Volvo 2008 C30 Service And Repair Manual Download | Manualshive

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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
removed, at the markings on the bumper cover. Fold down the bumper cover towards the bumper casing,
at the same time as securing the bumper cover into place.



Remove the protective tape from the other side. Align it with the remaining tape markings and press the
bumper cover into place.



Remove the pieces of tape.

2012 Volvo C30 T-5

ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories

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Summary of Contents for 2008 C30

Page 1: ...2007 2013 VOLVO C30 SERVICE AND REPAIR MANUAL ...

Page 2: ...PEDAL REMOVAL AND INSTALLATION Fig 1 Identifying Accelerator Pedal Courtesy of VOLVO CARS CORPORATION Torque M6 10 Nm 2012 Volvo C30 T 5 ENGINE Engine Control Removal Replacement And Installation 2012 Volvo C30 T 5 ENGINE Engine Control Removal Replacement And Installation ...

Page 3: ...ING Fig 1 Identifying Bolts Courtesy of VOLVO CARS CORPORATION Remove the auxiliaries belt See ACCESSORY DRIVE BELT TENSIONER NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ELECTRICAL Alternator And Regulator Removal Replacement And Installation 2012 Volvo C30 T 5 ELECTRICAL Alternator And Regulator Removal Replacement And Installation ...

Page 4: ...54T3 2007 B5254T7 2008 12 REMOVAL Fig 3 Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Remove the air filter housing See AIR CLEANER HOUSING Remove the throttle body See THROTTLE BODY Remove the auxiliaries belt See ACCESSORY DRIVE BELT TENSIONER NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ELECTRICAL Alternator And Regulator Rem...

Page 5: ...g Generator B Terminal And Nuts Courtesy of VOLVO CARS CORPORATION Remove the following items 1 Torque Generator B terminal 15 Nm 2 Torque M10 50 Nm INSTALLATION To install reverse the removal procedure 2012 Volvo C30 T 5 ELECTRICAL Alternator And Regulator Removal Replacement And Installation ...

Page 6: ...997113 Courtesy of VOLVO CARS CORPORATION see 9997113 see 9997113 CHARGE REGULATOR CHARGE REGULATOR B5244S4 2007 11 B5254T3 2007 B5254T7 2008 12 REMOVAL Special tools 999 7113 Spanner Tool number 999 7113 Tool description Spanner Tool boards 30 NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ELECTRICAL Alternator And Regulator Removal Replacement And Instal...

Page 7: ...OR B5244S4 2007 11 or GENERATOR B5254T3 2007 B5254T7 2008 12 Fig 8 Identifying M4 Generator Bolts Courtesy of VOLVO CARS CORPORATION Torque M4 3 5 Nm INSTALLATION To install reverse the removal procedure 2012 Volvo C30 T 5 ELECTRICAL Alternator And Regulator Removal Replacement And Installation ...

Page 8: ...d Torsion Rod Nuts And Cover Courtesy of VOLVO CARS CORPORATION Torque M8 24 Nm Fig 2 View Of Battery And Cover NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ELECTRICAL Battery And Mounting Removal Replacement And Installation 2012 Volvo C30 T 5 ELECTRICAL Battery And Mounting Removal Replacement And Installation ...

Page 9: ...VOLVO CARS CORPORATION Fig 4 Identifying Battery Holder And Bolts Courtesy of VOLVO CARS CORPORATION Torque M6 10 Nm INSTALLATION To install reverse the removal procedure VEHICLES WITH BATTERY MONITORING SENSOR BMS Reset according to DIAGNOSTICS VEHICLE COMMUNICATION CEM Advanced Resetting information 2012 Volvo C30 T 5 ELECTRICAL Battery And Mounting Removal Replacement And Installation ...

Page 10: ...when replacing battery main battery function VIDA Volvo Scan Tool is necessary to perform this procedure 2012 Volvo C30 T 5 ELECTRICAL Battery And Mounting Removal Replacement And Installation ...

Page 11: ...T LEFT Remove the right drive shaft see DRIVE SHAFT RIGHT Fig 1 Identifying M7 Bolts Courtesy of VOLVO CARS CORPORATION Torque M7 17 Nm NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 TRANSMISSION Manual Transmission 2012 Volvo C30 T 5 TRANSMISSION Manual Transmission ...

Page 12: ... 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 2012 Volvo C30 T 5 TRANSMISSION Manual Transmission ...

Page 13: ...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 2012 Volvo C30 T 5 TRANSMISSION Manual Transmission ...

Page 14: ...ing Bevel Gear Courtesy of VOLVO CARS CORPORATION For information about transmission lubricants see LUBRICANT TRANSMISSION To install reverse the removal procedure 2012 Volvo C30 T 5 TRANSMISSION Manual Transmission ...

Page 15: ...ROL UNIT TURBO or FUEL FIRED BOOSTER HEATER CONTROL UNIT NON TURBO REMOVAL REMOVING THE GLOW PLUG PRESSURE EQUALIZER 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 2012 Volvo C30 T 5 HVAC Automatic HVAC System 2012 Volvo C30 T 5 HVAC Automatic HVAC ...

Page 16: ...ng 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 NOTE The nearest connection pipe may need to be adjusted in order to remove the cover See COOLANT PIPE FUEL POWERED PREHEATER TURBO or COOLANT PIPE FUEL POWERED PREHEATER NON TURBO 2012 Volvo C30 T 5 HVAC Automatic HVAC System ...

Page 17: ...sy 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 2012 Volvo C30 T 5 HVAC Automatic HVAC System ...

Page 18: ...e the glow plug the pressure equalizer and the fuel pipe INSTALLATION INSTALLING THE GLOW PLUG PRESSURE EQUALIZER Install the pressure equalizer NOTE Make sure that the O ring and the filter are also removed Otherwise the fan motor has to be disconnected from the combustion housing NOTE For tightening torques see TIGHTENING TORQUE 2012 Volvo C30 T 5 HVAC Automatic HVAC System ...

Page 19: ...e cable runs behind the fan motor like the others Install the cover using 4 screws If necessary adjust the pipe connection see COOLANT PIPE FUEL POWERED PREHEATER TURBO or COOLANT PIPE FUEL POWERED PREHEATER NON TURBO Install the control module see FUEL FIRED BOOSTER HEATER CONTROL UNIT TURBO or FUEL FIRED BOOSTER HEATER CONTROL UNIT NON TURBO FINISHING TESTING THE ENGINE COOLANT HEATER Perform a ...

