31: Removing Rear Bumper Cover - All Versions (1 Of 9) Courtesy of VOLVO CARS CORPORATION Fig. 32: Removing Rear Bumper Cover - All Versions (2 Of 9)
Page 280 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 33: Removing Rear Bumper Cover - All Versions (3 Of 9) Courtesy of VOLVO CARS CORPORATION On both sides. Fig. 34: Removing Rear Bumper Cover - All Versions (4 Of 9)
Page 281 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 35: Early Version (1 Of 5) Courtesy of VOLVO CARS CORPORATION NOTE: This step requires the aid of another technician. On both sides.
Page 282 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 37: Early Version (3 Of 5) Courtesy of VOLVO CARS CORPORATION On both sides. Fig. 38: Early Version (4 Of 5) Courtesy of VOLVO CARS CORPORATION...
Page 283 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 39: Early Version (5 Of 5) Courtesy of VOLVO CARS CORPORATION VEHICLES LATE VERSION Fig. 40: Late Version (1 Of 8) Courtesy of VOLVO CARS CORPORATION NOTE: This step requires the aid of another technician.
Page 284 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 42: Late Version (3 Of 8) Courtesy of VOLVO CARS CORPORATION Fig. 43: Late Version (4 Of 8) Courtesy of VOLVO CARS CORPORATION...
Page 285 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 44: Late Version (5 Of 8) Courtesy of VOLVO CARS CORPORATION Fig. 45: Late Version (6 Of 8) Courtesy of VOLVO CARS CORPORATION Fig.
Page 286 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 47: Late Version (8 Of 8) Courtesy of VOLVO CARS CORPORATION ALL VEHICLES Fig. 48: Removing Rear Bumper Cover - All Versions (5 Of 9)
Page 287 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 49: Removing Rear Bumper Cover - All Versions (6 Of 9) Courtesy of VOLVO CARS CORPORATION Fig. 50: Removing Rear Bumper Cover - All Versions (7 Of 9)
Page 288 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 51: Removing Rear Bumper Cover - All Versions (8 Of 9) Courtesy of VOLVO CARS CORPORATION Fig. 52: Removing Rear Bumper Cover - All Versions (9 Of 9)
Page 289 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 53: Removing Rear Bumper Cover (1 Of 17) Courtesy of VOLVO CARS CORPORATION Fig. 54: Removing Rear Bumper Cover (2 Of 17) Courtesy of VOLVO CARS CORPORATION Fig.
Page 290 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 56: Removing Rear Bumper Cover (4 Of 17) Courtesy of VOLVO CARS CORPORATION Fig. 57: Removing Rear Bumper Cover (5 Of 17) Courtesy of VOLVO CARS CORPORATION NOTE: This step requires the aid of another technician.
Page 291 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 58: Removing Rear Bumper Cover (6 Of 17) Courtesy of VOLVO CARS CORPORATION Fig. 59: Removing Rear Bumper Cover (7 Of 17) Courtesy of VOLVO CARS CORPORATION...
Page 292 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 60: Removing Rear Bumper Cover (8 Of 17) Courtesy of VOLVO CARS CORPORATION Fig. 61: Removing Rear Bumper Cover (9 Of 17) Courtesy of VOLVO CARS CORPORATION Fig.
Page 293 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 63: Removing Rear Bumper Cover (11 Of 17) Courtesy of VOLVO CARS CORPORATION Fig. 64: Removing Rear Bumper Cover (12 Of 17) Courtesy of VOLVO CARS CORPORATION...
Page 294 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 65: Removing Rear Bumper Cover (13 Of 17) Courtesy of VOLVO CARS CORPORATION Fig. 66: Removing Rear Bumper Cover (14 Of 17) Courtesy of VOLVO CARS CORPORATION Fig.
Page 295 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 68: Removing Rear Bumper Cover (16 Of 17) Courtesy of VOLVO CARS CORPORATION Fig. 69: Removing Rear Bumper Cover (17 Of 17) Courtesy of VOLVO CARS CORPORATION INSTALLATION To install, reverse the removal procedure.
Page 296 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 70: Removing Rear Bumper Cover Lower Section (1 Of 9) Courtesy of VOLVO CARS CORPORATION Fig. 71: Removing Rear Bumper Cover Lower Section (2 Of 9) Courtesy of VOLVO CARS CORPORATION...
Page 297 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 73: Removing Rear Bumper Cover Lower Section (4 Of 9) Courtesy of VOLVO CARS CORPORATION NOTE: This step requires assistance from another technician.
Page 298 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 75: Removing Rear Bumper Cover Lower Section (6 Of 9) Courtesy of VOLVO CARS CORPORATION Fig. 76: Removing Rear Bumper Cover Lower Section (7 Of 9) Courtesy of VOLVO CARS CORPORATION...
Page 299 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 78: Removing Rear Bumper Cover Lower Section (9 Of 9) Courtesy of VOLVO CARS CORPORATION REAR BUMPER COVER LOWER SECTION (2010 - 2011 EARLY) REMOVAL Fig.
Page 300 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 80: Removing Rear Bumper Cover Lower Section - All Vehicles (2 Of 8) Courtesy of VOLVO CARS CORPORATION VEHICLES WITH REAR UNDERBODY AIR DEFLECTOR Fig. 81: Removing Rear Bumper Cover Lower Section - Vehicles With Rear Underbody Air Deflector...
Page 301 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 82: Removing Rear Bumper Cover Lower Section - Vehicles Without Underbody Air Deflectors Courtesy of VOLVO CARS CORPORATION ALL VEHICLES Fig. 83: Removing Rear Bumper Cover Lower Section - All Vehicles (3 Of 8)
Page 302 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 84: Removing Rear Bumper Cover Lower Section - All Vehicles (4 Of 8) Courtesy of VOLVO CARS CORPORATION Fig. 85: Removing Rear Bumper Cover Lower Section - All Vehicles (5 Of 8) Courtesy of VOLVO CARS CORPORATION Fig.
Page 303 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 87: Removing Rear Bumper Cover Lower Section - All Vehicles (7 Of 8) Courtesy of VOLVO CARS CORPORATION Fig. 88: Removing Rear Bumper Cover Lower Section - All Vehicles (8 Of 8)
Page 304 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 89: Removing Rear Bumper Cover Upper Section (1 Of 4) Courtesy of VOLVO CARS CORPORATION Fig. 90: Removing Rear Bumper Cover Upper Section (2 Of 4) Courtesy of VOLVO CARS CORPORATION NOTE: This step requires the aid of another technician.
Page 305 ACCESSORIES AND BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation Fig. 91: Removing Rear Bumper Cover Upper Section (3 Of 4) Courtesy of VOLVO CARS CORPORATION Fig. 92: Removing Rear Bumper Cover Upper Section (4 Of 4) Courtesy of VOLVO CARS CORPORATION...
Page 306 2012 Volvo C30 T-5 2012 Volvo C30 T-5 CABIN AIR FILTER Volvo - C30 & C70 CABIN AIR FILTER Volvo - C30 & C70 CABIN AIR FILTER Volvo - C30 & C70 REMOVAL & INSTALLATION NOTE: Manufacturer's terminology for this filter is passenger compartment air cleaner or particle filter.
Page 307 2012 Volvo C30 T-5 CABIN AIR FILTER Volvo - C30 & C70 the 3 screws and raise the cover  Fig. 2: Identifying Passenger Compartment Air Cleaner (ACL) Courtesy of VOLVO CARS CORPORATION the filter by pulling it out behind the brake pedal.
Page 308 2012 Volvo C30 T-5 CABIN AIR FILTER Volvo - C30 & C70 Fig. 3: Identifying Passenger Compartment Air Cleaner (ACL) Courtesy of VOLVO CARS CORPORATION NOTE: The direction of the air flow is indicated on the top of the filter. Ensure that the filter is installed with the text side facing up and so that the arrows on the filter point straight back into the vehicle.
Page 309 2012 Volvo C30 T-5 2012 Volvo C30 T-5 ELECTRICAL Body Electrical ELECTRICAL Body Electrical ELECTRICAL Body Electrical CAN NETWORK FAULT TRACING ON CAN NETWORK SIGNAL MISSING GENERAL INFORMATION NOTE: Illustrations shown are only examples. HINT: For general information about CAN-troubleshooting: see GENERAL INFORMATION ABOUT FAULT-TRACING IN THE CAN NETWORK ...
Page 310 Central electronic module (CEM) should not be replaced in case of CAN- fault, unless troubleshooting reveals that Central electronic module (CEM) has an internal fault. Fig. 1: View Of Control Module Block Diagram, Communications Network, And Trouble Codes Courtesy of VOLVO CARS CORPORATION Continue  Refer to CHECKING RESISTANCE IN CAN-NET CHECKING RESISTANCE IN CAN-NET Fig.
Page 311 2012 Volvo C30 T-5 ELECTRICAL Body Electrical Connect OBDII-Box (951 3015) to the diagnostics socket.  For general information about CAN-troubleshooting: see GENERAL INFORMATION ABOUT FAULT-TRACING IN THE CAN NETWORK  Measure resistance between the following connections on the OBDII-box/diagnostics socket.
Page 312 2012 Volvo C30 T-5 ELECTRICAL Body Electrical Fig. 3: Identifying Resistance Measurement In Low-Speed Net LS CAN Courtesy of VOLVO CARS CORPORATION Was a fault detected?  Refer to VERIFICATION  Refer to CHECKING SHORT-CIRCUITING TO GROUND/VOLTAGE IN CAN-NET CHECKING THE TRAFFIC LOAD ON THE CAN CABLES Fig.
Page 313 2012 Volvo C30 T-5 ELECTRICAL Body Electrical Faults in the CAN network may be due to a control module sending faulty messages that disrupt normal communication. When messages are sent incorrectly, this results in a considerable increase in the amount of traffic on the CAN network.
Page 314 TROUBLESHOOTING USING DICE ERROR FRAME FINDER  see CHECKING WIRING AND TERMINALS  Fig. 5: Identifying PCM Wiring Terminals Courtesy of VOLVO CARS CORPORATION Was a fault detected?  Refer to IDENTIFYING A CONTROL MODULE IN THE CAN NETWORK ...
Page 315 2012 Volvo C30 T-5 ELECTRICAL Body Electrical For general information about CAN-troubleshooting: see GENERAL INFORMATION ABOUT FAULT-TRACING IN THE CAN NETWORK  HINT: DiCE can be used as fault detection tool if fault is suspected on the CAN-net that cannot be detected with normal troubleshooting.
Page 316 For certain faults in the CAN-net where control modules have stopped communicating, it may help to disconnect/reconnect the battery to "restart" the control module/CAN-net. Fig. 7: Identifying CCM Schematic Courtesy of VOLVO CARS CORPORATION Continue  Refer to VERIFICATION VERIFICATION HINT: Once a fault has been repaired, conduct a verification to check that the fault has been remedied.
Page 317 2012 Volvo C30 T-5 ELECTRICAL Body Electrical Fig. 9: Identifying Belt Routing Courtesy of VOLVO CARS CORPORATION Reinstall the connectors, components etc.  Ignition on  NOTE: For certain faults in the CAN-net where control modules have stopped communicating, it may help to disconnect/reconnect the battery to "restart"...
Page 318 2012 Volvo C30 T-5 ELECTRICAL Body Electrical Connect OBDII-Box (951 3015) to the diagnostics socket.  For general information about CAN-troubleshooting: see GENERAL INFORMATION ABOUT FAULT-TRACING IN THE CAN NETWORK  Checking for a short-circuit to ground Measure resistance between the following connections on the OBDII-box/diagnostics socket.
Page 319 2012 Volvo C30 T-5 ELECTRICAL Body Electrical Fig. 11: Identifying OWS Schematic Courtesy of VOLVO CARS CORPORATION Was a fault detected?  Refer to VERIFICATION  Refer to CHECKING THE TRAFFIC LOAD ON THE CAN CABLES CHECKING VOLTAGE-DROP IN CABLE FOR CAN-H AND CAN-L, RESPECTIVELY Fig.
Page 320 2012 Volvo C30 T-5 ELECTRICAL Body Electrical In principle, the voltage measured in each cable in the CAN-net shall be the same at each control module in the network. This means that the voltage-drop in the cable for CAN-H and CAN-L, respectively, between the control modules should be very low.
Page 321 2012 Volvo C30 T-5 ELECTRICAL Body Electrical Fig. 13: Identifying DIM Wiring Terminals Courtesy of VOLVO CARS CORPORATION Continue  Refer to VERIFICATION INFORMATION FAULT-TRACING INFORMATION The fault should have been detected and remedied. As this is not the case fault-tracing has failed.
Page 322 Wait at least five minutes before disassembling the connectors or removing other electrical equipment. Fig. 1: Identifying Door Handle Internal Panel Courtesy of VOLVO CARS CORPORATION Remove the door handle's interior panel Carefully pry loose the door handle's small interior panel by positioning a weatherstrip in the joint ...
Page 323 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Interior - Installation Instructions, Accessories Fig. 2: Identifying Door Handle Clips Courtesy of VOLVO CARS CORPORATION Carefully pry around the door handle panel with door module so that the six clips release and the ...
Page 324 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Interior - Installation Instructions, Accessories Fig. 4: Identifying Door Module Screws Courtesy of VOLVO CARS CORPORATION Removing the door module Remove the four screws holding the door module at the panel. ...
Page 325 ACCESSORIES AND BODY, CAB Interior - Installation Instructions, Accessories Fig. 5: Attaching Sun Visor To Top Of Child Seat Courtesy of VOLVO CARS CORPORATION The sun visor can be attached to the top of the child seat with the press studs.
Page 326 ACCESSORIES AND BODY, CAB Interior - Installation Instructions, Accessories Fig. 7: Child Seat Sun Visor (2 Of 3) Courtesy of VOLVO CARS CORPORATION The sun visor can also be secured in the seat belt lead-ins in the seat backrest. ...
Page 327 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Interior - Installation Instructions, Accessories Fig. 9: Identifying Luggage Compartment Windows Courtesy of VOLVO CARS CORPORATION INSTALLING Fig. 10: Identifying Sun Blind Courtesy of VOLVO CARS CORPORATION...
Page 328 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Interior - Installation Instructions, Accessories Fig. 11: View Of Sun Blind Clips Courtesy of VOLVO CARS CORPORATION Fig. 12: Identifying Sun Blind Clips Installation Courtesy of VOLVO CARS CORPORATION REMOVING NOTE: When removing the sun blind, hold the clips by the rear windscreen so that they...
Page 329 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Interior - Installation Instructions, Accessories Fig. 13: Folding Rear Window Sun Blind (1 of 4) Courtesy of VOLVO CARS CORPORATION Fig. 14: Folding Rear Window Sun Blind (2 of 4) Courtesy of VOLVO CARS CORPORATION...
Page 330 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Interior - Installation Instructions, Accessories Fig. 15: Folding Rear Window Sun Blind (3 of 4) Courtesy of VOLVO CARS CORPORATION Fig. 16: Folding Rear Window Sun Blind (4 of 4) Courtesy of VOLVO CARS CORPORATION...
Page 331 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Interior - Installation Instructions, Accessories Fig. 17: Identifying Rear Side Window Sun Blind Courtesy of VOLVO CARS CORPORATION Fig. 18: Installing Rear Side Window Sun Blind Courtesy of VOLVO CARS CORPORATION...
Page 332 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Interior - Installation Instructions, Accessories Fig. 19: View Of Rear Side Window Sun Blind Courtesy of VOLVO CARS CORPORATION ARMREST, REAR SEAT (2007-2008) ARMREST, REAR SEAT REMOVE Fig. 20: Identifying Backrest Panel...
Page 333 ACCESSORIES AND BODY, CAB Interior - Installation Instructions, Accessories Fig. 21: Identifying Rear Seat Cushion Courtesy of VOLVO CARS CORPORATION Pull off the seat cushion, first at the rear edge where it is secured by one holder. Then at the front edge ...
Page 334 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Interior - Installation Instructions, Accessories Fig. 23: Identifying Armrest Mounting Courtesy of VOLVO CARS CORPORATION Fig. 24: Removing Backrest Courtesy of VOLVO CARS CORPORATION Fold the backrest away from the left-hand mounting.
Page 335 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Interior - Installation Instructions, Accessories Fig. 25: View Of Control Arm Lug Components Courtesy of VOLVO CARS CORPORATION Fig. 26: Identifying Control Arm Lug Courtesy of VOLVO CARS CORPORATION Install the new bearing on the backrest's shaft journal. Ensure that the control arm's lug (1) locates in the ...
Page 336 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Interior - Installation Instructions, Accessories Fig. 27: Reinstall The Backrest Courtesy of VOLVO CARS CORPORATION Reinstall the backrest. Check that it is securely in its mountings.  Fig. 28: View Of Screw And Lock Pin Courtesy of VOLVO CARS CORPORATION Secure the backrest in the left-hand mounting with the screw and lock pin.
Page 337 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Interior - Installation Instructions, Accessories Fig. 29: Installing Backrest Cover Courtesy of VOLVO CARS CORPORATION Fig. 30: Repositioning Backseat Courtesy of VOLVO CARS CORPORATION Repeat points for the other backrest. ...
Page 338 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Interior - Installation Instructions, Accessories Fig. 31: Identifying Central Arm Rest Courtesy of VOLVO CARS CORPORATION Install the central armrest by grasping each end, moving it up towards the backrest lugs (1) and aligning ...
Page 339 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Interior - Installation Instructions, Accessories Fig. 33: Identifying Passenger Seat Backrest Forward Courtesy of VOLVO CARS CORPORATION Fold the passenger seat backrest forward.  Fig. 34: View Of Seat Runners Courtesy of VOLVO CARS CORPORATION Slide the front seat as far forward as possible so that the seat wings are visible.
Page 340 ACCESSORIES AND BODY, CAB Interior - Installation Instructions, Accessories Fig. 35: View Of Seat Runner Screw Courtesy of VOLVO CARS CORPORATION Remove the seat wings on the left side by using a screwdriver to pry between the wings and the seat rail ...
Page 341 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Interior - Installation Instructions, Accessories Fig. 37: Tighten Nut Jacket On Eyelet Courtesy of VOLVO CARS CORPORATION Tighten the nut jacket on the eyelet on the left and right side.  NOTE: Store the removed seat wings in a suitable spot so that they can be reinstalled if the child seat eyelets are removed.
Page 342 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Interior - Installation Instructions, Accessories Fig. 38: Folding Backrest Forward On Front Passenger Side Courtesy of VOLVO CARS CORPORATION Fold the backrest forward on the front passenger side.  INSTALL Fig. 39: ISOFIX Attachment And Screws Courtesy of VOLVO CARS CORPORATION Install the ISOFIX attachment to the SIPS tube with the four screws from the kit.
Page 343 ACCESSORIES AND BODY, CAB Interior - Installation Instructions, Accessories REMOVE / INSTALL Fig. 40: Identifying RH Tunnel Console Floor Carpet Courtesy of VOLVO CARS CORPORATION Fold down the floor carpet on the right-hand side of the tunnel console.  Fig. 41: View Of Center Console Mounting Screw Courtesy of VOLVO CARS CORPORATION Remove the rear screw in the center console mounting.
Page 344 ACCESSORIES AND BODY, CAB Interior - Installation Instructions, Accessories Fig. 42: Identifying LH Mounting Screw Courtesy of VOLVO CARS CORPORATION Install the left-hand mounting with the existing screw. Torque tighten the screw to 24 Nm (18 lbf. ft.) . ...
Page 345 ACCESSORIES AND BODY, CAB Interior - Installation Instructions, Accessories Fig. 44: View Of Floor Carpet Mounting Eyelet Courtesy of VOLVO CARS CORPORATION Make a small cut in the floor carpet opposite the marking, equally as wide as the mounting eyelet.
Page 346 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Interior - Installation Instructions, Accessories Fig. 46: Identifying Cover Panel Courtesy of VOLVO CARS CORPORATION Remove the cover panel over the front right-hand mounting by carefully prizing it off with a weatherstrip ...
Page 347 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Interior - Installation Instructions, Accessories Fig. 48: Identifying T-Shape Cut In Carpet Courtesy of VOLVO CARS CORPORATION Fig. 49: View Of Mounting Eyelet Courtesy of VOLVO CARS CORPORATION Insert the mounting eyelet through the small cut in the floor carpet. Position the mounting over the hole ...
Page 348 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Interior - Installation Instructions, Accessories Fig. 50: View Of Mounting Eyelet Courtesy of VOLVO CARS CORPORATION CHILD SEAT, PROTECTIVE CUSHION (2007-2012) CHILD SEAT, PROTECTIVE CUSHION (2007-2009) REMOVE / INSTALL Fig. 51: View Of Protective Cushion In Position...
Page 349 ACCESSORIES AND BODY, CAB Interior - Installation Instructions, Accessories Fig. 52: Washing Back Of Child Seat Courtesy of VOLVO CARS CORPORATION Wash the back of the child seat for affixing the Velcro strap using a mixture of 30% washer fluid and ...
Page 350 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Interior - Installation Instructions, Accessories Fig. 54: View Of Velcro Strap On The Centre Of Backrest Courtesy of VOLVO CARS CORPORATION Pull off the protective tape from the detached Velcro strap. ...
Page 351 Fold the backrest forward on the front passenger side.  Fig. 56: ISOFIX Attachment And Screws Courtesy of VOLVO CARS CORPORATION Install the ISOFIX attachment to the SIPS tube with the four screws from the kit. Tighten the screws to 10 ...
Page 352 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Interior - Installation Instructions, Accessories Courtesy of VOLVO CARS CORPORATION Illustration applies to the rear seat and car models Fig. 58: Identifying Isofix Guide Courtesy of VOLVO CARS CORPORATION Installing the Isofix guide: Press the Isofix guide (1) into place between the backrest and seat cushion.
Page 353 LOCATING THE CLIMATE CONTROL SYSTEM COMPONENTS IN THE PASSENGER COMPARTMENT/DOOR MIRROR Fig. 1: Identifying Climate Control System Components Courtesy of VOLVO CARS CORPORATION 1. Climate control unit (ECC or MCC) 2. Outside temperature sensor (left-hand side) 3. Passenger compartment temperature sensor (ECC)
Page 354 5. Climate control unit 6. Air quality sensor (AQS). LOCATION OF THE CLIMATE CONTROL UNIT COMPONENTS Fig. 2: Identifying Climate Control Unit Components Courtesy of VOLVO CARS CORPORATION 1. Heat exchanger 2. Evaporator 3. Fan motor 4. Damper motor module (DMM) air distribution 5.