Page 20: ...jacking plate must have a rubber pad to prevent damage to the vehicle Do not lift at the front suspension as there is a risk of the wheel alignment being altered NOTE The graphics in this service information are used for different model years and or models Some variation may occur However the essential information in the graphics is always correct 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Body ...

Page 21: ...ent is given from centre Measurement is given from an edge Measurement is given from a cut marking Fig 3 Identifying Measurement Tools Courtesy of VOLVO CARS CORPORATION NOTE Some variation may occur However the essential information in the graphics is always correct 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Body Frame Specifications Mechanical ...

Page 22: ...lectronic 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 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Body Frame Specifications Mechanical ...

Page 23: ... CORPORATION Symbol legend Measurement is given from center Measurement is given from an edge Measurement is given from a cut marking Fig 7 Identifying Measurement Tools NOTE Some variation may occur However the essential information in the graphics is always correct 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Body Frame Specifications Mechanical ...

Page 24: ...imilar A deviation of 2 mm is acceptable Fig 8 Identifying Side Measurements 1 Of 3 Courtesy of VOLVO CARS CORPORATION B1 1012 mm B2 826 mm B3 945 mm Fig 9 Identifying Side Measurements 2 Of 3 Courtesy of VOLVO CARS CORPORATION B4 1198 mm B5 1063 mm 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Body Frame Specifications Mechanical ...

Page 25: ...mm B7 1421 mm ROOF WINDSHIELD AND REAR WINDSHIELD FRAME ROOF Fig 11 View Of Symbol Numbers Courtesy of VOLVO CARS CORPORATION Symbol legend Measurement is given from centre Measurement is given from an edge 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Body Frame Specifications Mechanical ...

Page 26: ...rement takes place from the bottom of the recess If only a measuring point symbol is shown this applies to both points Otherwise the symbols are shown on one side each of the measurement designation shown Fig 13 Identifying Roof Measurements Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Body Frame Specifications Mechanical ...

Page 27: ...y of VOLVO CARS CORPORATION BODY SIDE Fig 15 View Of Symbol Numbers Courtesy of VOLVO CARS CORPORATION Explanation of symbols As measured from centre As measured from one edge 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Body Frame Specifications Mechanical ...

Page 28: ...from the bottom of the recess If only one measurement point symbol is shown it applies to both points Otherwise the symbols appear on each side of the measurement designation in the graphic Fig 17 Identifying Body Side Measurements 1 Of 5 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Body Frame Specifications Mechanical ...

Page 29: ...Side Measurements 2 Of 5 Courtesy of VOLVO CARS CORPORATION Fig 19 Identifying Body Side Measurements 3 Of 5 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Body Frame Specifications Mechanical ...

Page 30: ...Side Measurements 4 Of 5 Courtesy of VOLVO CARS CORPORATION Fig 21 Identifying Body Side Measurements 5 Of 5 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Body Frame Specifications Mechanical ...

Page 31: ...ee FRONT END Remove the bracket for the power steering It is secured using 4 M8 screws 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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation 2012 Volvo C30 T 5 ACCE...

Page 32: ... It is secured using 4 M8 screws Remove the remaining 6 M8 screws for the bumper rail Remove the bumper rail INSTALLATION INSTALLING THE FRONT BUMPER RAIL Fig 2 Installing Front Bumper Rail Courtesy of VOLVO CARS CORPORATION NOTE Note how the washer hose and cable are routed on the rail NOTE For tightening torques see TIGHTENING TORQUE 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal...

Page 33: ... See RUSTPROOFING FRONT WHEEL BEARING REMOVAL REMOVING THE FRONT WHEEL ARCH Remove components See FRONT SECTION EXPOSING Grind off the welds Cut off the damaged section Grind clean and apply welding primer INSTALLATION INSTALLING THE FRONT WHEEL ARCH NOTE The illustrations in this service information are used for different model years and or models Some variation may occur However the essential in...

Page 34: ...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 M1 136 mm M2 146 mm 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 35: ...ROOFING Install components See FRONT SECTION EXPOSING REAR BUMPER RAIL 2007 2009 Remove the following items Shell lower part of rear bumper See REAR BUMPER COVER LOWER SECTION 2007 2009 Shell upper part of rear bumper See REAR BUMPER COVER UPPER SECTION Determine the extent of the damage See REAR SECTION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 36: ...REAR BUMPER RAIL 2010 2012 REMOVAL Remove casing bumper rear see COVER BUMPER REAR 2007 2011 EARLY or COVER BUMPER REAR 2011 2012 For information about rear piece see REAR SECTION NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 37: ...ents seeREAR SECTION EXPOSING 2007 2009 or REAR SECTION EXPOSING 2010 2012 Pull out the damage Determine the extent of the damage See REAR SECTION and SIDE MEMBERS REAR Expose See REAR SECTION EXPOSING 2007 2009 or REAR SECTION EXPOSING 2010 2012 NOTE The illustrations in this service information are used for different model years and or models Some variation may occur However the essential inform...

Page 38: ...RATION 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 INSTALLATION INSTALLING THE REAR SIDE MEMBER 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 39: ...N EXPOSING 2007 2009 or REAR SECTION EXPOSING 2010 2012 Check the whiplash system in the vehicle seeCOLLISION PROTECTION UNIT FROM BEHIND FRONT SEAT CHECK SIDE MEMBER FRONT Special tools see 9997072 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 2012 Volvo C30 T 5 ACCESSORIES AND BODY...

Page 40: ...ve components See FRONT SECTION EXPOSING Determine the extent of the damage See SIDE MEMBERS FRONT and FRONT END METHOD CONTENTS This method consists of see SIDE MEMBER LOWER REPLACEMENT see SIDE MEMBER UPPER REPLACING SIDE MEMBER LOWER REPLACEMENT the illustrations is always correct 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 41: ...tting point in the illustration Remove the support plate the front side panel See BRACKET FRONT PIECE the wheel arch FRONT WHEEL BEARING Cut the side member 30 mm M1 from the 2 square holes or replace the entire member Grind and drill out the member REMOVING THE INNER SECTION OF THE LOWER SIDE MEMBER 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 42: ...oint is used in the event of minor damage to the side member Cutting point 1 is located 180 mm M2 from the end of the member Take care when sawing as there is a reinforcement inside See the shaded part of the illustration Cutting point 2 Cutting point 2 is located 680 mm M3 from the end of the member 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 43: ... 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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 44: ...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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 45: ...PORATION Grind clean Apply welding primer Seam weld the join Spot weld the replacement part Tip diameter Ø 8 mm For location of the spot weld see LOCATION OF THE SPOT WELD Also see WELDING GENERAL 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 46: ...ORATION Weld the outer part of the cross member cowl panel Drill Ø 8 mm diameter holes for plug welds Weld the side member extension into place INSTALLING THE OUTER SECTION OF THE LOWER SIDE MEMBER 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 47: ...CORPORATION Grind clean Apply welding primer Spot weld the replacement part Tip diameter Ø 8 mm For location of the spot weld see below Also see WELDING GENERAL LOCATION OF THE SPOT WELD 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 48: ...Fig 17 Identifying Spot Weld Location Courtesy of VOLVO CARS CORPORATION INSTALLING COMPONENTS 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 49: ...m See the illustration Install the wheel arch See FRONT WHEEL BEARING the front side panel See BRACKET FRONT PIECE Carry out finishing work See FINISHING WORK COMMON TO BOTH METHODS SIDE MEMBER UPPER REPLACING REMOVING THE OUTER SECTION OF THE UPPER SIDE MEMBER 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 50: ...e spot welds Cut off the damaged section The member can also be joined at 1 REMOVING THE INNER SECTION OF THE UPPER SIDE MEMBER NOTE If the inner section is joined the distance between the joins must be at least 50mm 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 51: ...ION OF THE UPPER SIDE MEMBER Grind clean Apply welding primer Secure the upper side member Spot weld the replacement part Tip diameter against the suspension turret Ø6 mm Tip diameter against the wheel arch Ø 4 5 mm Carry out finishing work See FINISHING WORK COMMON TO BOTH METHODS 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 52: ...ENTS Seal See BODY SEAL SEALING DIAGRAM Rustproof See RUSTPROOFING Install components See FRONT SECTION EXPOSING 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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB B...

Page 53: ...Courtesy of VOLVO CARS CORPORATION Fig 23 Removing Spare Wheel Well 3 Of 4 Courtesy of VOLVO CARS CORPORATION Fig 24 Removing Spare Wheel Well 4 Of 4 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 54: ...mponents See WELDING GENERAL 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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 55: ...ith a 50 mm offset This applies when replacing all roof pillars C minimum 50 mm HINT When replacing a pillar it is often difficult to identify where the deformation ends It may be best to replace a larger section of the pillar 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 illustr...

Page 56: ...internal components Determine the extent of the damage See BODY SIDE and ROOF Roughly cut at the appropriate point so that the old and new sections are overlapping See the recommended cutting points in the illustration HINT The cantrail is under the roof panel at the top edge NOTE Do not replace too small a section of the cant rail roof side since the damage may have spread 2012 Volvo C30 T 5 ACCE...

Page 57: ...ry off the cantrail Grind clean Apply welding primer 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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and insta...

Page 58: ... 2007 2009 or ROOF SECTION EXPOSING 2010 2012 ROOF ARCH Information for welding body details See WELDING GENERAL 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 ROOF PANEL Materials 2012 Volvo C30 T 5 ACC...

Page 59: ...ION 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 Designation Part number 2 component foam 3M 08463 Masking tape 9511050 8 Seal 3M 08115 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 60: ...ling Roof Panel 3 Of 8 Courtesy of VOLVO CARS CORPORATION Use 2 component foam 3M 08463 Fig 34 Installing Roof Panel 4 Of 8 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 61: ... Use Masking tape 9511050 8 For information about body sealant sealing diagram see BODY SEAL SEALING DIAGRAM Fig 36 Installing Roof Panel 6 Of 8 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 62: ...Use Seal 3M 08115 For information about corrosion protection see RUSTPROOFING Install the roof section exposing see ROOF SECTION EXPOSING 2007 2009 or ROOF SECTION EXPOSING 2010 2012 BODY SIDE A PILLAR NOTE Make sure that the seal is correctly located 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 63: ...EXPOSING Determine the extent of the damage See BODY SIDE Fig 39 Removing Installing A Pillar 1 Of 8 Courtesy of VOLVO CARS CORPORATION Materials Designation Part number Insulation foam 3M 08463 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 64: ... 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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 65: ...ing A Pillar 4 Of 8 Courtesy of VOLVO CARS CORPORATION Fig 43 Removing Installing A Pillar 5 Of 8 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 66: ...ing A Pillar 6 Of 8 Courtesy of VOLVO CARS CORPORATION Fig 45 Removing Installing A Pillar 7 Of 8 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 67: ...RUSTPROOFING Install the side section See SIDE SECTION EXPOSING B POST Remove the following items rear fender See FENDER sill molding See BODY SILL REINFORCEMENT Welding body components See WELDING GENERAL Determine the extent of the damage See BODY SIDE Materials Designation Part number 2 component foam 3M 08463 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and instal...

Page 68: ...he following items side section exposing See SIDE SECTION EXPOSING rear section exposing See REAR SECTION EXPOSING 2007 2009 or REAR SECTION EXPOSING 2010 2012 B pillar See B POST Determine the extent of the damage on the body side See BODY SIDE Determine the extent of the damage on the rear section See REAR SECTION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and ins...

Page 69: ...rtesy of VOLVO CARS CORPORATION Fig 49 Removing Body Side Inner Section 2 Of 3 Courtesy of VOLVO CARS CORPORATION Fig 50 Removing Body Side Inner Section 3 Of 3 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 70: ...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 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 71: ... 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 See B POST A pillar See A PILLAR 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 72: ...PER RAIL Determine the extent of the damage See REAR SECTION HINT Save color edges that indicate where the panels are located This will make aligning easier REMOVAL REMOVING THE INNER REAR SECTION Drill off the spot welds and the bead welds Pry off the inner rear section Grind clean INSTALLATION INSTALLING THE INNER REAR SECTION NOTE The illustrations in this service information are used for diffe...