Page 355 2012 Volvo C30 T-5 HVAC Climate Units - Component Location Fig. 3: Identifying Engine Compartment Components Courtesy of VOLVO CARS CORPORATION 1. Compressor 2. The pipe/hose between the compressor and the condenser 3. Condenser 4. Service valve HT, draining/vacuum pumping 5.
Page 356 2012 Volvo C30 T-5 HVAC Climate Units - Component Location Fig. 4: Identifying Passenger Compartment Components Courtesy of VOLVO CARS CORPORATION Overview, passenger compartment 1. Climate control module (CCM) 2. Switch for STC/DSTC 3. Passenger compartment temperature sensor with blower fan 4.
Page 357 2012 Volvo C30 T-5 HVAC Climate Units - Component Location Fig. 5: Identifying Climate Control Unit Components Courtesy of VOLVO CARS CORPORATION Overview, climate control unit 1. Damper motor module (DMM) recirculation 2. Damper motor module (DMM) temperature right. Only applies to vehicles equipped with ECC 3.
Page 358 2012 Volvo C30 T-5 HVAC Climate Units - Component Location Fig. 6: Identifying Passenger Compartment Components Courtesy of VOLVO CARS CORPORATION Overview, passenger compartment 1. Climate control module (CCM) 2. Switch tunnel console front 3. Switch tunnel console rear 4. Passenger compartment temperature sensor with blower fan 5.
Page 359 2012 Volvo C30 T-5 HVAC Climate Units - Component Location Fig. 7: Identifying Climate Control Unit Components Courtesy of VOLVO CARS CORPORATION Overview, climate control unit 1. Damper motor module (DMM) recirculation 2. Damper motor module (DMM) temperature right 3. Damper motor module (DMM) defroster 4.
Page 360 The engine coolant heater is located in the rear right-hand part of the engine compartment. Fig. 8: Identifying Engine Coolant Heater Components Courtesy of VOLVO CARS CORPORATION Main components: 1. Engine coolant heater with radiator hose connections, exhaust system and external water pump (D5WS and B5WS) 2.
Page 361 2012 Volvo C30 T-5 HVAC Climate Units - Component Location Fig. 9: Identifying Booster Heater Courtesy of VOLVO CARS CORPORATION...
Page 362 2012 Volvo C30 T-5 HVAC Climate Units - Component Location Fig. 10: Exploded View Of Booster Heater Components Courtesy of VOLVO CARS CORPORATION 1. Combustion preheater module (CPM) 2. Fan shroud 3. Fan motor 4. Heat exchanger together with housing 5.
Page 363 2012 Volvo C30 T-5 HVAC Climate Units - Component Location Fig. 11: Identifying Water Pump (Parking Heater), Combustion Preheater Module (CPM) And Fuel Pump (FP) Courtesy of VOLVO CARS CORPORATION Overview 1. Water pump (parking heater) 2. Combustion preheater module (CPM)
Page 364 Some variation may occur. However, the essential information is always correct. PREPARATORY WORK IMPORTANT INFORMATION Fig. 1: Identifying Climate Control Module Components Courtesy of VOLVO CARS CORPORATION The unit is a complete control module that has many different functions in addition to controlling the climate functions. REMOVAL...
Page 365 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation REMOVING CENTER CONSOLE Ignition off. Fig. 2: Identifying 4 Hidden Clips Courtesy of VOLVO CARS CORPORATION Remove the panel inside the center console. It is secured with 4 hidden clips.
Page 366 HVAC Climate Units - Removal, Replacement And Installation Fig. 3: Identifying Radio Panel Courtesy of VOLVO CARS CORPORATION Remove the radio panel. It is secured with 2 hidden hooks. HINT: Insert a small screwdriver and push the hooks away, 1 per side.
Page 367 HVAC Climate Units - Removal, Replacement And Installation Fig. 4: Identifying Infotainment Control Module Courtesy of VOLVO CARS CORPORATION Remove the infotainment control module (ICM). It is secured with 2 hidden clips. HINT: Grip the infotainment control module (ICM) with both hands. Push the control module straight out of the center console.
Page 368 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 5: Identifying 4 Screws Courtesy of VOLVO CARS CORPORATION Remove: the panel. See: POWER SOCKET 12V (2007) or POWER SOCKET 12V (2008-2012)  the 4 screws. ...
Page 369 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 6: Identifying Screws Courtesy of VOLVO CARS CORPORATION Remove: the 8 screws. ...
Page 370 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 7: Identifying Climate Control Module (CCM) Screws Courtesy of VOLVO CARS CORPORATION the 4 screws  the climate control module (CCM).  INSTALLATION INSTALLING THE CLIMATE CONTROL MODULE (CCM) CAUTION: Tighten the screws carefully.
Page 371 PROGRAMMING CUSTOMER PARAMETERS AND ADJUSTING DAMPER MOTORS Reprogram the customer programmed data Carry out self-adjustment of the damper motor end positions. This is carried out in VIDA (Volvo scan tool) Vehicle communication. Test drive the vehicle. Check that the engine and climate control system are functioning.
Page 372 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 8: Identifying Ventilation Grilles And Vent Housing Courtesy of VOLVO CARS CORPORATION Remove: the ventilation grilles. Pry off the grilles from inside  the vent housing by prying up the hooks. See the illustration ...
Page 373 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation REMOVING OUTER VENTILATION VENTS Fig. 9: Identifying Ventilation Grilles And Vent Housing Courtesy of VOLVO CARS CORPORATION Remove: the ventilation grilles. Pry off the grilles from outside ...
Page 374 Remove the accelerator pedal (AP). See ACCELERATOR PEDAL . REMOVAL REMOVING THE PASSENGER COMPARTMENT AIR CLEANER (ACL) Fig. 10: Identifying Screws Courtesy of VOLVO CARS CORPORATION Fold the floor carpet out of the way. Remove: the 3 screws and raise the cover...
Page 375 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 11: Identifying Passenger Compartment Air Cleaner (ACL) Courtesy of VOLVO CARS CORPORATION the filter by pulling it out behind the brake pedal.  INSTALLATION INSTALLING THE PASSENGER COMPARTMENT AIR CLEANER (ACL)
Page 376 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 12: Identifying Passenger Compartment Air Cleaner (ACL) Courtesy of VOLVO CARS CORPORATION NOTE: The direction of the air flow is indicated on the top of the filter. Ensure that the filter is installed with the text side facing up and so that the arrows on the filter point straight back into the vehicle.
Page 377 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 13: Identifying Screws Courtesy of VOLVO CARS CORPORATION Torque: M6 10 Nm Fig. 14: Identifying Screw Courtesy of VOLVO CARS CORPORATION...
Page 378 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 15: Identifying Pollen Filter Courtesy of VOLVO CARS CORPORATION Fig. 16: Identifying Air Flow Courtesy of VOLVO CARS CORPORATION VENTILATION DUCT FOOT SPACE REAR REMOVE / INSTALL...
Page 379 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 17: Identifying Air Ducts Courtesy of VOLVO CARS CORPORATION AIR DISTRIBUTION UNIT DASHBOARD LOUDSPEAKER, REPLACING REMOVING THE AIR DISTRIBUTION UNIT FROM THE DASHBOARD...
Page 380 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 18: Identifying Air Distribution Unit Courtesy of VOLVO CARS CORPORATION Remove the dashboard. See: DASHBOARD . Turn the dashboard upside down. Remove the 3 screws and the 2 tie straps. Lift up the cable duct.
Page 381 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 19: Identifying Air Duct Outer Vent Courtesy of VOLVO CARS CORPORATION Remove the dashboard. See: DASHBOARD Turn the dashboard upside down. Remove the screw and pull the duct away from the air vent.
Page 382 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation the soundproofing panel on the driver's side. See: INSTRUMENT PANEL LOWER  the air duct on the driver's side. Slacken off the screw a few turns and pry off the air duct ...
Page 383 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Courtesy of VOLVO CARS CORPORATION Remove: the front seat as described in, see FRONT SEAT  the tunnel compartment. See: FLOOR CONSOLE  the front sill trim panel. See: SILL EDGE ...
Page 384 HVAC Climate Units - Removal, Replacement And Installation Fig. 21: Identifying Air Duct Courtesy of VOLVO CARS CORPORATION Remove center console. See: REMOVING CENTER CONSOLE. Pull down the top of the air duct. Angle the duct out from the dashboard. Remove the duct.
Page 385 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 22: Identifying Front Side Door Sill Trim Panel Courtesy of VOLVO CARS CORPORATION Pull the rear edge straight up. Ease out the front mount against the dashboard.
Page 386 HVAC Climate Units - Removal, Replacement And Installation Fig. 23: Identifying Removal Of Sill Trim Panel From Rear Side Door Courtesy of VOLVO CARS CORPORATION Pull the front edge straight up. Ease out the rear mount against the C-post panel.
Page 387 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 24: Identifying Removal Of Sill Trim Panel Trunk Lid Courtesy of VOLVO CARS CORPORATION Lift up the cargo compartment floor. Remove the 2 screw clips. Pull the sill trim panel straight up.
Page 388 REMOVING THE DAMPER MOTOR MODULE (DMM) FOR TEMPERATURE Fig. 25: Identifying Screws And Control Module Courtesy of VOLVO CARS CORPORATION Disconnect the connector. HINT: Using a small electrician's screwdriver, pry up the connector at the lock. Pull the connector off.
Page 389  the dashboard. See: DASHBOARD  NOTE: Identify the damper motor module (DMM) temperature. See VIDA (Volvo scan tool) Vehicle communication. FINISHING TESTING THE CLIMATE CONTROL SYSTEM Carry out a performance test on the climate control unit. See: CLIMATE CONTROL SYSTEM, CHECK .
Page 390 HVAC Climate Units - Removal, Replacement And Installation Fig. 26: Identifying Screws And Control Module Courtesy of VOLVO CARS CORPORATION Disconnect the connector. HINT: Using a small electrician's screwdriver, pry up the connector at the lock. Pull the connector off.
Page 391 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation NOTE: Identify the damper motor module (DMM) air distribution. See VIDA (Volvo scan tool) Vehicle communication. FINISHING TESTING THE CLIMATE CONTROL SYSTEM Carry out a performance test on the climate control unit. See: CLIMATE CONTROL SYSTEM, CHECK .
Page 392 HVAC Climate Units - Removal, Replacement And Installation Fig. 27: Identifying Screws And Control Module Courtesy of VOLVO CARS CORPORATION Disconnect the connector. HINT: Using a small electrician's screwdriver, pry up the connector at the lock. Pull the connector off.
Page 393 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation NOTE: Identify the damper motor module (DMM) recirculation. See VIDA (Volvo scan tool) Vehicle communication. FINISHING TESTING THE CLIMATE CONTROL SYSTEM Carry out a performance test on the climate control unit. See: CLIMATE CONTROL SYSTEM, CHECK .
Page 394 HVAC Climate Units - Removal, Replacement And Installation Fig. 28: Identifying Screws And Control Module Courtesy of VOLVO CARS CORPORATION Disconnect the connector. HINT: Using a small electrician's screwdriver, pry up the connector at the lock. Pull the connector off.
Page 395 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation NOTE: Identify the damper motor module (DMM) defroster. See VIDA (Volvo scan tool) Vehicle communication. FINISHING TESTING THE CLIMATE CONTROL SYSTEM Carry out a performance test on the climate control unit. See: CLIMATE CONTROL SYSTEM, CHECK .
Page 396 REMOVING THE AIR QUALITY SENSOR (AQS) Fig. 30: Air Quality Sensor Courtesy of VOLVO CARS CORPORATION The air quality sensor (AQS) is located in front of the damper motor module (DMM) recirculation. Turn the air quality sensor (AQS) approximately 60 degrees counter-clockwise.
Page 397 PREPARATORY WORK Remove the cowl. See PLENUM CHAMBER . CHECK CHECKING AIR QUALITY SENSOR (AQS) Fig. 31: Identifying Air Quality Sensor (AQS) Courtesy of VOLVO CARS CORPORATION Start the car with the climate control system automatic button in the ON position.
Page 398 Wipe away any fluid around the air quality sensor (AQS). Install the cowl. See: PLENUM CHAMBER AIR QUALITY SENSOR (2008-2012) REMOVAL AND INSTALLATION Remove glove compartment, see GLOVE COMPARTMENT Fig. 32: Identifying Air Quality Sensor Courtesy of VOLVO CARS CORPORATION...
Page 399 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 33: Identifying Sensor Rotating 60 Degrees Courtesy of VOLVO CARS CORPORATION BLOWER MOTOR PASSENGER COMPARTMENT Special tools: see 9997115 NOTE: The illustrations in this service information are used for different model years and/or models.
Page 400 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 34: Identifying Air Distribution Damper Cover Screws Courtesy of VOLVO CARS CORPORATION the air quality sensor (AQS)  the connector for the damper motor module (DMM) recirculation ...
Page 401 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 35: Identifying Catch On Connector For Fan Motor Courtesy of VOLVO CARS CORPORATION Press in the catch on the connector for the fan motor and pull straight out.
Page 402 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 36: Identifying Lock Button And Limit Position Courtesy of VOLVO CARS CORPORATION Press the lock button (1). Turn the fan motor counter-clockwise to the limit position (2).
Page 403 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 37: Identifying Blower Fan Motor Courtesy of VOLVO CARS CORPORATION Remove the fan motor from the passenger side. Use: see 9997115 . INSTALLATION INSTALLING THE BLOWER FAN MOTOR...
Page 404 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 38: Identifying Blower Fan Motor Courtesy of VOLVO CARS CORPORATION Place the fan motor in the correct position for installation. Use: see 9997115 . NOTE: Turn the fan motor to the position for installation.
Page 405 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Test the operation of the fan motor. Install the dashboard. See: DASHBOARD CLIMATE UNITS NOTE: The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.
Page 406 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 39: Identifying Shield And Clips Courtesy of VOLVO CARS CORPORATION Remove the expansion tank cap. Raise the vehicle. Remove the shield under the vehicle. It is secured with 7 clips.
Page 407 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 40: Identifying Dashboard Courtesy of VOLVO CARS CORPORATION Remove the dashboard. See: DASHBOARD REMOVAL REMOVING THE CLIMATE CONTROL UNIT...
Page 408 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 41: Identifying Spacer And Right-Hand Half Of Lead-In Courtesy of VOLVO CARS CORPORATION Remove: the 2 screws and remove the right-hand half of the lead-in.  the section that holds the heat exchanger and evaporator pipes apart.
Page 409 HVAC Climate Units - Removal, Replacement And Installation Fig. 42: Identifying Screw Securing Air Conditioning (A/C) Pipes Courtesy of VOLVO CARS CORPORATION Lift up both air conditioning (A/C) hoses from their mountings below the right-hand spring strut turret. Remove the 1 screw securing the air conditioning (A/C) pipes to the evaporator. See the illustration.
Page 410 HVAC Climate Units - Removal, Replacement And Installation Fig. 43: Identifying Drainage Hose From Lower Connection On Right-Hand Side Under Heat Exchanger Housing Courtesy of VOLVO CARS CORPORATION Remove: the drainage hose from the lower connection on the right-hand side under the heat exchanger housing ...
Page 411 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation the 1 M8 screw securing the air conditioning (A/C) pipes to the evaporator in the engine compartment.  Tighten both the air conditioning (A/C) hoses in their mountings below the right-hand spring strut turret ...
Page 412 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 44: Identifying Shield And Clips Courtesy of VOLVO CARS CORPORATION Install: the glove compartment. See GLOVE COMPARTMENT  the shield under the vehicle using the 7 clips ...
Page 413 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation CAUTION: Always use new O-rings lubricated with compressor oil. NOTE: Plug the pipes and connections when working on the climate control system. Drain the refrigerant from the air conditioning (A/C) system. See: REFRIGERANT, DRAINING .
Page 414 HVAC Climate Units - Removal, Replacement And Installation Fig. 45: Identifying Nut Under Front Fender Liner On Right-Hand Side Courtesy of VOLVO CARS CORPORATION Remove the nut under the front fender liner on the right-hand side. See the illustration. NOTE: Lubricate the thread using a little rustproofing agent so that the pressed in screw does not come loose.
Page 415 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 46: Identifying Pipe/Hose Connector Courtesy of VOLVO CARS CORPORATION Disconnect the pipe / hose connection to the receiver. See the illustration.
Page 416 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 47: Identifying Pipe Coupling Courtesy of VOLVO CARS CORPORATION Remove: the screw (A) for the pipe coupling  the 3 screws (B) for mounting the receiver. ...
Page 417 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation the receiver together with 3 M8 screws. Tighten.  the pipe couplings, 2 x M8. Make sure the O-rings are securely located. Tighten the screws.  the M8 nut below the fender liner. Tighten.
Page 418 HVAC Climate Units - Removal, Replacement And Installation Fig. 48: Identifying Screws For Right-Hand Mounting Bracket, Clamps For Cable Harness And Connectors Courtesy of VOLVO CARS CORPORATION Remove: the cable harness from the mounting bracket. This is secured with 2 clips ...
Page 419 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 49: Identifying Preheater Screws Courtesy of VOLVO CARS CORPORATION WARNING: Do not perform any work on the electrical preheater until the heating coil has cooled to ambient temperature.
Page 420 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation the 3 connectors  the cable harness on the mounting bracket using the 2 clips  the right-hand mounting bracket using the 4 screws (of which 3 M8). Tighten.
Page 421 HVAC Climate Units - Removal, Replacement And Installation Fig. 50: Identifying Screws For Right-Hand Mounting Bracket, Clamps For Cable Harness And Connectors Courtesy of VOLVO CARS CORPORATION Remove: the cable harness from the mounting bracket. This is secured with 2 clips ...
Page 422 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 51: Identifying Preheater Screws Courtesy of VOLVO CARS CORPORATION WARNING: Do not perform any work on the electrical preheater until the heating coil has cooled to ambient temperature.
Page 423 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation the 3 connectors  the cable harness on the mounting bracket using the 2 clips  the right-hand mounting bracket using the 4 screws (of which 3 M8). Tighten.
Page 424 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 52: Identifying Engine Splash Guard Courtesy of VOLVO CARS CORPORATION Draining coolant and removing the engine splash guard. Remove: the cover for the expansion tank and raise the vehicle ...
Page 425 HVAC Climate Units - Removal, Replacement And Installation Fig. 54: Identifying Climate Control Unit Brackets, Air Duct And Screws Courtesy of VOLVO CARS CORPORATION Remove: the brackets on both sides of the climate control unit and the screws, 3 per bracket ...
Page 426 Press the pipes towards the firewall so that they protrude into the engine compartment. HINT: To facilitate, also route the pipes from the engine compartment. Fig. 56: Identifying Screws And Lead-In's Right Half Courtesy of VOLVO CARS CORPORATION Remove: the 2 x screws and the lead-in's right half.
Page 427 Use new O-rings for the pipe ends. Install the pipes at the connection to the heat exchanger pipes. Fig. 57: Identifying Clips Courtesy of VOLVO CARS CORPORATION Install the clips so that they lock securely. A click must be heard. NOTE: The clips only fit one way in the pipe connection.
Page 428 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Install: the 8 x screws for the cover. Tighten  the air duct  the brackets on both sides of the climate control unit and the screws, 3 per bracket. Tighten.
Page 429 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 59: Identifying Passenger Compartment Temperature Sensor (ECC Only) Courtesy of VOLVO CARS CORPORATION REMOVING COMPONENTS Fig. 60: Identifying 4 Hidden Clips Courtesy of VOLVO CARS CORPORATION Use a weatherstrip tool and remove the panel inside the center console. It is secured with 4 hidden clips.
Page 430 HVAC Climate Units - Removal, Replacement And Installation Fig. 61: Identifying Driver's Side Soundproofing Panel Courtesy of VOLVO CARS CORPORATION Remove the end cover on the left-hand side. Use a weatherstrip tool and start at the rear edge. Remove the 3 screws and the clip for the driver's side soundproofing panel. Leave the soundproofing panel hanging from the cable harness.
Page 431 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 62: Identifying Catches Courtesy of VOLVO CARS CORPORATION Disconnect the connector. Press in the catches. Lift straight up. INSTALLATION INSTALLING THE BLOWER FAN MOTOR PASSENGER COMPARTMENT TEMPERATURE SENSOR...
Page 432 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation NOTE: The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.
Page 433 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 63: Identifying Shield And Clips Courtesy of VOLVO CARS CORPORATION Remove the cover under the vehicle. It is secured with 7 clips. REMOVAL REMOVING COMPRESSOR...
Page 434 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 64: Identifying Lower/Front Pipe/Hose Connector Courtesy of VOLVO CARS CORPORATION Remove: the connector to the magnetic clutch  the pipe connections for the compressor (1) and (2).
Page 435 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 65: Identifying Compressor Mounting Screws Courtesy of VOLVO CARS CORPORATION the 3 mounting screws for the compressor.  Remove the compressor. INSTALLATION NOTE: For tightening torques, see: TIGHTENING TORQUE .
Page 436 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 66: Identifying Lower/Front Pipe/Hose Connector Courtesy of VOLVO CARS CORPORATION Position the compressor. Fasten the compressor with screws, 3 pcs. M8  Install the longest screw in the rear mounting ...
Page 437 CHECKING THE PERFORMANCE Fig. 67: Identifying Shield And Clips Courtesy of VOLVO CARS CORPORATION Install the shield under the vehicle using the 7 clips. Carry out a performance test on the climate control unit. See: CLIMATE CONTROL SYSTEM, CHECK .
Page 438 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation NOTE: The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.
Page 439 HVAC Climate Units - Removal, Replacement And Installation Fig. 68: Identifying Nut Under Front Fender Liner On Right-Hand Side Courtesy of VOLVO CARS CORPORATION Remove the nut under the front fender liner on the right-hand side. See the illustration. NOTE: Lubricate the thread using a little rustproofing agent so that the pressed in screw does not come loose.
Page 440 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 69: Identifying Pipe/Hose Connector Courtesy of VOLVO CARS CORPORATION Disconnect the pipe / hose connection to the receiver. See the illustration.
Page 441 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 70: Identifying Pipe Coupling Courtesy of VOLVO CARS CORPORATION Remove: the screw (A) for the pipe coupling  the 3 screws (B) for mounting the receiver. ...
Page 442 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation the receiver together with 3 M8 screws. Tighten  the pipe couplings, 2 x M8. Make sure the O-rings are securely located. Tighten the screws  the M8 nut below the fender liner. Tighten ...
Page 443 Plug the pipes and connections when working on the climate control system. Drain the refrigerant from the AC-system acc. to: REFRIGERANT, DRAINING . REMOVING COMPONENTS Fig. 71: Identifying Rear Connector Courtesy of VOLVO CARS CORPORATION Remove: the bumper shell. See COVER BUMPER FRONT (2010, 2011 EARLY) or COVER BUMPER ...
Page 444 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 72: Removing The Condenser Courtesy of VOLVO CARS CORPORATION Press in the catch. Carefully pry off both sides using a screwdriver. Remove the condenser from the air conditioning unit.
Page 445 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 73: Installing The Condenser Courtesy of VOLVO CARS CORPORATION Fill the condenser with oil. See AC-SYSTEM, OIL, REFILLING . Press the condenser into the mounting points. NOTE: Ensure that both retaining clips secure the condenser.
Page 446 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 74: Identifying Rear Connector Courtesy of VOLVO CARS CORPORATION Install: the air conditioning unit. See: RADIATOR (B5254T3, B5254T7) or RADIATOR (B5244S4)  the 2 M8 screws (1) and (2) at the condenser connection (see the illustration). Tighten.
Page 447 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation CONDENSER (B5254T7) NOTE: The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.
Page 448 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 75: Identifying Screws And Cover From Frame Courtesy of VOLVO CARS CORPORATION Remove: the 4 screws  the cover from the frame. ...
Page 449 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 76: Identifying Condenser Courtesy of VOLVO CARS CORPORATION Lift the condenser straight up. INSTALLATION INSTALLING THE CONDENSER...
Page 450 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 77: Identifying Screws And Cover From Frame Courtesy of VOLVO CARS CORPORATION Fill the condenser with oil. See AC-SYSTEM, OIL, REFILLING . Install: the condenser  the cover for the frame ...
Page 451 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Leak trace the system. See: LEAK DETECTION, TRACER AGENT , LEAK TRACING, ELECTRONIC LEAK TRACER (2008-2009) or LEAK TRACING, ELECTRONIC LEAK TRACER (2007, 2010-11) . ELECTROMAGNETIC CLUTCH Special tools:...
Page 452 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 78: Identifying Shield And Clips Courtesy of VOLVO CARS CORPORATION Raise the vehicle. Remove: the shield under the vehicle. It is secured with 7 clips. See the illustration ...
Page 453 HVAC Climate Units - Removal, Replacement And Installation Fig. 79: Identifying Right-Hand Screw Securing Air Baffle Courtesy of VOLVO CARS CORPORATION the 5 screws and the plastic nut. Detach the front edge of the right-hand fender liner. Fold the fender ...
Page 454 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 80: Identifying Clutch Plate And Counterhold Courtesy of VOLVO CARS CORPORATION Remove: the screw for the flex plate. Use: see 9995596 ...
Page 455 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 81: Identifying Shims Courtesy of VOLVO CARS CORPORATION the flex plate. Use: see 9995596 ...
Page 456 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 82: Identifying Snap Ring Courtesy of VOLVO CARS CORPORATION the snap ring. ...
Page 457 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 83: Identifying Puller And Socket Courtesy of VOLVO CARS CORPORATION Pull off the pulley. Use: see 9995598 and: see 9995599 .
Page 458 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 84: Identifying Solenoid Coil's Cable And Compressor Housing Courtesy of VOLVO CARS CORPORATION NOTE: Note the position of the solenoid coils cable in relation to the compressor housing.
Page 459 HVAC Climate Units - Removal, Replacement And Installation Fig. 85: Identifying Cable And Retaining Clip Courtesy of VOLVO CARS CORPORATION Lower the compressor a little by slackening off the 3 mounting screws. Remove the cable from the solenoid coil connector.
Page 460 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 86: Identifying Magnet Coil Courtesy of VOLVO CARS CORPORATION the solenoid coil using the 3 screws.  NOTE: Make sure that the solenoid coils cable is located correctly in relation to the...
Page 461 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 87: Identifying Puller And Socket Courtesy of VOLVO CARS CORPORATION Install a new belt pulley. Use: see 9995598 and: see 9995600 . NOTE: Place the tools behind the compressor mountings.
Page 462 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 88: Identifying Shims Courtesy of VOLVO CARS CORPORATION Install: the snap ring  the shims  the flex plate. Use: see 9995596 and tighten the screw acc. to: TIGHTENING TORQUE .
Page 463 HVAC Climate Units - Removal, Replacement And Installation Fig. 89: Identifying Feeler Gauge Between Clutch Plate And Pulley Courtesy of VOLVO CARS CORPORATION Check the clearance between the clutch plate and pulley. Use a feeler gauge. The clearance should ideally be 0.3 mm all the way around, although a play up to max. 0.5 mm is allowed.
Page 464 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 90: Identifying Shield And Clips Courtesy of VOLVO CARS CORPORATION Install: the auxiliaries belts. See: ACCESSORY DRIVE BELT TENSIONER  the right-hand screw securing the air baffle ...
Page 465 HVAC Climate Units - Removal, Replacement And Installation DRAINING COOLANT AND REMOVING THE COVER Fig. 91: Identifying Shield And Clips Courtesy of VOLVO CARS CORPORATION Remove the expansion tank cap. Raise the vehicle. Remove the shield under the vehicle. It is secured with 7 clips. See the illustration.
Page 466 ENTERTAINMENT the glove compartment. See: GLOVE COMPARTMENT  Fig. 92: Identifying Central Electrical Unit Bracket Nuts Courtesy of VOLVO CARS CORPORATION the central electrical unit from its bracket. See: CONTROL MODULE RELAY BOX PASSENGER  COMPARTMENT the 2 nuts for the central electrical unit bracket (see the illustration). Disconnect the cable harness from ...
Page 467 HVAC Climate Units - Removal, Replacement And Installation Fig. 93: Identifying Screw Securing Air Conditioning (A/C) Pipes Courtesy of VOLVO CARS CORPORATION Lift up both air conditioning (A/C) pipes from their mountings below the right-hand spring strut turret. Remove the 1 screw securing the air conditioning (A/C) pipes to the evaporator. See the illustration.
Page 468 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 94: Identifying Spacer And Right-Hand Half Of Lead-In Courtesy of VOLVO CARS CORPORATION Remove: the 2 screws and remove the right-hand half of the lead-in. See the illustration ...
Page 469 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 95: Identifying Evaporator Pipes Courtesy of VOLVO CARS CORPORATION Cut off the evaporator pipes. Pull and press out the pipes through the seal. See the illustration.
Page 470 HVAC Climate Units - Removal, Replacement And Installation Fig. 96: Identifying Evaporator Screws Courtesy of VOLVO CARS CORPORATION Remove the 3 screws. Remove the cover. Pull out the evaporator. Pull alternately at the top and bottom edges. It may be hard to remove.
Page 471 HVAC Climate Units - Removal, Replacement And Installation Fig. 97: Identifying Screws Courtesy of VOLVO CARS CORPORATION Install the evaporator far enough that the cover can be installed (approximately 3-4 mm inside the opening). Position the front edge of the cover between the evaporator and the heater unit.
Page 472 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 98: Identifying Spacer And Right-Hand Half Of Lead-In Courtesy of VOLVO CARS CORPORATION NOTE: Pull the insulation for the pipes as far in towards the evaporator as possible before installing the spacer and the right-hand half of the lead-in.
Page 473 Leak trace the air conditioning (A/C) system. See: LEAK DETECTION, TRACER AGENT , LEAK TRACING, ELECTRONIC LEAK TRACER (2008-2009) or LEAK TRACING, ELECTRONIC LEAK TRACER (2007, 2010-11) . Fig. 99: Identifying Shield And Clips Courtesy of VOLVO CARS CORPORATION Install:...
Page 474 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation the glove compartment. See: GLOVE COMPARTMENT  the multimedia module (MMM) (if applicable). See: CONTROL MODULE INFORMATION AND  ENTERTAINMENT the shield under the vehicle using the 7 clips.
Page 475 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 100: Identifying Cap Nut For Expansion Valve Courtesy of VOLVO CARS CORPORATION Clean the join thoroughly. Slacken off the cap nut. NOTE: Make a note of the position of the expansion valve in the pipe.
Page 476 HVAC Climate Units - Removal, Replacement And Installation Fig. 101: Identifying Filter Sections Of Expansion Valve Courtesy of VOLVO CARS CORPORATION (A) shows an approved expansion valve. If 4 or 5 filter sections in the expansion valve are clogged (B) , the compressor oil must be inspected.
Page 477 Carry out a performance test on the climate control unit. See: CLIMATE CONTROL SYSTEM, CHECK . LOW PRESSURE SWITCH CLIMATE CONTROL REMOVE / INSTALL NOTE: Removal steps in this procedure may contain installation details. Fig. 102: Identifying Low Pressure Switch Climate Control Courtesy of VOLVO CARS CORPORATION...
Page 478 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation NOTE: For tightening torques, see TIGHTENING TORQUE To install, reverse the removal procedure NEEDLE VALVE Special tools: see 9511204 see 9811994 NOTE: The illustrations in this service information are used for different model years and/or models.
Page 479 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 103: Identifying Needle Valve/Service Valve Courtesy of VOLVO CARS CORPORATION Remove the needle valve in the service valve. Use: see 9511204 . INSTALLATION INSTALLING THE NEEDLE VALVE / SERVICE VALVE Install the needle valve.
Page 480 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Leak trace the air conditioning (A/C) system. See: LEAK DETECTION, TRACER AGENT , LEAK TRACING, ELECTRONIC LEAK TRACER (2008-2009) or LEAK TRACING, ELECTRONIC LEAK TRACER (2007, 2010-11) .
Page 481 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 104: Identifying Shield And Clips Courtesy of VOLVO CARS CORPORATION Raise the vehicle. Remove the shield under the vehicle. It is secured with 7 clips. PIPE/HOSE BETWEEN COMPRESSOR AND CONDENSER (PRESSURE SIDE), REPLACING...
Page 482 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 105: Identifying Lower/Front Pipe/Hose Connector Courtesy of VOLVO CARS CORPORATION Remove: the rear/upper pipe/hose connector (1) on the compressor.  the front bumper cover. See: COVER BUMPER FRONT (2010-2011 EARLY) , COVER BUMPER ...
Page 483 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 106: Identifying Rear Connector Courtesy of VOLVO CARS CORPORATION Lower the vehicle. Remove the upper charge air cooler (CAC) hose. Remove the dip stick. Disconnect the rear connector (1) to the condenser, to the left of the right-hand headlamp. See the illustration.
Page 484 Carry out finishing work. See: FINISHING. PIPE/HOSE BETWEEN COMPRESSOR AND RECEIVER (SUCTION SIDE), REPLACING REMOVING THE PIPE/HOSE BETWEEN THE COMPRESSOR AND THE RECEIVER Fig. 107: Identifying Lower/Front Pipe/Hose Connector Courtesy of VOLVO CARS CORPORATION Remove the lower/front pipe/hose connector (2) on the compressor.
Page 485 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 108: Identifying Pipe/Hose Connector Courtesy of VOLVO CARS CORPORATION Lower the vehicle. Remove the upper connector of the charge air hose to the charge air cooler (CAC).
Page 486 TRACING, ELECTRONIC LEAK TRACER (2008-2009) or LEAK TRACING, ELECTRONIC LEAK TRACER (2007, 2010-11) . INSTALLING SHIELD AND BUMPER COVER Fig. 109: Identifying Shield And Clips Courtesy of VOLVO CARS CORPORATION Install the shield under the vehicle with 7 clips. See the illustration.
Page 487 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Carry out a performance test on the climate control unit. See: CLIMATE CONTROL SYSTEM, CHECK . Install the front bumper cover. See: COVER BUMPER FRONT (2010, 2011 EARLY) , COVER BUMPER...
Page 488 HVAC Climate Units - Removal, Replacement And Installation Fig. 110: Identifying Coolant Reservoir, Power Steering Fluid Reservoir And Hoses Courtesy of VOLVO CARS CORPORATION Remove: the coolant reservoir (1) but leave the hoses in place. Place the reservoir on the valve cover ...
Page 489 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 111: Identifying Screw Securing Air Conditioning (A/C) Pipes Courtesy of VOLVO CARS CORPORATION Lift up the hose from the mounting below the right-hand suspension turret. Remove: the screw securing the air conditioning (A/C) pipes to the evaporator. See the illustration ...
Page 490 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 112: Identifying Pipe Coupling Courtesy of VOLVO CARS CORPORATION Remove: the right-hand headlamp. See: HEADLAMP BULB (2007) or HEADLAMP BULB (2008-2012) .  the nut. Disconnect the pipe coupling (A) at the receiver.
Page 491 PIPE/HOSE BETWEEN CONDENSER AND EXPANSION VALVE, REPLACING REMOVING COMPONENTS Fig. 113: Identifying Coolant Reservoir, Power Steering Fluid Reservoir And Hoses Courtesy of VOLVO CARS CORPORATION Remove: the coolant reservoir (1) but leave the hoses in place. Place the reservoir on the valve cover ...
Page 492 REMOVING THE PIPE / HOSE BETWEEN THE CONDENSER AND THE EXPANSION VALVE Fig. 114: Identifying Cap Nut For Expansion Valve Courtesy of VOLVO CARS CORPORATION Lift up the hose from the mounting below the right-hand suspension turret. Remove the cap nut for the expansion valve. See the illustration.
Page 493 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 115: Identifying Rear Connector Courtesy of VOLVO CARS CORPORATION Unscrew the cover from the service valve. Remove: the service valve using an extended 24 mm sleeve ...
Page 494 PIPE BETWEEN EXPANSION VALVE AND EVAPORATOR, REPLACING REMOVING THE PIPE BETWEEN THE EXPANSION VALVE AND THE EVAPORATOR Fig. 116: Identifying Screw Securing Air Conditioning (A/C) Pipes Courtesy of VOLVO CARS CORPORATION Lift up the hose from the mounting below the right-hand suspension turret. Remove: the screw securing the air conditioning (A/C) pipes to the evaporator.
Page 495 HVAC Climate Units - Removal, Replacement And Installation Fig. 117: Identifying Cap Nut For Expansion Valve Courtesy of VOLVO CARS CORPORATION Remove the cap nut for the expansion valve. See the illustration. INSTALLING THE PIPE BETWEEN THE EXPANSION VALVE AND THE EVAPORATOR NOTE: For tightening torques, see: TIGHTENING TORQUE .
Page 496 TRACING, ELECTRONIC LEAK TRACER (2008-2009) or LEAK TRACING, ELECTRONIC LEAK TRACER (2007, 2010-11) . SWITCH HIGH PRESSURE (2007-2011) REMOVE / INSTALL NOTE: Removal steps in this procedure may contain installation details. Fig. 118: Identifying High Pressure Switch Courtesy of VOLVO CARS CORPORATION NOTE: For tightening torques, see TIGHTENING TORQUE...
Page 497 To install, reverse the removal procedure SWITCH HIGH PRESSURE (2012) REMOVAL Fig. 119: Identifying High Pressure Switch Courtesy of VOLVO CARS CORPORATION Follow the instruction for tightening torques, see TIGHTENING TORQUE INSTALLATION To install, reverse the removal procedure. Perform climate unit, checking, see CLIMATE CONTROL SYSTEM, CHECK...
Page 498 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 120: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Ignition off. REMOVAL REMOVING THE TEMPERATURE SENSOR FOR THE EVAPORATOR...
Page 499 HVAC Climate Units - Removal, Replacement And Installation Fig. 121: Identifying Temperature Sensor For Evaporator Courtesy of VOLVO CARS CORPORATION Fold down the carpet in the driver's side footwell towards the heater unit. Turn the temperature sensor together with the cable harness a 1/4 turn clockwise.
Page 500 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation TESTING THE CLIMATE CONTROL SYSTEM Carry out a performance test on the climate control unit. See: CLIMATE CONTROL SYSTEM, CHECK . AUXILIARY HEATER, FUEL OPERATED COOLANT PIPE FUEL-POWERED PREHEATER (B5244S4)
Page 501 HVAC Climate Units - Removal, Replacement And Installation Fig. 122: Identifying Heat Exchanger Cover Screws Courtesy of VOLVO CARS CORPORATION Remove cover over heat exchanger. It is secured using 4 screws. Lift up the cover a little until the snap rings for the pipe couplings release.
Page 502 HVAC Climate Units - Removal, Replacement And Installation Fig. 123: Identifying Pipe Coupling And Snap Rings Courtesy of VOLVO CARS CORPORATION There are snap rings on the underneath of the cover that also hold the pipe couplings in place. The snap rings are located in a groove on the pipe coupling.
Page 503 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 124: Clamping Snap Ring By Compressing Groove Courtesy of VOLVO CARS CORPORATION Install the pipe. Clamp the snap ring by compressing the groove. See the illustration. Press in the pipes. Adjust the pipes so that they are positioned according to previous markings.
Page 504 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Perform a performance test of the engine's preheater. See: FUEL-POWERED PREHEATER, CHECKING COOLANT PIPE FUEL-POWERED PREHEATER (B5254T3, B5254T7) NOTE: The illustrations in this service information are used for different model years and/or models.
Page 505 HVAC Climate Units - Removal, Replacement And Installation Fig. 125: Identifying Heat Exchanger Cover Screws Courtesy of VOLVO CARS CORPORATION Remove cover over heat exchanger. It is secured using 4 screws. Lift up the cover a little until the snap rings for the pipe couplings release.
Page 506 HVAC Climate Units - Removal, Replacement And Installation Fig. 126: Identifying Pipe Coupling And Snap Rings Courtesy of VOLVO CARS CORPORATION There are snap rings on the underneath of the cover that also hold the pipe couplings in place. The snap rings are located in a groove on the pipe coupling.
Page 507 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 127: Clamping Snap Ring By Compressing Groove Courtesy of VOLVO CARS CORPORATION Install the pipe. Clamp the snap ring by compressing the groove. See the illustration. Press in the pipes. Adjust the pipes so that they are positioned according to previous markings.
Page 508 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Perform a performance test of the engine's preheater. See: FUEL-POWERED PREHEATER, CHECKING FAN MOTOR FUEL-POWERED PREHEATER (B5244S4) NOTE: The illustrations in this service information are used for different model years and/or models.
Page 509 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Courtesy of VOLVO CARS CORPORATION Remove the 4 screws for the cover over the fan housing. Remove the cover. NOTE: The nearest connection pipe may need to be adjusted in order to remove the cover.
Page 510 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 130: Identifying Cable Terminals And Cables Courtesy of VOLVO CARS CORPORATION Disconnect the cable terminals and wiring for the fan motor at positions 13 and 14 (black and brown).
Page 511 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 131: Identifying Screws Courtesy of VOLVO CARS CORPORATION Remove the 3 screws. Lift the fan motor away from the heat exchanger. TRANSFERRING COMPONENTS TRANSFERRING FLAME TRAP Transfer: the flame trap.
Page 512 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 132: Identifying Gasket, Combustion Chamber And Molded Gasket Courtesy of VOLVO CARS CORPORATION Replace both gaskets supplied with the fan motor. Install: the gasket (1) between the heat exchanger housing and the combustion chamber ...
Page 513 4 screws.  Fig. 133: Identifying Cable Terminals And Cables Courtesy of VOLVO CARS CORPORATION If necessary adjust the pipe coupling. See: COOLANT PIPE FUEL-POWERED PREHEATER (B5244S4). Install: the control module. See: FUEL FIRED BOOSTER HEATER CONTROL UNIT (B5244S4) ...
Page 514 REMOVAL REMOVING THE FAN MOTOR FOR THE ENGINE COOLANT HEATER Fig. 134: Identifying Screws For Cover Over Fan Housing Courtesy of VOLVO CARS CORPORATION Remove the 4 screws for the cover over the fan housing. Remove the cover. NOTE: The nearest connection pipe may need to be adjusted in order to remove the...
Page 515 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 135: Identifying Fan Housing Courtesy of VOLVO CARS CORPORATION Carefully pull the fan housing straight out, viewed from the shorter side of the engine coolant heater. See the illustration.
Page 516 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 136: Identifying Cable Terminals And Cables Courtesy of VOLVO CARS CORPORATION Disconnect the cable terminals and wiring for the fan motor at positions 13 and 14 (black and brown).
Page 517 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 137: Identifying Screws Courtesy of VOLVO CARS CORPORATION Remove the 3 screws. Lift the fan motor away from the heat exchanger. TRANSFERRING COMPONENTS TRANSFERRING FLAME TRAP Transfer: the flame trap.
Page 518 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 138: Identifying Gasket, Combustion Chamber And Molded Gasket Courtesy of VOLVO CARS CORPORATION Replace both gaskets supplied with the fan motor. Install: the gasket (1) between the heat exchanger housing and the combustion chamber ...
Page 519 HVAC Climate Units - Removal, Replacement And Installation the cover over the fan motor using 4 screws.  Fig. 139: Identifying Cable Terminals And Cables Courtesy of VOLVO CARS CORPORATION If necessary adjust the pipe coupling. See: COOLANT PIPE FUEL-POWERED PREHEATER (B5254T3, B5254T7). Install: the control module.
Page 520 REMOVAL REMOVING THE FLAME SENSOR Fig. 140: Identifying Screws For Cover Over Fan Housing Courtesy of VOLVO CARS CORPORATION Remove the 4 screws for the cover over the fan housing. Remove the cover. NOTE: The nearest connection pipe may need to be adjusted in order to remove the...
Page 521 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 141: Identifying Fan Housing Courtesy of VOLVO CARS CORPORATION Carefully pull the fan housing straight out, viewed from the shorter side of the engine coolant heater. See the illustration.
Page 522 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 142: Identifying Cable Terminals And Cables Courtesy of VOLVO CARS CORPORATION Disconnect the cable terminal and cable for the flame sensor at positions 1 and 2 (blue and brown).
Page 523 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 143: Identifying Flame Sensor And Pressure Equalizer Courtesy of VOLVO CARS CORPORATION Remove the flame sensor (1). INSTALLATION INSTALLING THE FLAME SENSOR Install the flame sensor. Tighten. See TIGHTENING TORQUE .
Page 524 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation like the others. Install the cover using 4 screws. If necessary adjust the pipe coupling. See: COOLANT PIPE FUEL-POWERED PREHEATER (B5244S4). Install the control module. See: FUEL FIRED BOOSTER HEATER CONTROL UNIT (B5244S4).
Page 525 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 144: Identifying Screws For Cover Over Fan Housing Courtesy of VOLVO CARS CORPORATION Remove the 4 screws for the cover over the fan housing. Remove the cover. NOTE: The nearest connection pipe may need to be adjusted in order to remove the cover.
Page 526 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 145: Identifying Fan Housing Courtesy of VOLVO CARS CORPORATION Carefully pull the fan housing straight out, viewed from the shorter side of the engine coolant heater. See the illustration.