Page 73: ...eld the load eyelets into place Install the rear bumper rail see REAR BUMPER RAIL the outer rear section see TAIL SECTION EXTERNAL Seal See BODY SEAL SEALING DIAGRAM Rustproof See RUSTPROOFING Install components See REAR SECTION EXPOSING 2007 2009 or REAR SECTION EXPOSING 2010 2012 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 74: ...Fig 56 Removing External Tail Section 1 Of 3 Courtesy of VOLVO CARS CORPORATION Alternative cutting points Welding body components See WELDING GENERAL Materials Designation Part number Insulation foam 3M 08643 NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 75: ...K TAIL SECTION SIDE PREPARATORY WORK REMOVING COMPONENTS AND ASCERTAINING THE DAMAGE Remove parts according to REAR SECTION EXPOSING 2007 2009 or REAR SECTION EXPOSING 2010 2012 the rear bumper rail see REAR BUMPER RAIL Determine the extent of the damage See REAR SECTION NOTE The illustrations in this service information are used for different model years and or models Some variation may occur How...

Page 76: ... Joints should be used to limit the painted surfaces on the rear fender Grind and drill out the spot welds and bead welds Pry off the side rear section Grind clean INSTALLATION INSTALLING THE SIDE REAR SECTION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 77: ...acement part Spot weld the replacement part Tip diameter Ø 4 5 mm Also see WELDING GENERAL Seam weld as shown in the illustration 1 65 mm 2 85 mm Seal See BODY SEAL SEALING DIAGRAM Rust proof See RUSTPROOFING Install 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 78: ... REAR SECTION EXPOSING 2007 2009 or REAR SECTION EXPOSING 2010 2012 NOTE Check the whiplash system in the vehicle seeCOLLISION PROTECTION UNIT FROM BEHIND FRONT SEAT CHECK 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Removal replacement and installation ...

Page 79: ...et metal parts the joints between the different sheet metal parts shall be sealed according to illustration Use Seal 1161767 Materials Designation Part number Seal 1161767 Spray sealant 1161651 Seal 3M 08115 Soundproofing 68117640 2 component foam 3M 08463 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame General Information 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame General Infor...

Page 80: ...n a bead this type of putty is very difficult to rework since the putty has a loose texture The putty restores the vehicle to production like version after body work Fig 3 Seal 3M 08115 Courtesy of VOLVO CARS CORPORATION 3 Seal that can be sanded Use at visible joints such as the joint between the roof sill and roof panel Use Seal 3M 08115 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame Gen...

Page 81: ...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 Use Soundproofing 68117640 3M 2 component foam starts to foam when the components are mixed The foam is suitable for filling of larger hol...

Page 82: ... is used for e g weld seams and areas that have been reworked in other ways Tool number T9814075 Tool description SPRAY GUN Tool boards T9814076 SPRAY GUN Tool number T9814076 Tool description SPRAY GUN Tool boards Materials Designation Part number Cavity protection 1161682 Stone chip protection 1161815 Underbody protection 116 1298 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame General In...

Page 83: ...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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame General Information ...

Page 84: ...he areas of the vehicle marked in blue in the illustration see 9814076 Fig 9 Underbody protection 1161298 Courtesy of VOLVO CARS CORPORATION Rustproofing schedule for underbody protection Use Underbody protection 1161298 Apply underbody protection to the areas of the vehicle marked in grey in the illustration 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame General Information ...

Page 85: ...T METAL MATERIAL INFORMATION STEEL MATERIAL INFORMATION Fig 10 Identifying Sheet Metal Material Information Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame General Information ...

Page 86: ...entifying Steel Material Information Courtesy of VOLVO CARS CORPORATION Fig 12 Identifying Zinc Area Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame General Information ...

Page 87: ...ile strength between 180 280 MPa Very high tensile strength steels VHS Steel with a tensile strength between 280 380 MPa Extra high tensile strength steels EHS Steel with a tensile strength between 380 800 MPa Ultra High Strength steel UHS Steel with a tensile strength of more than 800 MPa Mild Steel This category of steel is used where use of a stronger steel is not necessary High Strength Steel ...

Page 88: ...ufacturing process and with higher additives of alloy substances BORON steel obtains its strength through the use of the basic element boron and contains relatively large amounts of carbon The plate profiles are formed heated between the die cutter and die cushion where the material is also hardened Due to its extremely high strength it is difficult to straighten with good results Grinding or plas...

Page 89: ...ways use welding primer between welded panel flanges PRIOR TO WELDING 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 CAUTION Always remove the battery cables before welding in accordance with BATTERY DISCONNECTING AND CONNECTING CAUTION Locate the w...

Page 90: ... spot weld with the location of the weld and lens diameter specified with color may be replaced with 2 2 Plug weld may be replaced with 1 3 Seam weld Seam weld with weld length specified in mm 4 Step weld Step weld with weld length followed by length between welds specified in mm Always start and finish with the weld 5 Tack weld CAUTION If the welding must be carried out in the immediate vicinity ...

Page 91: ...nt part for plug welding Select size of hole for plug welding according to the following panel thicknesses 8 mm for thicknesses less than 2 5 mm 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 illustration NOTE Always te...

Page 92: ...ig 19 Grinding Properly And Improperly Courtesy of VOLVO CARS CORPORATION Grind down the plug weld NOTE Use welding primer on all internal flanges CAUTION Make sure that the spot welds take properly on both panels CAUTION Only grind welds not the adjacent panel 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame General Information ...

Page 93: ...be the same as the original design 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 CAUTION Always remove the battery cables before welding in accordance with BATTERY DISCONNECTING AND CONNECTING CAUTION Locate the welding ground connection as close a...

Page 94: ...ith the weld 5 Tack weld 6 Glue RESISTANCE SPOT WELDING Resistance spot welding must primarily be used if the capacity of the welding equipment is matched to panel thickness When carrying out resistance spot welding grind down to bare metal Clean the surfaces with Scotch Brite or similar to minimize zinc and phosphating damage Apply welding primer between the panels MAG WELDING Punch replacement p...

Page 95: ...els apart and measure the size of the welding lens diameter A see illustration Fig 22 Identifying Proper Spot Welds On Both Panels Courtesy of VOLVO CARS CORPORATION Add filling primer if there is grinding damage NOTE Use welding primer on all internal flanges CAUTION Make sure that the spot welds take properly on both panels 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame General Informati...