Page 527 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 146: Identifying Cable Terminals And Cables Courtesy of VOLVO CARS CORPORATION Disconnect the cable terminal and cable for the flame sensor at positions 1 and 2 (blue and brown).
Page 528 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 147: Identifying Flame Sensor And Pressure Equalizer Courtesy of VOLVO CARS CORPORATION Remove the flame sensor (1). INSTALLATION INSTALLING THE FLAME SENSOR Install the flame sensor. Tighten. See TIGHTENING TORQUE .
Page 529 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation like the others. Install the cover using 4 screws. If necessary adjust the pipe coupling. See: COOLANT PIPE FUEL-POWERED PREHEATER (B5254T3, B5254T7). Install the control module. See: FUEL FIRED BOOSTER HEATER CONTROL UNIT (B5254T3, B5254T7).
Page 530 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 148: Identifying Shield And Clips Courtesy of VOLVO CARS CORPORATION Remove the expansion tank cap. Raise the vehicle. Remove the shield under the vehicle. It is secured with 7 clips. See the illustration.
Page 531 HVAC Climate Units - Removal, Replacement And Installation Fig. 149: Identifying Engine Coolant Hose, Connector, Fuel Line And Holder Courtesy of VOLVO CARS CORPORATION Disconnect the engine coolant hose (1). Plug the opening to prevent the remaining coolant in the heater running out in an uncontrolled way.
Page 532 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 150: Identifying Connector For Water Pump Courtesy of VOLVO CARS CORPORATION Disconnect the connector for the water pump. HINT: Mark the location of the upper hose on the water pump.
Page 533 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 151: Identifying Mounting Screw For Engine Coolant Heater Courtesy of VOLVO CARS CORPORATION Remove: the mounting screw for the engine coolant heater. See the illustration  the bracket for the connector.
Page 534 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation NOTE: Mark the internal position of the hoses in relation to each other before removal. This ensures that the hoses are correctly positioned and not under stress during installation.
Page 535 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 152: Identifying Shield And Clips Courtesy of VOLVO CARS CORPORATION Carry out a performance test of the engine coolant heater. See: FUEL-POWERED PREHEATER, CHECKING . Install the shield under the vehicle using the 7 clips.
Page 536 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 153: Identifying EVAP Canister Pipe And Upper Charge Air Pipe Courtesy of VOLVO CARS CORPORATION Remove: the EVAP canister hose (1) from the intake manifold  the intake manifold (2) between the air cleaner and the turbocharger.
Page 537 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 154: Identifying Shield And Clips Courtesy of VOLVO CARS CORPORATION Remove the expansion tank cap. Raise the vehicle. Remove the shield under the vehicle. It is secured with 7 clips. See the illustration.
Page 538 HVAC Climate Units - Removal, Replacement And Installation Fig. 155: Identifying Engine Coolant Hose, Connector, Fuel Line And Holder Courtesy of VOLVO CARS CORPORATION Disconnect the engine coolant hose (1). Plug the opening to prevent the remaining coolant in the heater running out in an uncontrolled way.
Page 539 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 156: Identifying Connector For Water Pump Courtesy of VOLVO CARS CORPORATION Disconnect the connector for the water pump. HINT: Mark the location of the upper hose on the water pump.
Page 540 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 157: Identifying Mounting Screw For Engine Coolant Heater Courtesy of VOLVO CARS CORPORATION Remove: the mounting screw for the engine coolant heater. See the illustration  the bracket for the connector.
Page 541 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation NOTE: Mark the internal position of the hoses in relation to each other before removal. This ensures that the hoses are correctly positioned and not under stress during installation.
Page 542 HVAC Climate Units - Removal, Replacement And Installation TESTING THE ENGINE COOLANT HEATER AND INSTALLING THE COVER Fig. 158: Identifying Shield And Clips Courtesy of VOLVO CARS CORPORATION Carry out a performance test of the engine coolant heater. See: FUEL-POWERED PREHEATER, CHECKING .
Page 543 REMOVING THE COMBUSTION PREHEATER MODULE (CPM) Fig. 159: Identifying Combustion Preheater Module (CPM) Screws Courtesy of VOLVO CARS CORPORATION Slacken off the 4 screws. See the illustration. Carefully pull the combustion preheater module (CPM) straight out to access the connector.
Page 544 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation INSTALLING THE COMBUSTION PREHEATER MODULE (CPM) Install the switch so that it is properly secured. Position the control module. Ensure that the control module housing goes correctly into the grooves at the top edge.
Page 545 HVAC Climate Units - Removal, Replacement And Installation Fig. 160: Identifying Combustion Preheater Module (CPM) Screws Courtesy of VOLVO CARS CORPORATION Slacken off the 4 screws. See the illustration. Carefully pull the combustion preheater module (CPM) straight out to access the connector.
Page 546 The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct. REMOVAL REMOVING THE EXHAUST PIPE FOR THE ENGINE COOLANT HEATER Fig. 161: Identifying Upper Mounting Courtesy of VOLVO CARS CORPORATION...
Page 547 Pull off the intake hose that covers the upper mounting for the exhaust system. Move the intake hose to one side. Disconnect the upper mounting (as illustrated). Remove the screw. Fig. 162: Identifying Shield And Clips Courtesy of VOLVO CARS CORPORATION Raise the vehicle. Remove: the right-hand front wheel ...
Page 548 HVAC Climate Units - Removal, Replacement And Installation Fig. 163: Identifying Lower Mounting For Fuel Pipe Courtesy of VOLVO CARS CORPORATION Remove the fuel hose/pipe from the exhaust pipe for the engine coolant heater at the quick-release connector under the vehicle.
Page 549 HVAC Climate Units - Removal, Replacement And Installation Fig. 164: Identifying Long Extension Rod Courtesy of VOLVO CARS CORPORATION Disconnect the lower mounting under the engine. Use a long extension rod. See the illustration. Pull the exhaust pipe down through the right-hand wheel arch.
Page 550 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 165: Identifying Shield And Clips Courtesy of VOLVO CARS CORPORATION Install: the right-hand front wheel  the lower mounting on the nut for the exhaust system. Tighten. See: TIGHTENING TORQUE ...
Page 551 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 166: Identifying EVAP Canister Pipe And Upper Charge Air Pipe Courtesy of VOLVO CARS CORPORATION Remove: the EVAP canister hose (1) from the intake manifold  the intake manifold (2) between the air cleaner (ACL) and the turbocharger (TC).
Page 552 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 167: Identifying Upper Mounting Courtesy of VOLVO CARS CORPORATION Pull off the intake hose that covers the upper mounting for the exhaust system. Move the intake hose to one side.
Page 553 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 168: Identifying Shield And Clips Courtesy of VOLVO CARS CORPORATION Raise the vehicle. Remove: the right-hand front wheel  the shield under the vehicle. It is secured with 7 clips.
Page 554 HVAC Climate Units - Removal, Replacement And Installation Fig. 169: Identifying Lower Mounting For Fuel Pipe Courtesy of VOLVO CARS CORPORATION Remove the fuel hose/pipe from the exhaust pipe for the engine coolant heater at the quick-release connector under the vehicle.
Page 555 HVAC Climate Units - Removal, Replacement And Installation Fig. 170: Identifying Long Extension Rod Courtesy of VOLVO CARS CORPORATION Disconnect the lower mounting under the engine. Use a long extension rod. See the illustration. Pull the exhaust pipe down through the right-hand wheel arch.
Page 556  FINISHING INSTALLING COMPONENTS AND TESTING THE ENGINE COOLANT HEATER Fig. 171: Identifying Shield And Clips Courtesy of VOLVO CARS CORPORATION Install: the right-hand front wheel  the lower mounting on the nut for the exhaust system. Tighten. See: TIGHTENING TORQUE ...
Page 557 PREPARATORY WORK REMOVING COMPONENTS Fig. 172: Identifying Screws For Cover Over Fan Housing Courtesy of VOLVO CARS CORPORATION Remove: the engine coolant heater. See: FUEL FIRED BOOSTER HEATER (B5254T3, B5254T7) or FUEL  FIRED BOOSTER HEATER (B5244S4) the combustion preheater module (CPM).
Page 558 REMOVAL REMOVING THE OVERHEAT PROTECTION THERMOSTAT/ENGINE COOLANT TEMPERATURE SENSOR Fig. 173: Identifying Overheat Protection Thermostat/Engine Coolant Temperature Sensor Courtesy of VOLVO CARS CORPORATION Remove the 1 screw for the holder. Remove the sensors from the recesses. Disconnect all the remaining cable terminals and cables apart from:...
Page 559 Install the holders for the sensors using 1 screw. Tighten. Fig. 174: Identifying Cable Terminals And Cables Courtesy of VOLVO CARS CORPORATION Install the removed cables together with cable terminals. - Flame sensor in positions 1 and 2 (blue and brown).
Page 560 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Install: the housing around the fan motor  the cover for the fan motor using 4 screws. Tighten  the cover and the pipe couplings. See: COOLANT PIPE FUEL-POWERED PREHEATER ...
Page 561 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 175: Identifying Screws For Cover Over Fan Housing Courtesy of VOLVO CARS CORPORATION Remove: the engine coolant heater. See: FUEL FIRED BOOSTER HEATER (B5254T3, B5254T7)  the combustion preheater module (CPM). See: FUEL FIRED BOOSTER HEATER CONTROL UNIT ...
Page 562 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 176: Identifying Overheat Protection Thermostat/Engine Coolant Temperature Sensor Courtesy of VOLVO CARS CORPORATION Remove the 1 screw for the holder. Remove the sensors from the recesses. Disconnect all the remaining cable terminals and cables apart from: - those for the overheat protection thermostat at positions 5 and 6 (red cables) - those for the engine coolant temperature sensor at positions 3 and 4 (blue cables).
Page 563 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 177: Identifying Cable Terminals And Cables Courtesy of VOLVO CARS CORPORATION Install the removed cables together with cable terminals. - Flame sensor in positions 1 and 2 (blue and brown).
Page 564 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation FINISHING TESTING THE ENGINE COOLANT HEATER Carry out a performance test of the engine coolant heater. See: FUEL-POWERED PREHEATER, CHECKING . FUEL LINE FUEL-POWERED PREHEATER (B5244S4) Special tools:...
Page 565 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 178: Identifying Lower Mounting For Fuel Pipe Courtesy of VOLVO CARS CORPORATION Remove the lower mounting for the fuel pipe. Disconnect the quick-release connector. NOTE: Wipe up any fuel spills.
Page 566 HVAC Climate Units - Removal, Replacement And Installation Fig. 179: Identifying Intake Hose, Exhaust System, Fuel Pipe And Mounting Screw Courtesy of VOLVO CARS CORPORATION Disconnect the intake hose (1). Disconnect the exhaust system (2) but do not remove it. See FUEL FIRED BOOSTER HEATER EXHAUST PIPE (B5244S4).
Page 567 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Position the fuel line. Install the upper fuel connection using a new clamp. HINT: Use: see 9512619 to secure the clamp. Secure the engine coolant heater in the bracket. Tighten. See: TIGHTENING TORQUE .
Page 568 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 180: Identifying Fuel Pump Connector Courtesy of VOLVO CARS CORPORATION Remove the fuel tank. See: FUEL TANK .
Page 569 HVAC Climate Units - Removal, Replacement And Installation Fig. 181: Identifying Quick-Release Connector To Suction Pipe Courtesy of VOLVO CARS CORPORATION Place paper around the suction pipe connection to the fuel tank unit. Release the quick-release connector to the suction pipe.
Page 570 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation TESTING THE ENGINE COOLANT HEATER Carry out a performance test of the engine coolant heater. See: FUEL-POWERED PREHEATER, CHECKING . FUEL LINE FUEL-POWERED PREHEATER (B5254T3, B5254T7) Special tools:...
Page 571 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 182: Identifying EVAP Canister Pipe And Upper Charge Air Pipe Courtesy of VOLVO CARS CORPORATION Remove: the EVAP canister pipe (1)  the upper charge air pipe (2).
Page 572 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 183: Identifying Lower Mounting For Fuel Pipe Courtesy of VOLVO CARS CORPORATION Remove the lower mounting for the fuel pipe. Disconnect the quick-release connector. NOTE: Wipe up any fuel spills.
Page 573 HVAC Climate Units - Removal, Replacement And Installation Fig. 184: Identifying Intake Hose, Exhaust System, Fuel Pipe And Mounting Screw Courtesy of VOLVO CARS CORPORATION Disconnect the intake hose (1). Disconnect the exhaust system (2) but do not remove it. See: FUEL FIRED BOOSTER HEATER EXHAUST PIPE.
Page 574 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Position the fuel line. Install the upper fuel connection using a new clamp. HINT: Use: see 9512619 to secure the clamp. Secure the engine coolant heater in the bracket. Tighten. See: TIGHTENING TORQUE .
Page 575 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 185: Identifying Fuel Pump Connector Courtesy of VOLVO CARS CORPORATION Remove the fuel tank. See: FUEL TANK .
Page 576 HVAC Climate Units - Removal, Replacement And Installation Fig. 186: Identifying Quick-Release Connector To Suction Pipe Courtesy of VOLVO CARS CORPORATION Place paper around the suction pipe connection to the fuel tank unit. Release the quick-release connector to the suction pipe.
Page 577 Some variation may occur. However, the essential information in the illustrations is always correct. PREPARATORY WORK IMPORTANT INFORMATION Fig. 187: Identifying Fuel Pump (FP) Courtesy of VOLVO CARS CORPORATION WARNING: Use protective gloves and protective goggles during all operations due to the risk of fuel spills. NOTE:...
Page 578  Fig. 188: Identifying Fuel Pump Connector Courtesy of VOLVO CARS CORPORATION Lower the fuel tank a little so that the fuel hoses to and from the fuel pump (FP) can be reached over the top of the fuel tank. See: FUEL TANK .
Page 579 HVAC Climate Units - Removal, Replacement And Installation Fig. 189: Identifying Fuel Lines, Fuel Pump (FP) And Hoses Courtesy of VOLVO CARS CORPORATION Remove the quick-release connector on the fuel hose routed to the fuel pump (FP) for the engine coolant heater at the suction hose on the fuel tank unit.
Page 580 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation the fuel pump and its bracket in the rear sub-frame. Do not tighten the mounting screw yet  the fuel lines on top of the fuel tank ...
Page 581 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 190: Identifying Fuel Pump (FP) Courtesy of VOLVO CARS CORPORATION WARNING: Use protective gloves and protective goggles during all operations due to the risk of fuel spill.
Page 582 HVAC Climate Units - Removal, Replacement And Installation Fig. 191: Identifying Fuel Pump Connector Courtesy of VOLVO CARS CORPORATION Lower the fuel tank a little so that the fuel hoses to and from the fuel pump (FP) can be reached over the top of the fuel tank.
Page 583 HVAC Climate Units - Removal, Replacement And Installation Fig. 192: Identifying Fuel Lines, Fuel Pump (FP) And Hoses Courtesy of VOLVO CARS CORPORATION Remove the quick-release connector on the fuel hose routed to the fuel pump (FP) for the engine coolant heater at the suction hose on the fuel tank unit.
Page 584 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation the fuel pump and its bracket in the rear sub-frame. Do not tighten the mounting screw yet  the fuel lines on top of the fuel tank ...
Page 585 HVAC Climate Units - Removal, Replacement And Installation Fig. 193: Identifying Shield And Clips Courtesy of VOLVO CARS CORPORATION Remove the expansion tank cap. Open the holder for the radiator hoses behind the engine to expose the lower radiator hose to the water pump.
Page 586 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 194: Identifying Water Pump Courtesy of VOLVO CARS CORPORATION Remove: the screw holding the water pump and rubber mounting.  the connector.  Pull the water pump forward a little.
Page 587 HVAC Climate Units - Removal, Replacement And Installation Fig. 195: Identifying Water Pump Courtesy of VOLVO CARS CORPORATION The water pump for the engine coolant heater has a rubber-mounted mounting. The lower section is hooked onto the mounting bracket on the vehicle.
Page 588 Check for leakage from the coolant hoses. Top up the coolant if necessary. INSTALLING THE COVER Fig. 196: Identifying Shield And Clips Courtesy of VOLVO CARS CORPORATION Install the cover. It is secured with 7 clips. Lower the vehicle. WATER PUMP, FUEL-DRIVEN AUXILIARY HEATER (B5254T3, B5254T7)
Page 589 DRAINING THE ENGINE COOLANT Fig. 197: Identifying Shield And Clips Courtesy of VOLVO CARS CORPORATION Remove the expansion tank cap. Open the holder for the radiator hoses behind the engine to expose the lower radiator hose to the water pump.
Page 590 2012 Volvo C30 T-5 HVAC Climate Units - Removal, Replacement And Installation Fig. 198: Identifying Water Pump Courtesy of VOLVO CARS CORPORATION Remove: the screw holding the water pump and rubber mounting.  the connector.  Pull the water pump forward a little.
Page 591 HVAC Climate Units - Removal, Replacement And Installation Fig. 199: Identifying Water Pump Courtesy of VOLVO CARS CORPORATION The water pump for the engine coolant heater has a rubber-mounted mounting. The lower section is hooked onto the mounting bracket on the vehicle.
Page 592 CHECKING . Check for leakage from the coolant hoses. Top up the coolant if necessary. INSTALLING THE COVER Fig. 200: Identifying Shield And Clips Courtesy of VOLVO CARS CORPORATION Install the cover. It is secured with 7 clips. Lower the vehicle.
Page 593 Materials Designation Part number Brake fluid 9437430 REMOVAL Fig. 1: Brake Fluid, 9437430 Courtesy of VOLVO CARS CORPORATION WARNING: Only use new specified brake fluid from airtight containers. CAUTION: The fluid level must remain between the MAX and MIN marks.
Page 594 2012 Volvo C30 T-5 TRANSMISSION Clutch - Cleaning, Inspection And Adjustment Use: Brake fluid, 9437430 Fig. 2: Identifying Bleeding Tool Courtesy of VOLVO CARS CORPORATION see 9997446...
Page 595 2012 Volvo C30 T-5 TRANSMISSION Clutch - Cleaning, Inspection And Adjustment Fig. 3: Clutch Bleeding Procedure (1 Of 11) Courtesy of VOLVO CARS CORPORATION Fig. 4: Clutch Bleeding Procedure (2 Of 11) Courtesy of VOLVO CARS CORPORATION...
Page 596 2012 Volvo C30 T-5 TRANSMISSION Clutch - Cleaning, Inspection And Adjustment Fig. 5: Clutch Bleeding Procedure (3 Of 11) Courtesy of VOLVO CARS CORPORATION Fig. 6: Clutch Bleeding Procedure (4 Of 11) Courtesy of VOLVO CARS CORPORATION WARNING: Be prepared to collect escaping fluid.
Page 597 2012 Volvo C30 T-5 TRANSMISSION Clutch - Cleaning, Inspection And Adjustment Fig. 7: Clutch Bleeding Procedure (5 Of 11) Courtesy of VOLVO CARS CORPORATION Fig. 8: Clutch Bleeding Procedure (6 Of 11) Courtesy of VOLVO CARS CORPORATION...
Page 598 2012 Volvo C30 T-5 TRANSMISSION Clutch - Cleaning, Inspection And Adjustment Fig. 9: Clutch Bleeding Procedure (7 Of 11) Courtesy of VOLVO CARS CORPORATION Fig. 10: Clutch Bleeding Procedure (8 Of 11)
Page 599 2012 Volvo C30 T-5 TRANSMISSION Clutch - Cleaning, Inspection And Adjustment Courtesy of VOLVO CARS CORPORATION Fig. 11: Clutch Bleeding Procedure (9 Of 11) Courtesy of VOLVO CARS CORPORATION Fig. 12: Clutch Bleeding Procedure (10 Of 11) Courtesy of VOLVO CARS CORPORATION...
Page 600 2012 Volvo C30 T-5 TRANSMISSION Clutch - Cleaning, Inspection And Adjustment Fig. 13: Clutch Bleeding Procedure (11 Of 11) Courtesy of VOLVO CARS CORPORATION INSTALLATION To install, reverse the removal procedure.
Page 601 2012 Volvo C30 T-5 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation TRANSMISSION Clutch - Removal, replacement and installation TRANSMISSION Clutch - Removal, replacement and installation MECHANICAL CLUTCH CLUTCH DISC AND PRESSURE PLATE (B5244S4) Special tools 999 7068 Counterhold...
Page 602 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 1: Identifying Counterhold Tool 9997068 And Gear Sector Tool 9997120 Courtesy of VOLVO CARS CORPORATION NOTE: Note the position of the component before removal. see 9997068 see 9997120 Fig.
Page 603 TRANSMISSION Clutch - Removal, replacement and installation Fig. 3: Identifying Compression Tool 9995662 And Pressure Plate Bolts Courtesy of VOLVO CARS CORPORATION see 9995662 Fig. 4: Identifying Centering Tool 999 5663 And Socket Tool 999 5675 Attached To Clutch Disc...
Page 604 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 5: Identifying Cleaning Agent, 1161721 Courtesy of VOLVO CARS CORPORATION Use: Cleaning agent, 1161721 Fig. 6: Identifying Compression Tool 9995662 Attached To Pressure Plate Courtesy of VOLVO CARS CORPORATION WARNING: Take care not to trap any fingers when removing the special tool.
Page 605 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 7: Identifying Removal Of Centering Tool Assembly Courtesy of VOLVO CARS CORPORATION INSTALLATION Perform transmission installation CLUTCH DISC AND PRESSURE PLATE (B5254T3, B5254T7) Special tools 999 7068 Counterhold...
Page 606 Designation Part number Cleaning agent 1161721 REMOVAL Remove transmission, see TRANSMISSION Fig. 8: Identifying Counterhold Tool 9997068 And Gear Sector Tool 9997120 Courtesy of VOLVO CARS CORPORATION NOTE: Note the position of the component before removal. see 9997068 see 9997120...
Page 607 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 9: Identifying Compression Tool 9995662 And Pressure Plate Bolts Courtesy of VOLVO CARS CORPORATION see 9995662 INSTALLATION Fig. 10: Identifying Centering Tool 999 5663 And Socket Tool 999 5675 Attached To Clutch Disc...
Page 608 TRANSMISSION Clutch - Removal, replacement and installation see 9995663 see 9995675 Fig. 11: Identifying Cleaning Agent, 1161721 Courtesy of VOLVO CARS CORPORATION Use: Cleaning agent, 1161721 Fig. 12: Identifying Compression Tool 9995662 Attached To Pressure Plate Courtesy of VOLVO CARS CORPORATION WARNING: Take care not to trap any fingers when removing the special tool.
Page 609 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 13: Identifying Removal Of Centering Tool Assembly Courtesy of VOLVO CARS CORPORATION Install the transmission, see TRANSMISSION CLUTCH CONTROL (B5244S4) CLUTCH SLAVE CYLINDER REMOVAL NOTE: Removal steps in this procedure may contain installation details.
Page 610 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 15: Locating Bolt For Clutch Slave Cylinder Courtesy of VOLVO CARS CORPORATION Torque: M6 10 Nm INSTALLATION To install, reverse the removal procedure Install the transaxle. See TRANSMISSION, INSTALLING.
Page 611 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation REMOVING THE LEFT-HAND ENGINE PAD Remove the left-hand engine pad. See ENGINE SUPPORT INSULATOR LEFT . REMOVING DRIVE SHAFTS Remove: the right drive shaft. See DRIVE SHAFT RIGHT ...
Page 612 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 16: Locating Ground Courtesy of VOLVO CARS CORPORATION Remove: the ground lead on the bracket. Tie up the ground lead  the terminal for the back-up (reversing) lamp switch and the clip on the transmission.
Page 613 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 17: Locating Bracket Bolts Courtesy of VOLVO CARS CORPORATION Remove the bracket from the transmission. REMOVING THE GEAR SELECTOR CABLES...
Page 614 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 18: Identifying Gear Selector Cable Ball Joints Courtesy of VOLVO CARS CORPORATION Remove: the ball joints. Use: see 9997077  the sleeves for the gear selector cables from the transmission cable bracket.
Page 615 TRANSMISSION Clutch - Removal, replacement and installation Fig. 19: Identifying Clutch Line Courtesy of VOLVO CARS CORPORATION Pull up the striker plate. Pull the clutch line including the bleed nipple from the terminal. Remove the rubber bushing from its bracket on the transmission.
Page 616 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 20: Locating Bellhousing Bolts Courtesy of VOLVO CARS CORPORATION Remove: the starter motor. See STARTER MOTOR (TURBO) or STARTER MOTOR (NON-TURBO)  the 4 screws between the engine and transmission.
Page 617 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 21: Locating Bracket Bolts Courtesy of VOLVO CARS CORPORATION Remove the torque rod together with the mounting in the sub-frame, 3 +1 screws. ANGLING THE ENGINE AND TRANSMISSION...
Page 618 TRANSMISSION Clutch - Removal, replacement and installation Fig. 22: Securing Transmission Courtesy of VOLVO CARS CORPORATION Install a tensioner strap between the rear engine mounting and the front cross member. Pull the engine and transmission as far forwards as possible without touching the radiator.
Page 619 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 23: Locating Bellhousing Bolts Courtesy of VOLVO CARS CORPORATION There are 7 screws between the engine and transmission. Remove 5 screws, leaving 2 screws in position.
Page 620 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 24: Locating Bellhousing Bolt Courtesy of VOLVO CARS CORPORATION NOTE: The screw above the drive shaft hole cannot be removed from the hole in the engine. Pull the screw backwards as far as possible and let it remain in the hole.
Page 621 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 25: Identifying Mobile Jack And Transmission Fixture Courtesy of VOLVO CARS CORPORATION Install: see 9995463 to: see 9995972 . Use the fixture and plate together with: see 9985972 . NOTE: Tighten all the screws to the fixtures.
Page 622 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 26: Locating Bolts Courtesy of VOLVO CARS CORPORATION Remove the remaining 2 screws between the engine and transmission. REMOVING THE TRANSMISSION NOTE: Ensure that the transmission is taken straight out in relation to the engine.
Page 623 PREPARATORY WORK TRANSFERRING COMPONENTS Fig. 27: Applying Thread Lock To Bolt Threads Courtesy of VOLVO CARS CORPORATION Move the ball catch to the new gear box. Apply the thread lock 1161056 to the threads. Tighten to 32 Nm.
Page 624 INSTALLING THE TRANSMISSION Fig. 28: Identifying Installation Of Transmission Courtesy of VOLVO CARS CORPORATION Adjust height and angle with the mobile jack and the transmission fixture. Locate the transmission on the engine. Ensure that the transmission goes straight in, in relation to the engine, and that no deviation occurs in the clutch driven plate center.
Page 625 TRANSMISSION Clutch - Removal, replacement and installation Fig. 29: Identifying Mounting For Transmission And Screws Courtesy of VOLVO CARS CORPORATION Install the mounting for the transmission. Use 4 M10 screws and 1 M8 screw. Tighten. LIFTING THE ENGINE AND THE TRANSMISSION...
Page 626 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 30: Identifying Lifting Tools Courtesy of VOLVO CARS CORPORATION Lift the engine/transmission. Align the mounting against the transmission in the engine pad. Install the M14 screw for the engine mounting.
Page 627 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Courtesy of VOLVO CARS CORPORATION Install: the 4 x M10 screws for the transmission and engine. Tighten  the starter motor.  INSTALLING THE CLUTCH LINE Fig. 32: Identifying Clutch Line Courtesy of VOLVO CARS CORPORATION Use a new O-ring for the clutch line.
Page 628 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 33: Identifying Bracket Holder, Bracket And Coolant Hose Courtesy of VOLVO CARS CORPORATION Install: the bracket holder  the bracket and the coolant hose.  INSTALLING THE GEAR SELECTOR CABLE...
Page 629 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 34: Identifying Back-Up Lamp Switch Connector And Transmission Cables To Bracket And Levers Courtesy of VOLVO CARS CORPORATION NOTE: Ensure that the cable and sleeve do not crack or break.
Page 630 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 36: Identifying Oil Line And Ground Lead Courtesy of VOLVO CARS CORPORATION Install: the ground lead on the transmission  the torque rod mounting to the transmission, 3 x M10. Tighten.
Page 631 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 38: Identifying Anti-Roll Bar Screws Courtesy of VOLVO CARS CORPORATION Install the anti-roll bar. Use 4 new M10 screws. Tighten. See TIGHTENING TORQUE . SECURING THE SUB-FRAME...
Page 632 TRANSMISSION Clutch - Removal, replacement and installation Fig. 39: Identifying Adjustment Tool 9997089 Courtesy of VOLVO CARS CORPORATION Install see 9997089 on both sides. Carefully raise the sub-frame so that the adjustment tools are lined up with the holes in the side members.
Page 633 Install the rubber mountings for the exhaust pipe mounting. INSTALLING THE SCREWS, CONTINUED Fig. 41: Identifying Screws For Steering Gear/Sub-Frame Courtesy of VOLVO CARS CORPORATION Tighten the front M12 screws to the subframe. See TIGHTENING TORQUE . Install new screws for the steering gear and sub-frame loosely.
Page 634 Install the front wheels. See WHEELS . INSTALLING COMPONENTS IN ENGINE COMPARTMENT Fig. 42: Identifying Steering Gear Screws Courtesy of VOLVO CARS CORPORATION Tighten the two M12 screws for the steering gear. INSTALLING THE BATTERY LEAD Fig. 43: Identifying Battery Box...
Page 635 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation CHECK THE BRAKE FLUID Check the brake fluid level. Use only Volvo Genuine parts brake fluid (Volvo DOT 4+) when topping up. CLUTCH PEDAL (2011) REMOVAL AND INSTALLATION Remove clutch pedal, see MASTER CYLINDER, CLUTCH...
Page 636 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 44: Identifying Clutch Pedal Courtesy of VOLVO CARS CORPORATION Fig. 45: Removing Clutch Pedal Spring Courtesy of VOLVO CARS CORPORATION...
Page 637 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 46: Centering Steering Wheel Courtesy of VOLVO CARS CORPORATION WARNING: The steering column may contain pyrotechnic components. NOTE: Make sure that the road wheels are in the straight ahead position.
Page 638 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 48: Removing Clutch Hose Courtesy of VOLVO CARS CORPORATION WARNING: Be prepared to collect escaping fluid. Fig. 49: Positioning Hose Above Fluid Level In Reservoir Courtesy of VOLVO CARS CORPORATION CAUTION: Make sure the open end of the hose is secured above the fluid level in the reservoir.
Page 639 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 50: Removing/Installing Steering Shaft Joint Courtesy of VOLVO CARS CORPORATION NOTE: Make sure that a new component is installed. Torque: steering column to steering gear (steering shaft joint) 25 Nm Fig.
Page 640 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 52: Identifying Clutch Line Removal Courtesy of VOLVO CARS CORPORATION Fig. 53: Identifying Steering Column To Dashboard Bolts Courtesy of VOLVO CARS CORPORATION Torque: Steering column to dashboard...
Page 641 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 54: Identifying Steering Column Assembly Courtesy of VOLVO CARS CORPORATION Fig. 55: Locating Switch Cover Courtesy of VOLVO CARS CORPORATION Torque: M6 10 Nm Remove Start Inhibitor Switch clutch pedal passenger compartment, see START INHIBIT SWITCH...
Page 642 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 56: Identifying Start Inhibit Switch Courtesy of VOLVO CARS CORPORATION VEHICLES MANUFACTURED FROM CHASSIS NUMBER: 22095 Remove the collision warning control module, see COLLISION WARNING CONTROL MODULE ALL VEHICLES Fig.
Page 643 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 58: Identifying Special Tool 9995511 Courtesy of VOLVO CARS CORPORATION see 9995511 Fig. 59: Locating Clutch Pedal Mounting Bracket Bolts Courtesy of VOLVO CARS CORPORATION Torque: M8 24 Nm...
Page 644 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 60: Identifying Wrench 9997172 To Adjust Clutch Tension Courtesy of VOLVO CARS CORPORATION see 9997172 Fig. 61: Identifying Seal Courtesy of VOLVO CARS CORPORATION NOTE: Note the position of each component before removal.
Page 645 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 62: Locating Seal For Disposal Courtesy of VOLVO CARS CORPORATION NOTE: Use a new seal. INSTALLATION Fig. 63: Identifying Bracket Courtesy of VOLVO CARS CORPORATION NOTE: This step is not necessary when installing a new component.
Page 646 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 64: Identifying Where to Cut Courtesy of VOLVO CARS CORPORATION Fig. 65: Visually Inspecting That Bracket Is At 90Degrees Courtesy of VOLVO CARS CORPORATION see 9997119...
Page 647 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 66: Anti-squeak tape, 1161842 Courtesy of VOLVO CARS CORPORATION Use: Anti-squeak tape, 1161842 Fig. 67: Identifying Silicone grease, 1161687 Courtesy of VOLVO CARS CORPORATION...
Page 648: Table Of Contents
999 7172 Wrench Tool number: 999 7172 Tool description: Wrench Tool boards: 43 REMOVAL NOTE: Removal steps in this procedure may contain installation details. Remove battery, see BATTERY Fig. 68: Identifying Removal Of M6 Screws Courtesy of VOLVO CARS CORPORATION Torque: M6...
Page 649 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 69: Identifying Removal Of Connector Courtesy of VOLVO CARS CORPORATION Fig. 70: Identifying Connector Removal Courtesy of VOLVO CARS CORPORATION WARNING: Be prepared to collect escaping fluid.
Page 650 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 71: Identifying Method To Detach Line Courtesy of VOLVO CARS CORPORATION WARNING: Be prepared to collect escaping fluid. Fig. 72: Identifying Removal Of Clutch Line Courtesy of VOLVO CARS CORPORATION CAUTION: Make sure the open end of the hose is secured above the fluid level in the reservoir.
Page 651 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 73: Centering Steering Wheel Courtesy of VOLVO CARS CORPORATION WARNING: The steering column may contain pyrotechnic components. NOTE: Make sure that the road wheels are in the straight ahead position.
Page 652 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 75: Locating Clutch Line Attachment Point Courtesy of VOLVO CARS CORPORATION Fig. 76: Locating Clutch Line Steering Wheel Connectors Courtesy of VOLVO CARS CORPORATION Fig. 77: Identifying Connector...
Page 653 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 78: Identifying Clutch Line Removal Courtesy of VOLVO CARS CORPORATION Fig. 79: Identifying Steering Column To Dashboard Bolts Courtesy of VOLVO CARS CORPORATION Torque: Steering column to dashboard...
Page 654 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 80: Locating Clutch Line Fasteners Courtesy of VOLVO CARS CORPORATION Fig. 81: Identifying Clutch Piston Attachment Clips Courtesy of VOLVO CARS CORPORATION...
Page 655 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 82: Identifying Clutch And M8 Bolts Courtesy of VOLVO CARS CORPORATION Torque: M8 24 Nm Fig. 83: Identifying Wrench 9997172 To Adjust Clutch Tension Courtesy of VOLVO CARS CORPORATION...
Page 656: Removal
2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 84: Locating Seal For Disposal Courtesy of VOLVO CARS CORPORATION NOTE: Use a new seal. INSTALLATION To install, reverse the removal procedure. Perform clutch system venting, see BLEEDING THE CLUTCH SYSTEM...
Page 657 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 85: Identifying Clutch Pedal Arm Courtesy of VOLVO CARS CORPORATION Fig. 86: Removing Connector Courtesy of VOLVO CARS CORPORATION Fig. 87: Identifying Start Inhibit Switch Courtesy of VOLVO CARS CORPORATION...
Page 658: Note: Removal Steps In This Procedure May Contain Installation Details
2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 88: Identifying Start Inhibit Switch Courtesy of VOLVO CARS CORPORATION To install, reverse the removal procedure. POSITION SENSOR CLUTCH PEDAL ENGINE COMPARTMENT Special tools 999 7402 Installer Tool number: 999 7402...
Page 659: Torque: M6
2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 89: Identifying Removal Of M6 Screws Courtesy of VOLVO CARS CORPORATION Torque: M6 10 Nm Fig. 90: Identifying Removal Of Connector Courtesy of VOLVO CARS CORPORATION...
Page 660 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 91: Identifying Installer Tool 999 7402 And Clutch Pedal Position Sensor Courtesy of VOLVO CARS CORPORATION see 9997402 INSTALLATION To install, reverse the removal procedure. CLUTCH CONTROL (B5254T3)
Page 661 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 92: Identifying Removal Of Retaining Pin To Link Arm Courtesy of VOLVO CARS CORPORATION Fig. 93: Locating Bolt For Clutch Slave Cylinder Courtesy of VOLVO CARS CORPORATION Torque: M6...
Page 662 MASTER CYLINDER, CLUTCH POSITION SENSOR CLUTCH PEDAL ENGINE COMPARTMENT see POSITION SENSOR CLUTCH PEDAL ENGINE COMPARTMENT (2011) CLUTCH CONTROL START INHIBIT SWITCH REMOVAL Fig. 94: Identifying Clutch Pedal Arm Courtesy of VOLVO CARS CORPORATION Remove instrument panel lower, see INSTRUMENT PANEL LOWER...
Page 663 2012 Volvo C30 T-5 TRANSMISSION Clutch - Removal, replacement and installation Fig. 95: Identifying Removal Start Inhibit Switch Courtesy of VOLVO CARS CORPORATION INSTALLATION Fig. 96: Identifying Start Inhibit Switch Courtesy of VOLVO CARS CORPORATION To install, reverse the removal procedure.
Page 664 COLLISION WARNING CONTROL MODULE REMOVAL NOTE: Removal steps in this procedure may contain installation details. Remove the combined instrument panel, see COMBINED INSTRUMENT PANEL Fig. 1: View of Collision Warning Control Module Courtesy of VOLVO CARS CORPORATION Torque: M6 10 Nm...
Page 665 2012 Volvo C30 T-5 ACCESSORIES & EQUIPMENT Collision Avoidance Fig. 2: Removing Collision Warning Control Module Courtesy of VOLVO CARS CORPORATION CAUTION: Take extra care not to damage the clips. NOTE: Make sure that the component terminals are not bent or damaged.
Page 666 2012 Volvo C30 T-5 2012 Volvo C30 T-5 COMMON SPECS & PROCEDURES C30 COMMON SPECS & PROCEDURES C30 COMMON SPECS & PROCEDURES SPECIFICATIONS INDEX SPECIFICATIONS INDEX - C30 System Specification/Procedure Air Conditioning Service Procedures see CLIMATE UNITS - CLEANING, INSPECTION AND...
Page 667 2012 Volvo C30 T-5 COMMON SPECS & PROCEDURES C30 Thermostat R & I see THERMOSTAT (B5254T7) Water Pump R & I see COOLANT PUMP Engine Mechanical Compression Oil Pressure @100 °C see appropriate engine under ENGINE - SPECIFICATIONS, MECHANICAL Overhaul...
Page 668 2012 Volvo C30 T-5 COMMON SPECS & PROCEDURES C30 Start impulse lead: 8.5 Nm Wheel Alignment Adjustment Specifications see WHEEL ALIGNMENT Torque see SUMMARY OF TIGHTENING TORQUES FOR SPECIFIC COMPONENTS Wheel & Tire Wheel To Wheel Hub Stage 1: 20 Nm...
Page 669 2012 Volvo C30 T-5 2012 Volvo C30 T-5 ELECTRICAL Cables And Fuses - Removal, Replacement And Installation ELECTRICAL Cables And Fuses - Removal, Replacement And Installation ELECTRICAL Cables And Fuses - Removal, Replacement And Installation CONNECTORS CONNECTOR ANTI-LOCK BRAKING SYSTEM MODULE (ABS)
Page 670 2012 Volvo C30 T-5 ELECTRICAL Cables And Fuses - Removal, Replacement And Installation Courtesy of VOLVO CARS CORPORATION Disconnect the secondary lock. Use an electrician's screwdriver, as shown. CAUTION: Disconnect and work with only one cable at a time to minimize the risk of mixing them up.
Page 671 2012 Volvo C30 T-5 ELECTRICAL Cables And Fuses - Removal, Replacement And Installation ASSEMBLING PRIMARY LOCK Check that the cable terminal is undamaged. Press the cable terminal into the housing. Check that the cable terminal is properly locked by pulling carefully on the cable.
Page 672 ELECTRICAL Cables And Fuses - Removal, Replacement And Installation Fig. 3: Identifying Receptacle Housings Removal Courtesy of VOLVO CARS CORPORATION Press in the active catches on both sides of the socket housing and slide out the receptacle housings. CAUTION: Disconnect and work with only one cable at a time to minimize the risk of mixing them up.
Page 673 Fig. 4: Identifying Locking Tab Pressed In On Cable Terminal Using Special Tool 9512812 Courtesy of VOLVO CARS CORPORATION Press in the locking tab on the cable terminal and carefully pull out the cable and the cable terminal. Use tool: see 9512812 or tool: see 9512637 , as shown.
Page 674 ELECTRICAL Cables And Fuses - Removal, Replacement And Installation REMOVAL Fig. 5: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Fig. 6: Identifying Accessory Control Module (AEM) Removal Procedure (1 Of 8) Courtesy of VOLVO CARS CORPORATION Remove side panel cargo compartment. See SIDE PANEL LOADSPACE...
Page 675 ELECTRICAL Cables And Fuses - Removal, Replacement And Installation Fig. 7: Identifying Accessory Control Module (AEM) Removal Procedure (2 Of 8) Courtesy of VOLVO CARS CORPORATION Fig. 8: Identifying Accessory Control Module (AEM) Removal Procedure (3 Of 8) Courtesy of VOLVO CARS CORPORATION...
Page 676 ELECTRICAL Cables And Fuses - Removal, Replacement And Installation Fig. 10: Identifying Accessory Control Module (AEM) Removal Procedure (5 Of 8) Courtesy of VOLVO CARS CORPORATION Fig. 11: Identifying Accessory Control Module (AEM) Removal Procedure (6 Of 8) Courtesy of VOLVO CARS CORPORATION...
Page 677 ELECTRICAL Cables And Fuses - Removal, Replacement And Installation Fig. 12: Identifying Accessory Control Module (AEM) Removal Procedure (7 Of 8) Courtesy of VOLVO CARS CORPORATION Fig. 13: Identifying Accessory Control Module (AEM) Removal Procedure (8 Of 8) Courtesy of VOLVO CARS CORPORATION INSTALLATION To install, reverse the removal procedure.
Page 678 2012 Volvo C30 T-5 ELECTRICAL Cables And Fuses - Removal, Replacement And Installation Fig. 14: Locating Connection To Battery, Nut On Starter And Air Cleaner Courtesy of VOLVO CARS CORPORATION Remove the following items: battery negative lead. See BATTERY DISCONNECTING AND CONNECTING ...
Page 679 Some variation may occur. However, the essential information in the graphics is always correct. Fig. 15: Locating Connection To Battery, Nut On Starter And Air Cleaner Courtesy of VOLVO CARS CORPORATION Remove the following items: Battery negative lead. See BATTERY DISCONNECTING AND CONNECTING ...
Page 680 Perform, see BATTERY DISCONNECTING AND CONNECTING CAUTION: The control module must be removed, reinstalled and downloaded with software before the control module is replaced. NOTE: This module contains customer parameters. Fig. 16: Identifying Control Module Relay Box & Clip Courtesy of VOLVO CARS CORPORATION...
Page 681 2012 Volvo C30 T-5 ELECTRICAL Cables And Fuses - Removal, Replacement And Installation Fig. 17: Identifying Zip Ties Courtesy of VOLVO CARS CORPORATION Fig. 18: Identifying Control Module Relay Box Tilted Down Courtesy of VOLVO CARS CORPORATION Fig. 19: Identifying Control Module Relay Box Pulled Forward And Down...
Page 682 2012 Volvo C30 T-5 ELECTRICAL Cables And Fuses - Removal, Replacement And Installation Fig. 20: Identifying Control Module Relays And Cables Courtesy of VOLVO CARS CORPORATION NOTE: Make sure that the component terminals are not bent or damaged. Fig. 21: Identifying Removal Of Control Module Relay Box...
Page 683: Tool Boards
2012 Volvo C30 T-5 ELECTRICAL Cables And Fuses - Removal, Replacement And Installation T9512636 TERMINAL REMOVAL TOOL (COLOR CODE: BLUE) Tool number: T9512636 Tool description: TERMINAL REMOVAL TOOL (COLOR CODE: BLUE) Tool boards: T9512852 TERMINAL REMOVAL TOOL Tool number: T9512852...
Page 684 ELECTRICAL Cables And Fuses - Removal, Replacement And Installation Fig. 22: Identifying Direction To Remove Central Electrical Unit Cover Courtesy of VOLVO CARS CORPORATION Fig. 23: Identifying Battery Lead To Battery Lead Terminal, 14 Nm Courtesy of VOLVO CARS CORPORATION...
Page 685 ELECTRICAL Cables And Fuses - Removal, Replacement And Installation Fig. 24: Identifying Relay/Fuse Holder's Screw(s) Courtesy of VOLVO CARS CORPORATION Remove the relay/fuse holder's screws, 2 pcs. Lift the relay/fuse holder straight up at the trailing edge. Remove the lower casing.