Page 96: ...nding Properly And Improperly Courtesy of VOLVO CARS CORPORATION Grind down the plug weld CAUTION Only grind welds not the adjacent panel 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Body Frame General Information ...

Page 97: ...LIGHTS 2007 2009 FRONT FOG LIGHTS 2010 2011 EARLY or FRONT FOG LIGHTS 2011 LATE 2012 Front section Auxiliary heater See FUEL FIRED BOOSTER HEATER Radiator See COOLING SYSTEM REMOVAL AND INSTALLATION Servo pump See STEERING REMOVAL AND INSTALLATION Dashboard See DASHBOARD Driver s airbag SRS See DRIVER S AIRBAG Passenger airbag SRS See AIRBAG PASSENGER SIDE Engine transmission See ENGINE REMOVAL AN...

Page 98: ...rim panel see B PILLAR TRIM PANEL C pillar trim panel see C PILLAR TRIM PANEL Headlining with sun roof see HEADLINING WITH SUN ROOF Side window fixed rear see FIXED SIDE WINDOW tailgate see TAILGATE Inflatable curtain see INFLATABLE CURTAIN 2010 2012 Wind deflector sunroof see WIND DEFLECTOR SUNROOF Glass sun roof see GLASS SUN ROOF Windshield see WINDSHIELD ROOF SECTION EXPOSING 2010 2012 REMOVAL...

Page 99: ...D SIDE WINDOW Rear Bumper Cover Lower Section see REAR BUMPER COVER LOWER SECTION 2007 2009 Rear Bumper Cover Upper Section see REAR BUMPER COVER UPPER SECTION REAR SECTION EXPOSING 2010 2012 REMOVAL Remove the following items tailgate see TAILGATE Side panel loadspace see SIDE PANEL LOADSPACE Rear bumper rail see REAR BUMPER RAIL Cover bumper rear see COVER BUMPER REAR 2007 2011 EARLY or COVER BU...

Page 100: ...es 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 14 Nm NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 BRAKES Brake Control System Removal Replacement And Installation 2012 Volvo C30 T 5 BRAKES Brake Control System Removal Replacement And Installati...

Page 101: ... 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 Perform anti lock brake system module ABS See ANTI LOCK BRAKE SYSTEM MODULE ABS NOTE Make sure that the mating faces are clean and free of foreign material 2012 Volvo C30 ...

Page 102: ...em Courtesy of VOLVO CARS CORPORATION INSTALLATION To install reverse the removal procedure NOTE When installing this component do not download any new software 2012 Volvo C30 T 5 BRAKES Brake Control System Removal Replacement And Installation ...

Page 103: ...lies to cars with automatic transmissions Remove the rubber covers from the pedals by grasping the upper edge and pulling backwards Clean if necessary all pedal surfaces where the new rubber covers will be positioned Fig 2 Removing Original Cover Automatic Transmissions 2012 Volvo C30 T 5 BRAKES Hydraulic Vacuum Hydraulic Brakes Installation Instructions Accessories 2012 Volvo C30 T 5 BRAKES Hydra...

Page 104: ...er cover from the kit Hold as shown and fold out the three tabs Fig 4 Fitting New Cover Courtesy of VOLVO CARS CORPORATION Hook the cover at the upper edge at the same time hold the tabs and pull downwards Press the cover firmly onto the pedal 2012 Volvo C30 T 5 BRAKES Hydraulic Vacuum Hydraulic Brakes Installation Instructions Accessories ...

Page 105: ...al edges Pull the cover to ensure that it is secure APPLIES TO CARS WITH MANUAL TRANSMISSIONS Fig 6 Identifying Spacers Courtesy of VOLVO CARS CORPORATION Take the two spacer washers from the kit Carefully separate the two covers from each other 2012 Volvo C30 T 5 BRAKES Hydraulic Vacuum Hydraulic Brakes Installation Instructions Accessories ...

Page 106: ... the pedals are clean Fig 8 Positioning Covers Courtesy of VOLVO CARS CORPORATION Place the two covers which have markings in the recesses on the clutch and brake pedal and press securely The thicker part of the covers must point downwards 2012 Volvo C30 T 5 BRAKES Hydraulic Vacuum Hydraulic Brakes Installation Instructions Accessories ...

Page 107: ... shown and fold out the three tabs Fig 10 Fitting New Cover Courtesy of VOLVO CARS CORPORATION Hook the cover at the upper edge at the same time hold the tabs and pull downwards Press the cover firmly onto the pedal 2012 Volvo C30 T 5 BRAKES Hydraulic Vacuum Hydraulic Brakes Installation Instructions Accessories ...

Page 108: ...ecure Repeat steps 8 10 for the remaining pedal APPLIES TO CARS WITH AUTOMATIC TRANSMISSIONS Fig 12 Removing Protective Film Courtesy of VOLVO CARS CORPORATION Take the two spacer washers from the kit Remove the protective film from the covers Ensure that the surfaces of the pedals are clean 2012 Volvo C30 T 5 BRAKES Hydraulic Vacuum Hydraulic Brakes Installation Instructions Accessories ...

Page 109: ...edal and press securely The thicker part of the cover must point downwards Fig 14 Opening the Tabs Courtesy of VOLVO CARS CORPORATION Take the brake pedal s metal trimmed rubber cover from the kit Hold as shown and fold out the three tabs 2012 Volvo C30 T 5 BRAKES Hydraulic Vacuum Hydraulic Brakes Installation Instructions Accessories ...

Page 110: ...the left and downwards Press the cover firmly onto the pedal Fig 16 Securing the 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 to ensure that it is secure BRAKE PEDALS 2012 Volvo C30 T 5 BRAKES Hydraulic Vacuum Hydraulic Brakes Installation Instructions Accessories ...

Page 111: ...s Courtesy of VOLVO CARS CORPORATION Sport pedals Equipment Fig 18 Weatherstrip Tool Courtesy of VOLVO CARS CORPORATION Kit contents 2012 Volvo C30 T 5 BRAKES Hydraulic Vacuum Hydraulic Brakes Installation Instructions Accessories ...

Page 112: ...Fig 19 Identify the Kit Contents Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 BRAKES Hydraulic Vacuum Hydraulic Brakes Installation Instructions Accessories ...

Page 113: ... Transmission Courtesy of VOLVO CARS CORPORATION INSTALLATION Fig 21 Verify Clean Surfaces Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 BRAKES Hydraulic Vacuum Hydraulic Brakes Installation Instructions Accessories ...