Page 686 ELECTRICAL Cables And Fuses - Removal, Replacement And Installation Fig. 26: Identifying Removal Of Front Secondary Catch With Terminal Removal Tool 9512636 Courtesy of VOLVO CARS CORPORATION Remove the thin cable. see 9512636 Fig. 27: Identifying Terminal Removal Tool 9512852 For Removal Of Front Secondary Catch Courtesy of VOLVO CARS CORPORATION Alternatively.
Page 687 RADIATOR (B5244S4; 2007-10) REMOVAL REMOVING THE ENGINE COOLING FAN (FC) Remove the cooling fan. See ENGINE COOLING FAN (FC) Fig. 1: Re-installing Radiator Bracket with Fan Removed Courtesy of VOLVO CARS CORPORATION Install the following items: bracket  screws, lightly, 4 pcs.
Page 688 2012 Volvo C30 T-5 ENGINE Cooling System - Removal, Replacement And Installation Fig. 2: Identifying Panel And Screws Courtesy of VOLVO CARS CORPORATION Remove the following items: screw  engine compartment panel.  Fig. 3: Locating Mounting Screws Courtesy of VOLVO CARS CORPORATION...
Page 689 ENGINE Cooling System - Removal, Replacement And Installation Fig. 4: Supporting Condenser Assembly Courtesy of VOLVO CARS CORPORATION Slightly raise the condenser and suspend from a suitable place, so that the condenser is not put under any strain. Fig. 5: Locating Mounting Screws...
Page 690 2012 Volvo C30 T-5 ENGINE Cooling System - Removal, Replacement And Installation Fig. 6: Re-installing Radiator Bracket with Fan Removed Courtesy of VOLVO CARS CORPORATION Install the following items: the radiator  Bracket  screws, 4 pcs, lightly.  Fig. 7: Locating Mounting Screws Courtesy of VOLVO CARS CORPORATION Install the screws for the upper radiator mounting, 2 pcs on both sides.
Page 691 2012 Volvo C30 T-5 ENGINE Cooling System - Removal, Replacement And Installation Fig. 8: Identifying Panel And Screws Courtesy of VOLVO CARS CORPORATION Install the following items: engine compartment panel.  screws, M6.  Fig. 9: Identifying Mobile Jack Courtesy of VOLVO CARS CORPORATION...
Page 692 2012 Volvo C30 T-5 ENGINE Cooling System - Removal, Replacement And Installation Fig. 10: Identifying Radiator Bracket Courtesy of VOLVO CARS CORPORATION Remove the bracket. Install the engine cooling fan. See ENGINE COOLING FAN (FC) RADIATOR (B5254T3; 2007-08, B5254T7; 2008-12)
Page 693 2012 Volvo C30 T-5 ENGINE Cooling System - Removal, Replacement And Installation Courtesy of VOLVO CARS CORPORATION Install: the bracket  the 4 x screws, lightly.  Remove the charge air cooler (CAC). See CHARGE AIR COOLER (B5244S4; 2007-09, B5254T3; 2007, B5254T7;...
Page 694 2012 Volvo C30 T-5 ENGINE Cooling System - Removal, Replacement And Installation Fig. 13: Locating Mounting Screws Courtesy of VOLVO CARS CORPORATION Remove the following on both sides: the screw  the radiator mounting.  SUSPENDING THE CONDENSER Fig. 14: Supporting Condenser Assembly Courtesy of VOLVO CARS CORPORATION Slightly raise the condenser and suspend from a suitable place, so that the condenser is not put under any strain.
Page 695 2012 Volvo C30 T-5 ENGINE Cooling System - Removal, Replacement And Installation Fig. 15: Locating Mounting Screws Courtesy of VOLVO CARS CORPORATION Remove: the screws for the upper radiator mounting, 2 on both sides.  the bracket under the air conditioning aggregate ...
Page 696  the 4x screws, lightly.  Fig. 17: Locating Mounting Screws Courtesy of VOLVO CARS CORPORATION the screws for the upper radiator mounting, 2 on both sides.  Fig. 18: Identifying Panel And Screws Courtesy of VOLVO CARS CORPORATION the engine compartment panel ...
Page 697 ENGINE Cooling System - Removal, Replacement And Installation INSTALLING ENGINE COOLANT FAN (FC) Fig. 19: Identifying Mobile Jack Courtesy of VOLVO CARS CORPORATION Install a mobile jack under the radiator. Fig. 20: Identifying Radiator Bracket Courtesy of VOLVO CARS CORPORATION Remove the bracket.
Page 698 Perform cooling system draining, charging and bleeding. See COOLING SYSTEM - DRAINING, CHARGING AND BLEEDING Remove timing belt. See TIMING BELT Fig. 21: Identifying Water Pump and Bolts Courtesy of VOLVO CARS CORPORATION WARNING: Be prepared to collect escaping fluid. Torque: M7...
Page 699 2012 Volvo C30 T-5 ENGINE Cooling System - Removal, Replacement And Installation Remove the air filter housing. See AIR CLEANER HOUSING Fig. 22: Identifying Water Outlet Courtesy of VOLVO CARS CORPORATION WARNING: Be prepared to collect escaping fluid. Torque: M6 10 Nm Fig.
Page 700 Drain cooling system, draining, filling, and bleeding, see COOLING SYSTEM - DRAINING, CHARGING AND BLEEDING Remove the air filter housing. See AIR CLEANER HOUSING Fig. 24: Identifying Water Outlet Courtesy of VOLVO CARS CORPORATION WARNING: Be prepared to collect escaping fluid. Torque: M6...
Page 701 2012 Volvo C30 T-5 ENGINE Cooling System - Removal, Replacement And Installation Fig. 25: Identifying Thermostat Courtesy of VOLVO CARS CORPORATION INSTALLATION To install, reverse the removal procedure. COOLING FAN ENGINE COOLING FAN (FC) (B5244S4; 2007-10, B5254T3; 2007-08, B5254T7; 2008-11 EARLY)
Page 702 2012 Volvo C30 T-5 ENGINE Cooling System - Removal, Replacement And Installation Fig. 26: Identifying Cover Courtesy of VOLVO CARS CORPORATION Remove: the cover for the brake control module (BCM)  Fig. 27: Identifying Expansion Tank Cap Courtesy of VOLVO CARS CORPORATION the expansion tank cap ...
Page 703 2012 Volvo C30 T-5 ENGINE Cooling System - Removal, Replacement And Installation Fig. 28: Identifying Connector And Clips Courtesy of VOLVO CARS CORPORATION the connector for the engine cooling fan (FC)  the hoses from the clips, x 2. ...
Page 704 2012 Volvo C30 T-5 ENGINE Cooling System - Removal, Replacement And Installation Fig. 30: Identifying Splash Panel Courtesy of VOLVO CARS CORPORATION Remove: the 7x screws  the splash guard under the engine.  Fig. 31: Identifying Mobile Jack Courtesy of VOLVO CARS CORPORATION Install a mobile jack under the radiator.
Page 705 2012 Volvo C30 T-5 ENGINE Cooling System - Removal, Replacement And Installation Fig. 32: Identifying Radiator Bracket Courtesy of VOLVO CARS CORPORATION Remove: the 4 screws  the bracket for the air conditioning aggregate.  Fig. 33: Locating Coolant Hoses Courtesy of VOLVO CARS CORPORATION Remove the 2x coolant hoses.
Page 706 2012 Volvo C30 T-5 ENGINE Cooling System - Removal, Replacement And Installation Fig. 34: Identifying Clips and Catches Courtesy of VOLVO CARS CORPORATION NOTE: When removing the engine cooling fan (FC), ensure that no cables are damaged. Press in both clips on the upper section and lift the engine cooling fan (FC) from the catches.
Page 707 2012 Volvo C30 T-5 ENGINE Cooling System - Removal, Replacement And Installation Fig. 35: Identifying Premair Sensor Courtesy of VOLVO CARS CORPORATION Only applies to vehicles with premair sensors Install the connector to the premair sensor Only applies to vehicles with automatic transmissions...
Page 708 Remove the bumper cover. See COVER BUMPER FRONT (2011 LATE - 2012) or COVER BUMPER FRONT (2010-11) Drain coolant. See COOLING SYSTEM - DRAINING, CHARGING AND BLEEDING REMOVING COMPONENTS Fig. 36: Identifying Cover Courtesy of VOLVO CARS CORPORATION Remove: the cover for the brake control module (BCM)  Fig. 37: Identifying Expansion Tank Cap...
Page 709 ENGINE Cooling System - Removal, Replacement And Installation the expansion tank cap  Fig. 38: Identifying Connector And Clips Courtesy of VOLVO CARS CORPORATION the connector for the engine cooling fan (FC)  the hoses from the clips, x 2.
Page 710 2012 Volvo C30 T-5 ENGINE Cooling System - Removal, Replacement And Installation Fig. 40: Identifying Splash Panel Courtesy of VOLVO CARS CORPORATION Remove: the 7x screws  the splash guard under the engine.  Fig. 41: Identifying Mobile Jack Courtesy of VOLVO CARS CORPORATION Install a mobile jack under the radiator.
Page 711 2012 Volvo C30 T-5 ENGINE Cooling System - Removal, Replacement And Installation Fig. 42: Identifying Radiator Bracket Courtesy of VOLVO CARS CORPORATION Remove: the 4 screws  the bracket for the air conditioning aggregate.  Fig. 43: Locating Coolant Hoses Courtesy of VOLVO CARS CORPORATION Remove the 2x coolant hoses.
Page 712 2012 Volvo C30 T-5 ENGINE Cooling System - Removal, Replacement And Installation Fig. 44: Identifying Clips and Catches Courtesy of VOLVO CARS CORPORATION NOTE: When removing the engine cooling fan (FC), ensure that no cables are damaged. Press in both clips on the upper section and lift the engine cooling fan (FC) from the catches.
Page 713 2012 Volvo C30 T-5 ENGINE Cooling System - Removal, Replacement And Installation Fig. 45: Identifying Premair Sensor Courtesy of VOLVO CARS CORPORATION Only applies to vehicles with premair sensors Install the connector to the premair sensor Only applies to vehicles with automatic transmissions...
Page 714 PREPARATORY WORK Remove the bumper cover. See COVER BUMPER FRONT (2010-11 EARLY) . REMOVAL REMOVING THE CHARGE AIR COOLER (CAC) Fig. 46: Identifying Screw Locations Courtesy of VOLVO CARS CORPORATION Remove: the switch  the hoses ...
Page 715 2012 Volvo C30 T-5 ENGINE Cooling System - Removal, Replacement And Installation Fold the air baffle up. Remove the charge air cooler (CAC). INSTALLATION INSTALLING THE CHARGE AIR COOLER (CAC) NOTE: For tightening torques, see TIGHTENING TORQUE . Fold the air baffle up.
Page 716 2012 Volvo C30 T-5 ENGINE Cooling System - Removal, Replacement And Installation Fig. 47: Locating Screws Courtesy of VOLVO CARS CORPORATION Remove the screws on both sides. REMOVING THE CHARGE AIR COOLER (CAC)
Page 717 2012 Volvo C30 T-5 ENGINE Cooling System - Removal, Replacement And Installation Fig. 48: Identifying Fasteners Courtesy of VOLVO CARS CORPORATION Remove: the hoses (1)  the 2 screws (2).  Lift the charge air cooler (CAC). Remove the charge air cooler (CAC).
Page 718 ENGINE Cooling System - Removal, Replacement And Installation INSTALLING THE UPPER SCREWS FOR THE LOWER AIR BAFFLE Fig. 49: Locating Screws Courtesy of VOLVO CARS CORPORATION Install the M5 screws on both sides. FINISHING The bumper shell. See COVER BUMPER FRONT .
Page 719 DATA LINK CONNECTOR (OBD-II) Special tools 951 2636 Terminal removal tool (Color code: Blue) Tool number: 951 2636 Tool description: Terminal removal tool (Color code: Blue) Tool boards: 39 REMOVAL Fig. 1: Locating Data Link Connector (OBD-II) Courtesy of VOLVO CARS CORPORATION...
Page 720 2012 Volvo C30 T-5 ELECTRICAL Body Electrical Fig. 2: Identifying Screws Courtesy of VOLVO CARS CORPORATION Fig. 3: Identifying Data Link Connector (OBD-II) Release Tab Courtesy of VOLVO CARS CORPORATION Fig. 4: Removing Data Link Connector...
Page 721 2012 Volvo C30 T-5 ELECTRICAL Body Electrical Fig. 5: Releasing Tab with Tool 9512636 Courtesy of VOLVO CARS CORPORATION NOTE: Make sure that the component terminals are not bent or damaged. see 9512636 NOTE: Only work on 1 cable at a time.
Page 722 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation FUEL TANK FILLER DOOR DOOR LATCH, FUEL FILLER DOOR REMOVAL AND INSTALLATION Fig. 1: Door Latch Fuel Filler Door Remove/Install Components (1 Of 3) Courtesy of VOLVO CARS CORPORATION...
Page 723 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Fig. 2: Door Latch Fuel Filler Door Remove/Install Components (2 Of 3) Courtesy of VOLVO CARS CORPORATION Fig. 3: Door Latch Fuel Filler Door Remove/Install Components (3 Of 3)
Page 724 REMOVAL REMOVING THE FUEL TANK FILLER COVER Open the fuel tank filler cover. Fig. 4: Removing Fuel Filler Door Courtesy of VOLVO CARS CORPORATION Remove: the 2 screws  the holder for the fuel tank filler cap (1).
Page 725 Remove the Front Door Interior Handle Cable, see FRONT DOOR INTERIOR HANDLE CABLE Fig. 5: Removing Front Door Latch (1 Of 4) Courtesy of VOLVO CARS CORPORATION Fig. 6: Removing Front Door Latch (2 Of 4) Courtesy of VOLVO CARS CORPORATION...
Page 726 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Fig. 7: Removing Front Door Latch (3 Of 4) Courtesy of VOLVO CARS CORPORATION Fig. 8: Removing Front Door Latch (4 Of 4) Courtesy of VOLVO CARS CORPORATION...
Page 727 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Remove glove compartment, see GLOVE COMPARTMENT Fig. 9: Removing Pins Courtesy of VOLVO CARS CORPORATION Fig. 10: Identifying Handle Courtesy of VOLVO CARS CORPORATION...
Page 728 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Fig. 11: Identifying Mounting Points Courtesy of VOLVO CARS CORPORATION FRONT DOOR INTERIOR HANDLE CABLE REMOVAL NOTE: Removal steps in this procedure may contain installation details.
Page 729 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Fig. 12: Removing Front Door Interior Handle Cable (1 Of 7) Courtesy of VOLVO CARS CORPORATION Fig. 13: Removing Front Door Interior Handle Cable (2 Of 7) Courtesy of VOLVO CARS CORPORATION Fig.
Page 730 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Fig. 15: Removing Front Door Interior Handle Cable (4 Of 7) Courtesy of VOLVO CARS CORPORATION Fig. 16: Removing Front Door Interior Handle Cable (5 Of 7) Courtesy of VOLVO CARS CORPORATION...
Page 731 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Fig. 18: Removing Front Door Interior Handle Cable (7 Of 7) Courtesy of VOLVO CARS CORPORATION INSTALLATION To install, reverse the removal procedure. FRONT DOOR OUTER HANDLE NOTE: Removal steps in this procedure may contain installation details.
Page 732 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Fig. 20: Removing Front Door Outer Handle (2 Of 3) Courtesy of VOLVO CARS CORPORATION NOTE: Slacken off the screw by 4 turns only.
Page 733 To install, reverse the removal procedure LOCK CYLINDER, DOOR REMOVAL AND INSTALLATION Fig. 22: View Of Removing Door Lock Cylinder Courtesy of VOLVO CARS CORPORATION NOTE: Do not loosen the bolt more than 4 turns. Fig. 23: Identifying Door Lock Cylinder...
Page 734 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Remove the liftgate trim panel, see TAILGATE/TRUNK LID PANEL Fig. 24: Removing Outer Tailgate/Trunk Lid Handle (1 Of 2) Courtesy of VOLVO CARS CORPORATION Torque: Exterior handle to tailgate/luggage compartment lid 3 Nm Fig.
Page 735 NOTE: Removal steps in this procedure may contain installation details. Fig. 26: Removing Trunk Lid/Tailgate Lock Mechanism (1 Of 2) Courtesy of VOLVO CARS CORPORATION Fig. 27: Removing Trunk Lid/Tailgate Lock Mechanism (2 Of 2) Courtesy of VOLVO CARS CORPORATION NOTE: Note the position of the component before removal.
Page 736 REMOVAL REMOVING THE APRON MOLDING FOR THE SUN ROOF Fig. 28: Identifying Apron Molding Pulled Into Car Courtesy of VOLVO CARS CORPORATION The sun roof must be in the half open position. Pull the apron molding backwards. Release the top edge and unhook the bottom edge of the apron molding.
Page 737 PREPARATORY WORK REMOVING THE SUNROOF GLASS Remove the sunroof glass. See: GLASS SUN ROOF. REMOVAL REMOVING THE GUTTER Fig. 29: Pressing Out The Front Mounting Courtesy of VOLVO CARS CORPORATION Press out the front mounting for the gutter on both sides.
Page 738 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Fig. 30: Pressing Out Gutter Courtesy of VOLVO CARS CORPORATION Carefully press out the center of the gutter and then press the corner outwards to release the gutter clips from the sunroof frame.
Page 739 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Fig. 32: Ensuring Clips Are In Correct Position Courtesy of VOLVO CARS CORPORATION First align one corner with the gutter and then the other. CAUTION: Ensure that the clips are in the correct position.
Page 740 REMOVAL REMOVING THE SUN ROOF GLASS Fig. 34: Identifying 4 Screws For The Glass Cover Courtesy of VOLVO CARS CORPORATION Close the sun roof. Slide the inner cover back as far as possible. Remove: the inner cover. See: APRON MOLDING SUNROOF ...
Page 741 Remove the weatherstrip from the sun roof. It is not bonded. INSTALLING WEATHERSTRIP SUN ROOF Fig. 35: Identifying Weatherstripping Courtesy of VOLVO CARS CORPORATION Press the weatherstrip into place in the T-groove. NOTE: The join for the weatherstrip must be in the middle of the rear edge of the sunroof (1).
Page 742 Some variation may occur. However, the essential information in the illustrations is always correct. PREPARATORY WORK IGNITION OFF Fig. 36: Disconnecting Battery Lead Courtesy of VOLVO CARS CORPORATION Ignition off. Remove the key from the ignition switch. Wait 1 minute before starting work. REMOVAL...
Page 743 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Fig. 37: Locating Connector Courtesy of VOLVO CARS CORPORATION Remove the headlining as described in, see HEADLINING WITH SUN ROOF . Remove: the 4 drain hoses ...
Page 744 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Fig. 38: Identifying 10 Screws For The Sun Roof Frame Courtesy of VOLVO CARS CORPORATION the 10 screws for the sun roof frame. ...
Page 745 2 people are required for this task. Fig. 39: Identifying Screw Locations Courtesy of VOLVO CARS CORPORATION HINT: Position the screws, spacers and nylon washers on the frame before installing the sun roof. Install the 10 M6 screws as follows: 1.
Page 746 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Guide in the sun roof in relation to the guide holes. Tighten the screws in numerical order as illustrated. Tighten. See: TIGHTENING TORQUE .
Page 747 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation REMOVING THE SUN VISOR / INNER COVER SUN ROOF Fig. 40: Identifying Screws And Mounting Courtesy of VOLVO CARS CORPORATION Remove the lens. See: GLASS SUN ROOF. Pull the sun visor / inner cover forwards.
Page 748 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation INSTALLING THE SUN VISOR / INNER COVER SUN ROOF Install: the 2 rear slides  the 2 screws at the rear mounting. Tighten. ...
Page 749 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Fig. 41: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Ignition off. REMOVAL REMOVING ELECTRIC MOTOR / SUN ROOF MODULE (SRM) Move the sun visors to one side.
Page 750 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Fig. 42: Locating Connector Courtesy of VOLVO CARS CORPORATION the connector.  Slacken off the 3 screws for the interior lighting frame.
Page 751 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Fig. 43: Locating Electric Motor / Control Module Screws Courtesy of VOLVO CARS CORPORATION Remove the 3 screws. Carefully lower the electric motor / control module.
Page 752 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Fold back the sun visors. FINISHING CALIBRATION OF NEW ELECTRIC MOTOR / SUN ROOF MODULE (SRM) When installing a new electric motor / control module, perform new calibration. See: NEW CALIBRATION OF ELECTRIC MOTOR / SUN ROOF MODULE (SRM) .
Page 753 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Fig. 44: Removing Wind Deflector Courtesy of VOLVO CARS CORPORATION Open the sun roof completely. Press the end of the wind deflector (1) using a screwdriver.
Page 754 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Fig. 45: Identifying Door Half Hinge Courtesy of VOLVO CARS CORPORATION Torque: M8 24 Nm DOOR PANEL Materials: Designation Part number Bodywork adhesive 1161524...
Page 755 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Fig. 46: Bodywork adhesive, 1161524 Courtesy of VOLVO CARS CORPORATION Attach the following items: 1. Use: Bodywork adhesive, 1161524 2. Use: PUR adhesive, 1161821 Fig.
Page 756 Remove door panel. See PANEL FRONT DOOR . Fig. 48: Removing Door Stop From Front Side Door (1 Of 2) Courtesy of VOLVO CARS CORPORATION Fig. 49: Removing Door Stop From Front Side Door (2 Of 2) Courtesy of VOLVO CARS CORPORATION Remove the following items: 1.
Page 757 See REAR VIEW MIRROR EXTERNAL  door stop side door. See DOOR STOP FRONT SIDE DOOR  Fig. 50: Removing Side Door (1 Of 4) Courtesy of VOLVO CARS CORPORATION Fig. 51: Removing Side Door (2 Of 4) Courtesy of VOLVO CARS CORPORATION...
Page 758 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Fig. 52: Removing Side Door (3 Of 4) Courtesy of VOLVO CARS CORPORATION Fig. 53: Removing Side Door (4 Of 4) Courtesy of VOLVO CARS CORPORATION Install in reverse order.
Page 759  panel C/D-pillar. See C/D-PILLAR TRIM PANEL  Fig. 54: Removing Tailgate And Trunk Lid Hinges (1 Of 2) Courtesy of VOLVO CARS CORPORATION Torque: M8 24 Nm Fig. 55: Removing Tailgate And Trunk Lid Hinges (2 Of 2) Courtesy of VOLVO CARS CORPORATION...
Page 760 C/D-pillar. See C/D-PILLAR TRIM PANEL  spoiler rear. See SPOILER REAR  spoiler rear (T5). See SPOILER REAR  Fig. 56: Removing Tailgate (1 Of 5) Courtesy of VOLVO CARS CORPORATION Torque: M8 24 Nm Fig. 57: Removing Tailgate (2 Of 5)
Page 761 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Courtesy of VOLVO CARS CORPORATION Fig. 58: Removing Tailgate (3 Of 5) Courtesy of VOLVO CARS CORPORATION Fig. 59: Removing Tailgate (4 Of 5)
Page 762 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Fig. 60: Removing Tailgate (5 Of 5) Courtesy of VOLVO CARS CORPORATION Torque: M6 10 Nm Install in reverse order. Adjust tailgate. See DOORS AND HATCHES.
Page 763 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Fig. 61: Identifying Level Adjustment Courtesy of VOLVO CARS CORPORATION The front part must be positioned above the part behind it (see illustration), partly to overlap in case of a collision, partly to reduce wind noise.
Page 764 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Fig. 62: Identifying Hood Measurements Courtesy of VOLVO CARS CORPORATION F1 = 3.0 mm F2 = 3.0 mm F3 = 3.0 mm F4 = 3.0 mm F5 = 1.0 mm...
Page 765 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Fig. 63: Identifying Door Measurements Courtesy of VOLVO CARS CORPORATION S1 = 3.1 mm S2 = 4.0 mm S3 = 3.3 mm S4 = 5.0 mm S5 = 2.5 mm...
Page 766 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Fig. 64: Identifying Door Measurements Courtesy of VOLVO CARS CORPORATION Measurements apply without rubber strip on the door arch. S8 = 8.0 mm S9 = 9.0 mm S10 = 9.3 mm...
Page 767 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Fig. 65: Identifying Trunk Lid Measurements Courtesy of VOLVO CARS CORPORATION R1 = 4.5 mm R2 = 6.1 mm R3 = 0.7 mm R4 = 4.0 mm R5 = 4.0 mm...
Page 768 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Fig. 66: Identifying Trunk Lid Measurements Courtesy of VOLVO CARS CORPORATION S40 (04-) R7 = 3.3 mm R8 = 3.1 mm R9 = 0.8 mm R10 = 1.3 mm...
Page 769 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Fig. 67: Removing Front Door Window Lift Mechanism Electric Motor (1 Of 2) Courtesy of VOLVO CARS CORPORATION Remove panel side door front, see PANEL FRONT DOOR Fig. 68: Removing Front Door Window Lift Mechanism Electric Motor (2 Of 2)
Page 770 Handle outer door front, see HANDLE OUTER DOOR FRONT  Fig. 69: Removing Front Door Window Lift Mechanism (1 Of 9) Courtesy of VOLVO CARS CORPORATION Fig. 70: Removing Front Door Window Lift Mechanism (2 Of 9) Courtesy of VOLVO CARS CORPORATION...
Page 771 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Fig. 71: Removing Front Door Window Lift Mechanism (3 Of 9) Courtesy of VOLVO CARS CORPORATION Torque: M6 10 Nm Fig. 72: Removing Front Door Window Lift Mechanism (4 Of 9)
Page 772 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Fig. 73: Removing Front Door Window Lift Mechanism (5 Of 9) Courtesy of VOLVO CARS CORPORATION Fig. 74: Removing Front Door Window Lift Mechanism (6 Of 9) Courtesy of VOLVO CARS CORPORATION...
Page 773 ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation Torque: M6 10 Nm Fig. 76: Removing Front Door Window Lift Mechanism (8 Of 9) Courtesy of VOLVO CARS CORPORATION Fig. 77: Removing Front Door Window Lift Mechanism (9 Of 9) Courtesy of VOLVO CARS CORPORATION INSTALLATION To install, reverse the removal procedure.
Page 774 Removal steps in this procedure may contain installation details. Remove the air filter housing, see AIR CLEANER HOUSING Fig. 1: Removing Back-Up Lamp Switch (1 Of 2) Courtesy of VOLVO CARS CORPORATION Fig. 2: Removing Back-Up Lamp Switch (2 Of 2) Courtesy of VOLVO CARS CORPORATION...
Page 775 REMOVING THE BACK-UP LAMP SWITCH, GEARBOX M56 Ignition off Remove the air cleaner (ACL) housing. Fig. 3: Identifying Tool P/N 9997077 Courtesy of VOLVO CARS CORPORATION Remove the following items: the gear selector cables from the levers. see 9997077 ...
Page 776 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 4: Identifying Tool P/N 9997221 Courtesy of VOLVO CARS CORPORATION Remove the following items: pin. see 9997221 .  the lever  Fig. 5: Identifying Back-Up Lamp Switch Connector...
Page 777 For tightening torques, see TIGHTENING TORQUE . INSTALLING BACK-UP (REVERSING) LAMP SWITCH Fig. 6: Identifying Back-Up Lamp Switch Connector Courtesy of VOLVO CARS CORPORATION Install the new back-up light switch. see 9995543 Tighten to: 24 Nm. INSTALLING THE CONNECTOR Fig. 7: View Of Secondary Lock Courtesy of VOLVO CARS CORPORATION Pull out the secondary lock.
Page 778 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 8: Back-Up Lamp Switch Leads Courtesy of VOLVO CARS CORPORATION Install the cables in the connector with the opening for the primary lock facing up as shown in the illustration.
Page 779 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 10: Identifying Tool P/N 9997221 Courtesy of VOLVO CARS CORPORATION Install the following items: transmission lever see 9997221 to press in the pin ...
Page 780 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 11: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Fig. 12: Identifying Control Stalk, Left Screws Courtesy of VOLVO CARS CORPORATION INSTALLATION To install, reverse the removal procedure.
Page 781 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 14: Identifying Control Stalk, Right Screws Courtesy of VOLVO CARS CORPORATION INSTALLATION To install, reverse the removal procedure. DATA LINK CONNECTOR (OBD-II) REMOVAL AND INSTALLATION Fig.
Page 782 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 16: View Of Data Link Connector (OBD-II) location Courtesy of VOLVO CARS CORPORATION Fig. 17: Identifying Data Link Connector (OBD-II) Release Tab Courtesy of VOLVO CARS CORPORATION...
Page 783 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Courtesy of VOLVO CARS CORPORATION Fig. 19: Inserting Terminal Removal Tool Courtesy of VOLVO CARS CORPORATION NOTE: Only work on 1 cable at a time.
Page 784 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 20: Pressing Tab And Removing Wire Courtesy of VOLVO CARS CORPORATION DRIVER DOOR MODULE (DDM) REMOVAL NOTE: Removal steps in this procedure may contain installation details.
Page 785 The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct. PREPARATORY WORK IGNITION OFF Fig. 23: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION...
Page 786 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Ignition off. REMOVAL REMOVING THE CIGARETTE LIGHTER/ELECTRICAL SOCKET Fig. 24: View Of Ashtray Panel Courtesy of VOLVO CARS CORPORATION Remove the rear panel. Disconnect the connector from the ashtray panel.
Page 787 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 25: Identifying Cigarette Lighter/Electrical Socket Catches Courtesy of VOLVO CARS CORPORATION Lift up the catches (as shown in the illustration) using a small screwdriver. Press out the cigarette lighter/electrical socket.
Page 788 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 26: Extra Power Socket Remove/Install Components (1 of 2) Courtesy of VOLVO CARS CORPORATION Fig. 27: Extra Power Socket Remove/Install Components (2 of 2) Courtesy of VOLVO CARS CORPORATION...
Page 789 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 28: Extra Power Socket Remove/Install Components (1 of 2) Courtesy of VOLVO CARS CORPORATION Fig. 29: Extra Power Socket Remove/Install Components (2 of 2) Courtesy of VOLVO CARS CORPORATION...
Page 790 Courtesy of VOLVO CARS CORPORATION Torque: M6 10 Nm INSTALLATION To install, reverse the removal procedure. Calibrate position sensor using VIDA (Volvo scan tool). FRONT POSITION SENSOR, HEADLAMP (2010 - 2011 EARLY) REMOVAL NOTE: Removal steps in this procedure may contain installation details.
Page 791 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 32: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Follow instructions for lifting points body frame, see JACKING POINTS BODY . Fig. 33: Identifying Front Position Sensor, Headlamp Screws...
Page 792 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation To install, reverse the removal procedure. FINISHING Calibrate position sensor using VIDA (Volvo scan tool). FRONT POSITION SENSOR, HEADLAMP (2011 LATE - 2012) REMOVAL NOTE: Removal steps in this procedure may contain installation details.
Page 793 Courtesy of VOLVO CARS CORPORATION Torque: M6 10 Nm INSTALLATION To install, reverse the removal procedure. Calibrate position sensor using VIDA (Volvo scan tool). INSTRUMENT PANEL CONSOLE SWITCH KNOB Special tools 981 4071 STRAIGHTENING TOOL Tool number: 981 4071 Tool description: STRAIGHTENING TOOL...
Page 794: Courtesy Of Volvo Cars Corporation
2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation REMOVAL Fig. 36: Removing Instrument Panel Console Switch Knob Courtesy of VOLVO CARS CORPORATION see 9814071...
Page 795 KEYPAD, STEERING WHEEL REMOVAL Remove airbag driver's side, see DRIVER'S AIRBAG Fig. 37: Identifying Steering Wheel Keypad Courtesy of VOLVO CARS CORPORATION Fig. 38: View Of Steering Wheel Keypad Connectors Courtesy of VOLVO CARS CORPORATION INSTALLATION To install, reverse the removal procedure.
Page 796 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation LIGHTING SWITCH REMOVAL Fig. 39: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Fig. 40: Identifying Lighting Switch in OFF Position Courtesy of VOLVO CARS CORPORATION...
Page 797 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 41: View Of Lighting Switch Components Courtesy of VOLVO CARS CORPORATION Fig. 42: Identifying Lighting Switch Screws Courtesy of VOLVO CARS CORPORATION INSTALLATION To install, reverse the removal procedure.
Page 798: Torque: M6
ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 43: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Remove panel side door front, see PANEL FRONT DOOR . Fig. 44: Identifying Driver Door Module (DDM) Screws...
Page 799 Removal steps in this procedure may contain installation details. Fig. 45: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Follow instructions for lifting points body frame, see JACKING POINTS BODY . Fig. 46: Identifying Position Sensor Rear, Headlamp Screws...
Page 800: Calibrate Position Sensor Using Vida (Volvo Scan Tool)
2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation INSTALLATION To install, reverse the removal procedure. Calibrate position sensor using VIDA (Volvo scan tool). POSITION SENSOR REAR, HEADLAMP (2010 - 2011 EARLY) REMOVAL NOTE: Removal steps in this procedure may contain installation details.
Page 801 Torque: M6 10 Nm INSTALLATION To install, reverse the removal procedure. FINISHING Calibrate position sensor using VIDA (Volvo scan tool). POSITION SENSOR REAR, HEADLAMP (2011 LATE - 2012) REMOVAL NOTE: Removal steps in this procedure may contain installation details. Fig. 49: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Follow instructions for lifting points body frame, see JACKING POINTS BODY .
Page 802 Courtesy of VOLVO CARS CORPORATION Torque: M6 10 Nm INSTALLATION To install, reverse the removal procedure. Calibrate position sensor using VIDA (Volvo scan tool). POWER SOCKET 12V (2007) REMOVAL Fig. 51: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION...
Page 803 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 52: Identifying Power Socket Panel Courtesy of VOLVO CARS CORPORATION Fig. 53: View Of Power Socket Clip Courtesy of VOLVO CARS CORPORATION INSTALLATION To install, reverse the removal procedure.
Page 804 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 54: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Fig. 55: Window Regulator Rotary Switch, Rear Door Remove/Install Components (1 Of 3) Courtesy of VOLVO CARS CORPORATION...
Page 805 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 56: Window Regulator Rotary Switch, Rear Door Remove/Install Components (2 of 3) Courtesy of VOLVO CARS CORPORATION Fig. 57: Window Regulator Rotary Switch, Rear Door Remove/Install Components (3 of 3)
Page 806 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 59: Removing Door Handle Panel Courtesy of VOLVO CARS CORPORATION Fig. 60: Identifying Door Handle Panel Clips Courtesy of VOLVO CARS CORPORATION...
Page 807 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 61: Identifying Window Regulator Rotary Switch Courtesy of VOLVO CARS CORPORATION INSTALLATION To install, reverse the removal procedure. ROTARY SWITCH, FRONT DOOR WINDOW REGULATOR (2011 LATE - 2012) REMOVAL Fig.
Page 808 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 63: Removing Door Handle Panel Courtesy of VOLVO CARS CORPORATION Fig. 64: Prying Up Front Side Switch Panel Frame Courtesy of VOLVO CARS CORPORATION...
Page 809 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 65: Prying Up Rear Side Switch Panel Frame Courtesy of VOLVO CARS CORPORATION Fig. 66: Identifying Window Regulator Rotary Switch Courtesy of VOLVO CARS CORPORATION...
Page 810 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 67: Identifying Window Regulator Rotary Switch Screws Courtesy of VOLVO CARS CORPORATION INSTALLATION Fig. 68: Installing Front Door Switch Panel (1 of 2)
Page 811 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation CAUTION: Only use moderate force. Fig. 69: Installing Front Door Switch Panel (2 of 2) Courtesy of VOLVO CARS CORPORATION CAUTION: Make sure that equal pressure is applied to the full length of the component.
Page 812 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 70: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Remove lighting interior front, see LIGHTING, INTERNAL FRONT Fig. 71: View Of Sun Roof Rotary Switch Release Clips...
Page 813 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation IGNITION OFF Fig. 72: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Ignition off. REMOVAL REMOVING THE INTERIOR LIGHTING Remove the interior lighting. See: LIGHTING, INTERNAL FRONT .
Page 814 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 73: Sun Roof Switch Catches Courtesy of VOLVO CARS CORPORATION Press the catches out. Pull the switch outwards and upwards. Pull out the catch. Pull out the conductive strap.
Page 815 Remove steering wheel lever left, see CONTROL STALK, LEFT Fig. 74: Identifying Steering Wheel Control Module Bolts Courtesy of VOLVO CARS CORPORATION CAUTION: Make sure that the clockspring pins are not bent or damaged. Torque: Steering wheel control module to steering column...
Page 816 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 75: Identifying Steering Wheel Control Module Connectors Courtesy of VOLVO CARS CORPORATION INSTALLATION Perform angle sensor, steering wheel, resetting To install, reverse the removal procedure.
Page 817 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 77: Remove/Install Central Locking System, Switch Components Courtesy of VOLVO CARS CORPORATION INSTALLATION To install, reverse the removal procedure. SWITCH, HAZARD WARNING FLASHERS...
Page 818 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation SWITCH TUNNEL COMPARTMENT REMOVAL Remove floor console, see FLOOR CONSOLE Fig. 79: Identifying Tunnel Compartment Switches Courtesy of VOLVO CARS CORPORATION Fig. 80: View Of Tunnel Compartment Switch Tabs Courtesy of VOLVO CARS CORPORATION...
Page 819 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 81: Removing Tunnel Compartment Switches Courtesy of VOLVO CARS CORPORATION Initiate switch using VIDA (Volvo scan tool). INSTALLATION To install, reverse the removal procedure. COLLISION AVOIDANCE...
Page 820 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 82: View Of Ignition In "0" Position Courtesy of VOLVO CARS CORPORATION Remove Rear Bumper Cover Upper Section, see REAR BUMPER COVER UPPER SECTION (2007 - 2011 EARLY Fig.
Page 821 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 84: Removing Rear Parking Assistance Distance Sensors (2 Of 2) Courtesy of VOLVO CARS CORPORATION INSTALLATION Fig. 85: Installing Rear Parking Assistance Distance Sensors (1 Of 2)
Page 822 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 86: Installing Rear Parking Assistance Distance Sensors (2 Of 2) Courtesy of VOLVO CARS CORPORATION To install, reverse the removal procedure. DISTANCE SENSORS, PARKING ASSISTANCE REAR (2011 LATE - 2012) REMOVAL Fig.
Page 823 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 88: Removing Rear Parking Assistance Distance Sensors (1 Of 2) Courtesy of VOLVO CARS CORPORATION Fig. 89: Removing Rear Parking Assistance Distance Sensors (2 Of 2) Courtesy of VOLVO CARS CORPORATION...
Page 824 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 90: Installing Rear Parking Assistance Distance Sensors (1 Of 2) Courtesy of VOLVO CARS CORPORATION Fig. 91: Installing Rear Parking Assistance Distance Sensors (2 Of 2) Courtesy of VOLVO CARS CORPORATION To install, reverse the removal procedure.
Page 825 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 92: Identifying Parking Assistance Module Courtesy of VOLVO CARS CORPORATION INSTALLATION To install, reverse the removal procedure. Order and download software according to: 30786805 DOOR LOCKS &...
Page 826 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 93: Identifying Ignition Switch In OFF Position Courtesy of VOLVO CARS CORPORATION Remove the tunnel console. See FLOOR CONSOLE Fig. 94: Locating Antenna Nuts...
Page 827 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 95: Locating Keyless Entry Locking System Antenna In Luggage Compartment Courtesy of VOLVO CARS CORPORATION ANTENNA, LOCKING SYSTEM, KEYLESS ENTRY, REAR (2007 - 2011 EARLY) Operation Number(s): 36646-2 NOTE: Removal steps in this procedure may contain installation details.
Page 828 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 97: Identifying Bumper Bracket Module Courtesy of VOLVO CARS CORPORATION Remove the following items: the antenna, fold out the catches at the lower edge ...
Page 829 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 99: Removing Keyless Entry Locking System Rear Antenna (1 Of 2) Courtesy of VOLVO CARS CORPORATION Fig. 100: Removing Keyless Entry Locking System Rear Antenna (2 Of 2)
Page 830 NOTE: Removal steps in this procedure may contain installation details. Fig. 101: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Remove the plenum cover, see PLENUM CHAMBER Fig. 102: Identifying Anti-Theft Protection Siren Bolts Courtesy of VOLVO CARS CORPORATION...
Page 831 NOTE: Removal steps in this procedure may contain installation details. Fig. 103: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Remove the plenum cover, see PLENUM CHAMBER Fig. 104: Locating Anti-Theft Protection Siren Courtesy of VOLVO CARS CORPORATION...
Page 832 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation 10 Nm Fig. 105: Removing Anti-Theft Protection Siren (1 of 2) Courtesy of VOLVO CARS CORPORATION Fig. 106: Removing Anti-Theft Protection Siren (2 of 2) Courtesy of VOLVO CARS CORPORATION INSTALLATION To install, reverse the removal procedure.
Page 833 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 107: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Fig. 108: Front Intrusion Sensor Cover Courtesy of VOLVO CARS CORPORATION...
Page 834 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 109: Front Intrusion Sensor Connector Courtesy of VOLVO CARS CORPORATION INSTALLATION To install, reverse the removal procedure. FRONT INTRUSION SENSOR (2012) REMOVAL...
Page 835 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 110: Front Intrusion Sensor Cover Courtesy of VOLVO CARS CORPORATION Fig. 111: Front Intrusion Sensor Connector Courtesy of VOLVO CARS CORPORATION INSTALLATION...
Page 836 To install, reverse the removal procedure. KEYLESS VEHICLE MODULE (KVM) PREPARATORY WORK IGNITION OFF Fig. 112: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Ignition off. REMOVING THE LEFT-HAND FRONT SEAT Remove the left-hand front seat. See: FRONT SEAT . REMOVAL...
Page 837 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 113: View Of Keyless Vehicle Module (KVM) Connectors Courtesy of VOLVO CARS CORPORATION Remove: the 5 connectors  the 2 x screws ...
Page 838 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation FINISHING INSTALLING THE LEFT-HAND FRONT SEAT Install the left-hand front seat. See: FRONT SEAT . ORDERING SOFTWARE Order software for the control module. See: 30772590...
Page 839 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Courtesy of VOLVO CARS CORPORATION Remove: the 2 x screws  the remote receiver module (RRX).  INSTALLATION INSTALLING RECEIVER LOCK SYSTEM Install: the remote receiver module (RRX) ...
Page 840 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 116: Removing Locking System Receiver Courtesy of VOLVO CARS CORPORATION CAUTION: Take extra care not to crease the headliner. INSTALLATION Fig. 117: Identifying Adhesive...
Page 841 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 118: Melting Adhesive, 1161656 Courtesy of VOLVO CARS CORPORATION Use: Melting adhesive, 1161656 Fig. 119: Installing Locking System Receiver Courtesy of VOLVO CARS CORPORATION To install, reverse the removal procedure.
Page 842 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 120: Locating Locking System Receiver Courtesy of VOLVO CARS CORPORATION Fig. 121: Removing Locking System Receiver Courtesy of VOLVO CARS CORPORATION CAUTION: Take extra care not to crease the headliner.
Page 843 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 122: Identifying Adhesive Courtesy of VOLVO CARS CORPORATION Fig. 123: Melting Adhesive, 1161656 Courtesy of VOLVO CARS CORPORATION Use: Melting adhesive, 1161656...
Page 844 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 124: Installing Locking System Receiver Courtesy of VOLVO CARS CORPORATION To install, reverse the removal procedure. SUN SENSOR NOTE: The illustrations in this service information are used for different model years and/or models.
Page 845 HEADLAMPS (2011 LATE - 2012) . Cover bumper front, see COVER BUMPER FRONT (2007 - 2011 EARLY) or COVER BUMPER  FRONT (2011 LATE - 2012) . Fig. 126: Identifying Headlight Washer Components (1 of 2) Courtesy of VOLVO CARS CORPORATION...
Page 846 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 127: Identifying Headlight Washer Components (2 of 2) Courtesy of VOLVO CARS CORPORATION INSTALLATION To install, reverse the removal procedure. Fig. 128: Installing Headlight Washer...
Page 847 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 129: Removing Rain Sensor (1 Of 3) Courtesy of VOLVO CARS CORPORATION Fig. 130: Removing Rain Sensor (2 Of 3) Courtesy of VOLVO CARS CORPORATION...
Page 848: Special Tools
2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation CAUTION: Take extra care when handling the component. CAUTION: The silicon surface must not be touched, any contamination of the surface will damage the sensor.
Page 849 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 132: Removing Rear Wiper Motor (1 Of 2) Courtesy of VOLVO CARS CORPORATION see 9987693 Fig. 133: Removing Rear Wiper Motor (2 Of 2)
Page 850 Removal steps in this procedure may contain installation details. Fig. 134: View Of Washer Fluid Reservoir Bolt Courtesy of VOLVO CARS CORPORATION Remove casing bumper front, see COVER BUMPER FRONT (2007 - 2011 EARLY) . For information on component position washer reservoir, see LOCATION OF COMPONENTS, WASHER...