Page 114: ...2 Removing Original Cover Courtesy of VOLVO CARS CORPORATION Fig 23 New Cover Fully in Place Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 BRAKES Hydraulic Vacuum Hydraulic Brakes Installation Instructions Accessories ...

Page 115: ...SMISSIONS Fig 25 Removing Brake Pedal Pad Courtesy of VOLVO CARS CORPORATION The part s are not to be reused CAUTION Using a mirror check that the pedal rubber covers the edges of the pedal 2012 Volvo C30 T 5 BRAKES Hydraulic Vacuum Hydraulic Brakes Installation Instructions Accessories ...

Page 116: ...ull the pedal rubber upward Fig 27 Use Tool As Needed Courtesy of VOLVO CARS CORPORATION Press the pedal rubber towards the pedal and at the same time fold the pedal rubber s profile over the pedal using a straightening tool 2012 Volvo C30 T 5 BRAKES Hydraulic Vacuum Hydraulic Brakes Installation Instructions Accessories ...

Page 117: ...NSMISSIONS Fig 29 Remove Original Pad Courtesy of VOLVO CARS CORPORATION The part s are not to be reused CAUTION Using a mirror check that the pedal rubber covers the edges of the pedal 2012 Volvo C30 T 5 BRAKES Hydraulic Vacuum Hydraulic Brakes Installation Instructions Accessories ...

Page 118: ...ull the pedal rubber upward Fig 31 Use Tool as Needed Courtesy of VOLVO CARS CORPORATION Press the pedal rubber towards the pedal and at the same time fold the pedal rubber s profile over the pedal using a straightening tool 2012 Volvo C30 T 5 BRAKES Hydraulic Vacuum Hydraulic Brakes Installation Instructions Accessories ...

Page 119: ...PORATION LEFT HAND DRIVE VEHICLES Repeat method steps for the clutch pedal CAUTION Using a mirror check that the pedal rubber covers the edges of the pedal 2012 Volvo C30 T 5 BRAKES Hydraulic Vacuum Hydraulic Brakes Installation Instructions Accessories ...

Page 120: ...ITH ELECTRIC ENGINE HEATERS NOTE The panel is installed the same way on cars with or without fog lamps Car with fog lamps shown Carry out the work at a temperature of at least 20 C 68 F Do not use the vehicle within 2 hours after doing the work Do not wash the vehicle within 48 hours after doing the work 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Ac...

Page 121: ...s with 4 cyl engines Remove the left front wheel Cars with 5 cyl engines Remove both the front wheels Fig 3 Identifying Underside Panel Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 122: ... 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 ENGINES WHERE AN ELECTRIC ENGINE HEATER IS INSTALLED 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 123: ...de by the stay on the sub frame Unplug the connectors Fig 7 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 underside 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 124: ...ide of the side member Fig 9 Identifying Tie Strap Courtesy of VOLVO CARS CORPORATION Remove the cable tie at the left hand lower bracket of the radiator APPLIES TO CARS WITH 5 CYL ENGINES WHERE AN ELECTRIC ENGINE HEATER IS INSTALLED 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 125: ... Applies to cars for USA For cars to the USA there is no splice joint on the cable Then this is loosened instead by the engine heater Fig 11 Identifying Double Clamp Courtesy of VOLVO CARS CORPORATION Loosen the cable from the double clamp on the brake pipe on the right side in the engine compartment 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Access...

Page 126: ... in the engine compartment Fig 13 Loosening Cable From Clips Along Metal Edge In Engine Compartment Courtesy of VOLVO CARS CORPORATION Loosen the cable from the clips along the metal edge in the trailing edge of the engine compartment 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 127: ... the bulkhead on the left side Fig 15 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 underside 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 128: ...Disconnect the ground lead from the outside of the side member Fig 17 Identifying Tie Strap Courtesy of VOLVO CARS CORPORATION Remove the cable tie at the left hand lower bracket of the radiator 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 129: ... edge and remove it Fig 19 Identifying Panel And Cable From Bumper Cover Courtesy of VOLVO CARS CORPORATION Remove the panel and cable from the bumper cover Remove the cable from the panel APPLIES TO ALL MODELS 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 130: ...S CORPORATION Fig 21 Enlarging Markings On Inside Of Panel Courtesy of VOLVO CARS CORPORATION Enlarge the markings on the inside of the panel 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 131: ...g to the markings Fig 23 Cleaning Outside Of Panel Courtesy of VOLVO CARS CORPORATION Clean the outside of the panel using isopropanol opposite where the securing tape on the new panel ends up 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 132: ...rtesy of VOLVO CARS CORPORATION Remove the protective tape from the new panel Fig 25 Identifying Tape Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 133: ...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 Press opposite the securing tape 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 134: ...s the locking washers into place APPLIES TO CARS WITH ENGINE BLOCK HEATERS Fig 29 Identifying Panel Courtesy of VOLVO CARS CORPORATION APPLIES TO CARS WITH ELECTRIC ENGINE HEATERS NOTE Position the panel on a surface that will not damage it when pressing the locking washers into place 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 135: ...onnector is turned so that the cover s sides are parallel with the plates in the panel and that the cover opens from the panel s left hand side Tighten the connector Fig 31 Open Connector Cover Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 136: ...To Wheel Hub Courtesy of VOLVO CARS CORPORATION Reinstall and clamp the loose cables to the heater Tightening torque 1 Step 1 Wheel to wheel hub 20 Nm 2 Step 2 Wheel to wheel hub 110 Nm Repeat appropriate steps for the other decor panel 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 137: ... Middle Ribs Using Tape Courtesy of VOLVO CARS CORPORATION NOTE The surface must be at a temperature of at least 20 C 68 F when work is carried out Do not use the vehicle for at least two hours after work has been carried out Do not wash the vehicle for at least 48 hours after work has been carried out 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Acce...

Page 138: ... VOLVO CARS CORPORATION Apply a piece of tape and mark the center of the bumper casing as shown Fig 37 Identifying Bumper Cover Centering Courtesy of VOLVO CARS CORPORATION Center the bumper cover according to the pieces of tape and measure the dimensions as shown 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 139: ...ly pieces of tape to mark out the dimensions Fig 39 Cleaning Marked Surface Courtesy of VOLVO CARS CORPORATION Remove the bumper cover Clean the marked surface using isopropanol and wipe dry 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 140: ...er on the side that had the protective tape removed at the markings on the bumper cover Fold down the bumper cover towards the bumper casing at the same time as securing the bumper cover into place Remove the protective tape from the other side Align it with the remaining tape markings and press the bumper cover into place Remove the pieces of tape 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bump...