Page 851 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 135: View Of Washer Reservoir Bolts Courtesy of VOLVO CARS CORPORATION WARNING: Be prepared to collect escaping fluid. Torque: M6 10 Nm INSTALLATION To install, reverse the removal procedure.
Page 852 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 136: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION For information on component position washer reservoir, see LOCATION OF COMPONENTS, WASHER RESERVOIR (2011 LATE - 2012) .
Page 853 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 138: View Of Escaping Fluid Courtesy of VOLVO CARS CORPORATION WARNING: Be prepared to collect escaping fluid. Fig. 139: Identifying Reservoir Tank Components...
Page 854 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 140: Identifying Reservoir Tank Bolts Courtesy of VOLVO CARS CORPORATION Torque: M6 10 Nm INSTALLATION To install, reverse the removal procedure. WIPER ARM...
Page 855 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation REMOVAL CAUTION: Make sure that the motor is in the park position. Fig. 141: Remove Key From Ignition Courtesy of VOLVO CARS CORPORATION...
Page 856 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 142: Identifying Windshield Wiper Arm Screws Courtesy of VOLVO CARS CORPORATION Torque: Windshield wiper arm 21 Nm Fig. 143: View Of Special Tool 9814088...
Page 857 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 144: View Of Wiper Blade Position Courtesy of VOLVO CARS CORPORATION WIPER MECHANISM, WINDSHIELD REMOVAL NOTE: Removal steps in this procedure may contain installation details.
Page 858 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 146: Identifying Wiper Mechanism Bolts Courtesy of VOLVO CARS CORPORATION Torque: M6 10 Nm INSTALLATION To install, reverse the removal procedure. WIPER MOTOR FRONT...
Page 859 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 147: Remove Key From Ignition Courtesy of VOLVO CARS CORPORATION Remove the wiper mechanism, windscreen, see WIPER MECHANISM, WINDSHIELD Fig. 148: Identifying Wiper Motor Front Components...
Page 860 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 149: Identifying Wiper Motor Front Position Courtesy of VOLVO CARS CORPORATION NOTE: Note the position of the component before removal. Fig. 150: Identifying Wiper Motor Front Screws...
Page 861 Removal steps in this procedure may contain installation details. Remove the air filter housing, see AIR CLEANER HOUSING Fig. 1: Removing Back-Up Lamp Switch (1 Of 2) Courtesy of VOLVO CARS CORPORATION Fig. 2: Removing Back-Up Lamp Switch (2 Of 2) Courtesy of VOLVO CARS CORPORATION...
Page 862 REMOVING THE BACK-UP LAMP SWITCH, GEARBOX M56 Ignition off Remove the air cleaner (ACL) housing. Fig. 3: Identifying Tool P/N 9997077 Courtesy of VOLVO CARS CORPORATION Remove the following items: the gear selector cables from the levers. see 9997077 ...
Page 863 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 4: Identifying Tool P/N 9997221 Courtesy of VOLVO CARS CORPORATION Remove the following items: pin. see 9997221 .  the lever  Fig. 5: Identifying Back-Up Lamp Switch Connector...
Page 864 For tightening torques, see TIGHTENING TORQUE . INSTALLING BACK-UP (REVERSING) LAMP SWITCH Fig. 6: Identifying Back-Up Lamp Switch Connector Courtesy of VOLVO CARS CORPORATION Install the new back-up light switch. see 9995543 Tighten to: 24 Nm. INSTALLING THE CONNECTOR Fig. 7: View Of Secondary Lock Courtesy of VOLVO CARS CORPORATION Pull out the secondary lock.
Page 865 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 8: Back-Up Lamp Switch Leads Courtesy of VOLVO CARS CORPORATION Install the cables in the connector with the opening for the primary lock facing up as shown in the illustration.
Page 866 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 10: Identifying Tool P/N 9997221 Courtesy of VOLVO CARS CORPORATION Install the following items: transmission lever see 9997221 to press in the pin ...
Page 867 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 11: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Fig. 12: Identifying Control Stalk, Left Screws Courtesy of VOLVO CARS CORPORATION INSTALLATION To install, reverse the removal procedure.
Page 868 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 14: Identifying Control Stalk, Right Screws Courtesy of VOLVO CARS CORPORATION INSTALLATION To install, reverse the removal procedure. DATA LINK CONNECTOR (OBD-II) REMOVAL AND INSTALLATION Fig.
Page 869 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 16: View Of Data Link Connector (OBD-II) location Courtesy of VOLVO CARS CORPORATION Fig. 17: Identifying Data Link Connector (OBD-II) Release Tab Courtesy of VOLVO CARS CORPORATION...
Page 870 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Courtesy of VOLVO CARS CORPORATION Fig. 19: Inserting Terminal Removal Tool Courtesy of VOLVO CARS CORPORATION NOTE: Only work on 1 cable at a time.
Page 871 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 20: Pressing Tab And Removing Wire Courtesy of VOLVO CARS CORPORATION DRIVER DOOR MODULE (DDM) REMOVAL NOTE: Removal steps in this procedure may contain installation details.
Page 872 The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct. PREPARATORY WORK IGNITION OFF Fig. 23: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION...
Page 873 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Ignition off. REMOVAL REMOVING THE CIGARETTE LIGHTER/ELECTRICAL SOCKET Fig. 24: View Of Ashtray Panel Courtesy of VOLVO CARS CORPORATION Remove the rear panel. Disconnect the connector from the ashtray panel.
Page 874 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 25: Identifying Cigarette Lighter/Electrical Socket Catches Courtesy of VOLVO CARS CORPORATION Lift up the catches (as shown in the illustration) using a small screwdriver. Press out the cigarette lighter/electrical socket.
Page 875 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 26: Extra Power Socket Remove/Install Components (1 of 2) Courtesy of VOLVO CARS CORPORATION Fig. 27: Extra Power Socket Remove/Install Components (2 of 2) Courtesy of VOLVO CARS CORPORATION...
Page 876 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 28: Extra Power Socket Remove/Install Components (1 of 2) Courtesy of VOLVO CARS CORPORATION Fig. 29: Extra Power Socket Remove/Install Components (2 of 2) Courtesy of VOLVO CARS CORPORATION...
Page 877 Courtesy of VOLVO CARS CORPORATION Torque: M6 10 Nm INSTALLATION To install, reverse the removal procedure. Calibrate position sensor using VIDA (Volvo scan tool). FRONT POSITION SENSOR, HEADLAMP (2010 - 2011 EARLY) REMOVAL NOTE: Removal steps in this procedure may contain installation details.
Page 878 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 32: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Follow instructions for lifting points body frame, see JACKING POINTS BODY . Fig. 33: Identifying Front Position Sensor, Headlamp Screws...
Page 879 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation To install, reverse the removal procedure. FINISHING Calibrate position sensor using VIDA (Volvo scan tool). FRONT POSITION SENSOR, HEADLAMP (2011 LATE - 2012) REMOVAL NOTE: Removal steps in this procedure may contain installation details.
Page 880 Courtesy of VOLVO CARS CORPORATION Torque: M6 10 Nm INSTALLATION To install, reverse the removal procedure. Calibrate position sensor using VIDA (Volvo scan tool). INSTRUMENT PANEL CONSOLE SWITCH KNOB Special tools 981 4071 STRAIGHTENING TOOL Tool number: 981 4071 Tool description: STRAIGHTENING TOOL...
Page 881: Courtesy Of Volvo Cars Corporation
2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation REMOVAL Fig. 36: Removing Instrument Panel Console Switch Knob Courtesy of VOLVO CARS CORPORATION see 9814071...
Page 882 KEYPAD, STEERING WHEEL REMOVAL Remove airbag driver's side, see DRIVER'S AIRBAG Fig. 37: Identifying Steering Wheel Keypad Courtesy of VOLVO CARS CORPORATION Fig. 38: View Of Steering Wheel Keypad Connectors Courtesy of VOLVO CARS CORPORATION INSTALLATION To install, reverse the removal procedure.
Page 883 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation LIGHTING SWITCH REMOVAL Fig. 39: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Fig. 40: Identifying Lighting Switch in OFF Position Courtesy of VOLVO CARS CORPORATION...
Page 884 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 41: View Of Lighting Switch Components Courtesy of VOLVO CARS CORPORATION Fig. 42: Identifying Lighting Switch Screws Courtesy of VOLVO CARS CORPORATION INSTALLATION To install, reverse the removal procedure.
Page 885: Torque: M6
ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 43: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Remove panel side door front, see PANEL FRONT DOOR . Fig. 44: Identifying Driver Door Module (DDM) Screws...
Page 886 Removal steps in this procedure may contain installation details. Fig. 45: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Follow instructions for lifting points body frame, see JACKING POINTS BODY . Fig. 46: Identifying Position Sensor Rear, Headlamp Screws...
Page 887: Calibrate Position Sensor Using Vida (Volvo Scan Tool)
2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation INSTALLATION To install, reverse the removal procedure. Calibrate position sensor using VIDA (Volvo scan tool). POSITION SENSOR REAR, HEADLAMP (2010 - 2011 EARLY) REMOVAL NOTE: Removal steps in this procedure may contain installation details.
Page 888 Torque: M6 10 Nm INSTALLATION To install, reverse the removal procedure. FINISHING Calibrate position sensor using VIDA (Volvo scan tool). POSITION SENSOR REAR, HEADLAMP (2011 LATE - 2012) REMOVAL NOTE: Removal steps in this procedure may contain installation details. Fig. 49: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Follow instructions for lifting points body frame, see JACKING POINTS BODY .
Page 889 Courtesy of VOLVO CARS CORPORATION Torque: M6 10 Nm INSTALLATION To install, reverse the removal procedure. Calibrate position sensor using VIDA (Volvo scan tool). POWER SOCKET 12V (2007) REMOVAL Fig. 51: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION...
Page 890 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 52: Identifying Power Socket Panel Courtesy of VOLVO CARS CORPORATION Fig. 53: View Of Power Socket Clip Courtesy of VOLVO CARS CORPORATION INSTALLATION To install, reverse the removal procedure.
Page 891 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 54: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Fig. 55: Window Regulator Rotary Switch, Rear Door Remove/Install Components (1 Of 3) Courtesy of VOLVO CARS CORPORATION...
Page 892 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 56: Window Regulator Rotary Switch, Rear Door Remove/Install Components (2 of 3) Courtesy of VOLVO CARS CORPORATION Fig. 57: Window Regulator Rotary Switch, Rear Door Remove/Install Components (3 of 3)
Page 893 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 59: Removing Door Handle Panel Courtesy of VOLVO CARS CORPORATION Fig. 60: Identifying Door Handle Panel Clips Courtesy of VOLVO CARS CORPORATION...
Page 894 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 61: Identifying Window Regulator Rotary Switch Courtesy of VOLVO CARS CORPORATION INSTALLATION To install, reverse the removal procedure. ROTARY SWITCH, FRONT DOOR WINDOW REGULATOR (2011 LATE - 2012) REMOVAL Fig.
Page 895 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 63: Removing Door Handle Panel Courtesy of VOLVO CARS CORPORATION Fig. 64: Prying Up Front Side Switch Panel Frame Courtesy of VOLVO CARS CORPORATION...
Page 896 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 65: Prying Up Rear Side Switch Panel Frame Courtesy of VOLVO CARS CORPORATION Fig. 66: Identifying Window Regulator Rotary Switch Courtesy of VOLVO CARS CORPORATION...
Page 897 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 67: Identifying Window Regulator Rotary Switch Screws Courtesy of VOLVO CARS CORPORATION INSTALLATION Fig. 68: Installing Front Door Switch Panel (1 of 2)
Page 898 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation CAUTION: Only use moderate force. Fig. 69: Installing Front Door Switch Panel (2 of 2) Courtesy of VOLVO CARS CORPORATION CAUTION: Make sure that equal pressure is applied to the full length of the component.
Page 899 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 70: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Remove lighting interior front, see LIGHTING, INTERNAL FRONT Fig. 71: View Of Sun Roof Rotary Switch Release Clips...
Page 900 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation IGNITION OFF Fig. 72: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Ignition off. REMOVAL REMOVING THE INTERIOR LIGHTING Remove the interior lighting. See: LIGHTING, INTERNAL FRONT .
Page 901 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 73: Sun Roof Switch Catches Courtesy of VOLVO CARS CORPORATION Press the catches out. Pull the switch outwards and upwards. Pull out the catch. Pull out the conductive strap.
Page 902 Remove steering wheel lever left, see CONTROL STALK, LEFT Fig. 74: Identifying Steering Wheel Control Module Bolts Courtesy of VOLVO CARS CORPORATION CAUTION: Make sure that the clockspring pins are not bent or damaged. Torque: Steering wheel control module to steering column...
Page 903 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 75: Identifying Steering Wheel Control Module Connectors Courtesy of VOLVO CARS CORPORATION INSTALLATION Perform angle sensor, steering wheel, resetting To install, reverse the removal procedure.
Page 904 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 77: Remove/Install Central Locking System, Switch Components Courtesy of VOLVO CARS CORPORATION INSTALLATION To install, reverse the removal procedure. SWITCH, HAZARD WARNING FLASHERS...
Page 905 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation SWITCH TUNNEL COMPARTMENT REMOVAL Remove floor console, see FLOOR CONSOLE Fig. 79: Identifying Tunnel Compartment Switches Courtesy of VOLVO CARS CORPORATION Fig. 80: View Of Tunnel Compartment Switch Tabs Courtesy of VOLVO CARS CORPORATION...
Page 906 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 81: Removing Tunnel Compartment Switches Courtesy of VOLVO CARS CORPORATION Initiate switch using VIDA (Volvo scan tool). INSTALLATION To install, reverse the removal procedure. COLLISION AVOIDANCE...
Page 907 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 82: View Of Ignition In "0" Position Courtesy of VOLVO CARS CORPORATION Remove Rear Bumper Cover Upper Section, see REAR BUMPER COVER UPPER SECTION (2007 - 2011 EARLY Fig.
Page 908 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 84: Removing Rear Parking Assistance Distance Sensors (2 Of 2) Courtesy of VOLVO CARS CORPORATION INSTALLATION Fig. 85: Installing Rear Parking Assistance Distance Sensors (1 Of 2)
Page 909 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 86: Installing Rear Parking Assistance Distance Sensors (2 Of 2) Courtesy of VOLVO CARS CORPORATION To install, reverse the removal procedure. DISTANCE SENSORS, PARKING ASSISTANCE REAR (2011 LATE - 2012) REMOVAL Fig.
Page 910 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 88: Removing Rear Parking Assistance Distance Sensors (1 Of 2) Courtesy of VOLVO CARS CORPORATION Fig. 89: Removing Rear Parking Assistance Distance Sensors (2 Of 2) Courtesy of VOLVO CARS CORPORATION...
Page 911 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 90: Installing Rear Parking Assistance Distance Sensors (1 Of 2) Courtesy of VOLVO CARS CORPORATION Fig. 91: Installing Rear Parking Assistance Distance Sensors (2 Of 2) Courtesy of VOLVO CARS CORPORATION To install, reverse the removal procedure.
Page 912 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 92: Identifying Parking Assistance Module Courtesy of VOLVO CARS CORPORATION INSTALLATION To install, reverse the removal procedure. Order and download software according to: 30786805 DOOR LOCKS &...
Page 913 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 93: Identifying Ignition Switch In OFF Position Courtesy of VOLVO CARS CORPORATION Remove the tunnel console. See FLOOR CONSOLE Fig. 94: Locating Antenna Nuts...
Page 914 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 95: Locating Keyless Entry Locking System Antenna In Luggage Compartment Courtesy of VOLVO CARS CORPORATION ANTENNA, LOCKING SYSTEM, KEYLESS ENTRY, REAR (2007 - 2011 EARLY) Operation Number(s): 36646-2 NOTE: Removal steps in this procedure may contain installation details.
Page 915 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 97: Identifying Bumper Bracket Module Courtesy of VOLVO CARS CORPORATION Remove the following items: the antenna, fold out the catches at the lower edge ...
Page 916 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 99: Removing Keyless Entry Locking System Rear Antenna (1 Of 2) Courtesy of VOLVO CARS CORPORATION Fig. 100: Removing Keyless Entry Locking System Rear Antenna (2 Of 2)
Page 917 NOTE: Removal steps in this procedure may contain installation details. Fig. 101: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Remove the plenum cover, see PLENUM CHAMBER Fig. 102: Identifying Anti-Theft Protection Siren Bolts Courtesy of VOLVO CARS CORPORATION...
Page 918 NOTE: Removal steps in this procedure may contain installation details. Fig. 103: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Remove the plenum cover, see PLENUM CHAMBER Fig. 104: Locating Anti-Theft Protection Siren Courtesy of VOLVO CARS CORPORATION...
Page 919 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation 10 Nm Fig. 105: Removing Anti-Theft Protection Siren (1 of 2) Courtesy of VOLVO CARS CORPORATION Fig. 106: Removing Anti-Theft Protection Siren (2 of 2) Courtesy of VOLVO CARS CORPORATION INSTALLATION To install, reverse the removal procedure.
Page 920 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 107: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Fig. 108: Front Intrusion Sensor Cover Courtesy of VOLVO CARS CORPORATION...
Page 921 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 109: Front Intrusion Sensor Connector Courtesy of VOLVO CARS CORPORATION INSTALLATION To install, reverse the removal procedure. FRONT INTRUSION SENSOR (2012) REMOVAL...
Page 922 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 110: Front Intrusion Sensor Cover Courtesy of VOLVO CARS CORPORATION Fig. 111: Front Intrusion Sensor Connector Courtesy of VOLVO CARS CORPORATION INSTALLATION...
Page 923 To install, reverse the removal procedure. KEYLESS VEHICLE MODULE (KVM) PREPARATORY WORK IGNITION OFF Fig. 112: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Ignition off. REMOVING THE LEFT-HAND FRONT SEAT Remove the left-hand front seat. See: FRONT SEAT . REMOVAL...
Page 924 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 113: View Of Keyless Vehicle Module (KVM) Connectors Courtesy of VOLVO CARS CORPORATION Remove: the 5 connectors  the 2 x screws ...
Page 925 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation FINISHING INSTALLING THE LEFT-HAND FRONT SEAT Install the left-hand front seat. See: FRONT SEAT . ORDERING SOFTWARE Order software for the control module. See: 30772590...
Page 926 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Courtesy of VOLVO CARS CORPORATION Remove: the 2 x screws  the remote receiver module (RRX).  INSTALLATION INSTALLING RECEIVER LOCK SYSTEM Install: the remote receiver module (RRX) ...
Page 927 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 116: Removing Locking System Receiver Courtesy of VOLVO CARS CORPORATION CAUTION: Take extra care not to crease the headliner. INSTALLATION Fig. 117: Identifying Adhesive...
Page 928 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 118: Melting Adhesive, 1161656 Courtesy of VOLVO CARS CORPORATION Use: Melting adhesive, 1161656 Fig. 119: Installing Locking System Receiver Courtesy of VOLVO CARS CORPORATION To install, reverse the removal procedure.
Page 929 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 120: Locating Locking System Receiver Courtesy of VOLVO CARS CORPORATION Fig. 121: Removing Locking System Receiver Courtesy of VOLVO CARS CORPORATION CAUTION: Take extra care not to crease the headliner.
Page 930 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 122: Identifying Adhesive Courtesy of VOLVO CARS CORPORATION Fig. 123: Melting Adhesive, 1161656 Courtesy of VOLVO CARS CORPORATION Use: Melting adhesive, 1161656...
Page 931 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 124: Installing Locking System Receiver Courtesy of VOLVO CARS CORPORATION To install, reverse the removal procedure. SUN SENSOR NOTE: The illustrations in this service information are used for different model years and/or models.
Page 932 HEADLAMPS (2011 LATE - 2012) . Cover bumper front, see COVER BUMPER FRONT (2007 - 2011 EARLY) or COVER BUMPER  FRONT (2011 LATE - 2012) . Fig. 126: Identifying Headlight Washer Components (1 of 2) Courtesy of VOLVO CARS CORPORATION...
Page 933 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 127: Identifying Headlight Washer Components (2 of 2) Courtesy of VOLVO CARS CORPORATION INSTALLATION To install, reverse the removal procedure. Fig. 128: Installing Headlight Washer...
Page 934 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 129: Removing Rain Sensor (1 Of 3) Courtesy of VOLVO CARS CORPORATION Fig. 130: Removing Rain Sensor (2 Of 3) Courtesy of VOLVO CARS CORPORATION...
Page 935: Special Tools
2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation CAUTION: Take extra care when handling the component. CAUTION: The silicon surface must not be touched, any contamination of the surface will damage the sensor.
Page 936 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 132: Removing Rear Wiper Motor (1 Of 2) Courtesy of VOLVO CARS CORPORATION see 9987693 Fig. 133: Removing Rear Wiper Motor (2 Of 2)
Page 937 Removal steps in this procedure may contain installation details. Fig. 134: View Of Washer Fluid Reservoir Bolt Courtesy of VOLVO CARS CORPORATION Remove casing bumper front, see COVER BUMPER FRONT (2007 - 2011 EARLY) . For information on component position washer reservoir, see LOCATION OF COMPONENTS, WASHER...
Page 938 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 135: View Of Washer Reservoir Bolts Courtesy of VOLVO CARS CORPORATION WARNING: Be prepared to collect escaping fluid. Torque: M6 10 Nm INSTALLATION To install, reverse the removal procedure.
Page 939 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 136: Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION For information on component position washer reservoir, see LOCATION OF COMPONENTS, WASHER RESERVOIR (2011 LATE - 2012) .
Page 940 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 138: View Of Escaping Fluid Courtesy of VOLVO CARS CORPORATION WARNING: Be prepared to collect escaping fluid. Fig. 139: Identifying Reservoir Tank Components...
Page 941 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 140: Identifying Reservoir Tank Bolts Courtesy of VOLVO CARS CORPORATION Torque: M6 10 Nm INSTALLATION To install, reverse the removal procedure. WIPER ARM...
Page 942 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation REMOVAL CAUTION: Make sure that the motor is in the park position. Fig. 141: Remove Key From Ignition Courtesy of VOLVO CARS CORPORATION...
Page 943 2012 Volvo C30 T-5 ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation Fig. 142: Identifying Windshield Wiper Arm Screws Courtesy of VOLVO CARS CORPORATION Torque: Windshield wiper arm 21 Nm Fig. 143: View Of Special Tool 9814088...

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Volvo C30 2007 Service And Repair Manual

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