Page 141: ...PLATE BENEATH THE ENGINE APPLIES TO ALL MODELS Fig 43 Identifying Engine Splash Guard Screws Courtesy of VOLVO CARS CORPORATION NOTE Do not use the vehicle for at least two hours after work has been carried out NOTE Do not wash the vehicle for at least 48 hours after work has been carried out 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 142: ...GINES Fig 45 Identifying Wood Positioned Inside Radiator Bracket Courtesy of VOLVO CARS CORPORATION Position three thin pieces of wood plastic or metal on the inside of the radiator bracket One opposite the hole in the centre and one above the hole to the right Place the third piece to the left of the left hand hole This is to protect components in the connection to the radiator bracket when drill...

Page 143: ... drill out the four holes where the clips were located Use tool P N 9814112 File down the edges of the holes Remove any shavings Remove the cover from under the engine NOTE Do not drill out the front hole to the left A new hole will be drilled to the side of it later NOTE Rustproof the hole edges thoroughly 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions...

Page 144: ...VO CARS CORPORATION Install the new protective plate for marking and drilling holes for the left front mounting At final attachment stage of the protective plate the two screws must have two spacer washers each between the mounting lugs and the subframe This is not required at this stage 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 145: ...rd Fig 50 Identifying Tool P N 9814112 Courtesy of VOLVO CARS CORPORATION Cover the underneath of the engine opposite the last hole with cardboard or similar so that drilling shavings does not blow up into the engine compartment Carefully drill out the last hole Use tool P N 9814112 File down the edge of the hole Remove any shavings 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps...

Page 146: ...stic or metal from the inside of the radiator bracket Fig 52 Identifying Engine Splash Guard Screws Courtesy of VOLVO CARS CORPORATION Install the engine splash guard using two existing screws and the five screws with washers from the kit according to the diagram NOTE Rustproof the hole edge thoroughly 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Acce...

Page 147: ...rews Courtesy of VOLVO CARS CORPORATION Torque tighten the M8 screws APPLIES TO CARS WITH 4 CYL ENGINES NOTE The two rear screws must have two spacer washers each between the mounting lug and the subframe as shown 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 148: ...ve it The two screws 1 will be reused place the others to one side Fig 56 Identifying Subframe Clips Courtesy of VOLVO CARS CORPORATION Remove the five clips in the subframe and bracket for the radiator They will not be reused 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 149: ...ing Cover For Nozzles For Headlamp Washers Courtesy of VOLVO CARS CORPORATION Remove the covers for the nozzles for the headlamp washers on the right and left hand sides Carefully grip the cover Pull the cover out until the catch becomes accessible 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 150: ...per Cover Using Weatherstrip Tool Courtesy of VOLVO CARS CORPORATION Apply a piece of tape to the panel of the wing edge to protect it Carefully pry off the corner of the bumper cover using a weatherstrip tool until the three hooks on the inside release Repeat the operation on the other side 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 151: ...s on top of the radiator Cut off the two locating lugs where the two first holes are to be drilled Reinstall the bumper cover Fig 62 View Of Cutting The Right Hand Side Courtesy of VOLVO CARS CORPORATION shows cutting on the right hand side 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 152: ...of the engine at the rear edge with cardboard or similar so that drilling shavings does not blow up into the engine compartment Carefully drill out the two holes at the rear edge where the clips were located Use tool P N 9814112 File down the edges of the holes Remove any shavings NOTE Rustproof the hole edges thoroughly 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installatio...

Page 153: ...les Use tool part no 9512782 Fig 66 View Of Splash Guard Center Line Marking Courtesy of VOLVO CARS CORPORATION Measure the center line between both rectangles where the old engine splash guard center front screw was and make a cross marking 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 154: ...of VOLVO CARS CORPORATION Take workshop lift part no 9985972 and fixture part no 9995972 and use it as a support when handling the engine splash guard in the following points Position the engine splash guard on the lift and raise it towards the subframe Secure it in the two rear holes using screws and washers from the kit One washer under the screw head and two washers between the panel and the su...

Page 155: ...f 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 Press up the workshop lift slightly so that the panel does not rub 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 156: ...e the engine splash guard after marking Fig 72 View Of Both Right Hand Front Mounting Holes Courtesy of VOLVO CARS CORPORATION Previous graphic shows the left front and the center mounting hole Graphic above shows both right hand front mounting holes NOTE take care when marking the two front hole Drill the large holes on the narrow panel edge 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers An...

Page 157: ...d finally with drill bit part no 9814112 Use a drill stop to prevent drilling through parts above Remove any shavings Remove the cover from under the engine 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 NOTE Rustproof the hole edges thoroughly and as well any scriber mark...

Page 158: ... to the left hand hole Graphic above applies to the right hand hole Fig 75 Identifying Tool P N 9512782 Courtesy of VOLVO CARS CORPORATION Rivet the nuts in the drilled holes Use tool part no 9512782 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 159: ...s and the subframe This is not required at this stage Fig 77 View Of Splash Guard And Radiator Bracket Drill Holes Courtesy of VOLVO CARS CORPORATION Take a drill bit with the same diameter as the three holes in the engine splash guard Use a drill stop Carefully drill out the three holes through the holes in the engine splash guard and radiator bracket Remove the engine splash guard 2012 Volvo C30...

Page 160: ...t the three holes File down the edges of the holes Remove any shavings Remove the cover from under the engine Fig 79 Identifying Rivet Nuts In Drill Holes Courtesy of VOLVO CARS CORPORATION NOTE Rustproof the hole edges thoroughly and as well any scriber markings 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 161: ...ews with washers from the kit according to the diagram Fig 81 View Of Mounting Lug And Subframe Screws Courtesy of VOLVO CARS CORPORATION NOTE The two rear screws must have two spacer washers each between the mounting lug and the subframe as shown below 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 162: ...OLVO CARS CORPORATION Torque tighten the M8 screws APPLIES TO THE C30 Fig 83 Identifying Front Bumper Inner Wing Courtesy of VOLVO CARS CORPORATION APPLIES TO ALL MODELS 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 163: ...f Nozzle Cover Courtesy of VOLVO CARS CORPORATION SIDE SCUFF PLATE 2009 12 SIDE SCUFF PLATE APPLIES TO ALL MODELS NOTE Some steps in these installation instructions are presented with graphic only 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 164: ... Cleaning Door Sills Courtesy of VOLVO CARS CORPORATION Clean the door sills thoroughly on both sides even underneath NOTE Wait at least one minute before unplugging the connectors or removing other electrical equipment 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 165: ...he decor panel s cradle is to sit on both sides using isopropanol Wipe dry APPLIES TO VEHICLES WITH DRIVE E Fig 89 Drilling Out Rivets Courtesy of VOLVO CARS CORPORATION Carefully drill out the rivets 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 166: ...S CORPORATION Fig 91 Identifying Panel Courtesy of VOLVO CARS CORPORATION Remove the panel Remove the remains of the rivets APPLIES TO ALL MODELS 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 167: ...Remove the protective tape from the two pieces of mounting tape Fig 93 Aligning Front Edge Of Cradle At Rear Edge Of Joint Between Front And Rear Door Sill Panel Courtesy of VOLVO CARS CORPORATION Align the front edge of the cradle at the rear edge of the joint between the front and rear door sill panel 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Acc...

Page 168: ...it Remove any shavings Fig 95 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 NOTE Ensure that the tape does not adhere yet At the same time hook the cradle at the upper edge on the door sill panel with the hooks 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Acce...

Page 169: ... 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 At the same time hook the holder on top of the door sill panel using the hooks NOTE Ensure that the tape does not adhere yet 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 170: ...he 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 Remove any shavings 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 171: ...p rivets from the kit Rivet the holder to the door sill panel Fig 101 Twisting Off Hooks From Cradles Courtesy of VOLVO CARS CORPORATION Carefully twist off the hooks from the cradles 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 172: ...o position securely so that all hooks engage Fig 103 Drilling Out Hole Courtesy of VOLVO CARS CORPORATION Press the sill decor opposite the mounting lug for the center hole against the underneath of the door sill panel Drill out the hole using a 6 mm 15 64 drill bit Remove the drill shavings 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 173: ...et Fig 105 Drilling Out Hole Courtesy of VOLVO CARS CORPORATION Press the lower part of the panel towards the door sill panel at the front hole Drill out the hole using a 6 mm 15 64 drill bit NOTE The front hole must be secured with plastic rivets and saved until last NOTE Drill through the middle of the oval hole 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instr...

Page 174: ...with a center pin APPLIES TO VEHICLES WITH DRIVE E 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 This is done because the decor panel springs in when the clip is attached and the central pin can break off when tapped in 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instruction...

Page 175: ...urtesy of VOLVO CARS CORPORATION Cut out the panel at the front mounting Fig 109 Identifying Underside Panel Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 176: ...O CARS CORPORATION Fig 111 Identifying Screws And Clips Courtesy of VOLVO CARS CORPORATION NOTE Do not tighten the clips and screws fully yet 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 177: ...ATE FRONT BUMPER Fig 113 Washing Surface Of Car Courtesy of VOLVO CARS CORPORATION NOTE Carry out the work at a temperature of at least 20 C 68 F Do not use the vehicle within 2 hours after doing the work Do not wash the vehicle within 48 hours after doing the work 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 178: ...affle 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 mounting lug to the clip s mounting Repeat the operation on the other side 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accesso...

Page 179: ...Plate And Screws Courtesy of VOLVO CARS CORPORATION Secure the skid plate using existing screws Do not tighten excessively so that the position can be adjusted laterally Ensure that the tape on the drilling template does not adhere yet 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 180: ...es not adhere yet Fig 119 Identifying Skid Plate Courtesy of VOLVO CARS CORPORATION Remove the skid plate from the grille NOTE Push the ends 2 of the skid plate up from underneath as far as possible and then press in front of the drilling templates 3 so that the tape adheres 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 181: ...ut the holes through the taped drilling templates Fig 121 Identifying Drilling Templates Courtesy of VOLVO CARS CORPORATION Remove the drilling templates on both sides 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 182: ...n Skid Plate Courtesy of VOLVO CARS CORPORATION Take the clip from the kit and take the skid plate again Insert one spike on the clip under the edge of the hole in the skid plate turn clockwise and at the same time press until the clip is in place Repeat the operation on the other side 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 183: ...pe slightly from each piece of tape on both sides and secure on the upper side outside using pieces of tape on both sides of the skid plate Fig 125 Identifying Pieces Of Tape Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 184: ...sopropanol Wipe dry Fig 127 Identifying Skid Plate Courtesy of VOLVO CARS CORPORATION Position the skid plate so that the clips can be felt against the edges of the holes on both sides Ensure that the tape does not adhere too soon 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 185: ...hey engage Fig 129 Pressing Skid Plate Into Place Courtesy of VOLVO CARS CORPORATION Now press the skid plate into place opposite the tape all the way around NOTE Ensure to press with approx 50 N of force for 15 seconds on all surfaces where the tape is attached so that it adheres properly 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 186: ...ig 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 Remove any shavings 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 187: ...id plate in the outer ends SKID PLATE FRONT BUMPER 2010 11 SKID PLATE FRONT BUMPER Fig 133 Identifying Spring Nuts Courtesy of VOLVO CARS CORPORATION Take the spring nuts from the kit and press them into the bumper cover 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 188: ...2 SKID PLATE REAR BUMPER Fig 135 Cutting Out Skid Plate Courtesy of VOLVO CARS CORPORATION Applies to cars with a tow hitch Take the Skid plate from the kit Saw out the new Skid plate according to the markings Remove the shaded area 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 189: ... Out New Skid Plate Courtesy of VOLVO CARS CORPORATION APPLIES TO CARS WITH PARKING ASSISTANCE Fig 137 Identifying Sensor Courtesy of VOLVO CARS CORPORATION NOTE Take extra care not to damage the painted surface of the components 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 190: ... Layer Of Activator Courtesy of VOLVO CARS CORPORATION Apply a thin and even layer of activator to the cleaned surfaces Use 8637076 Activator Allow to dry for a minimum of 10 minutes and a maximum of 30 minutes before painting 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 191: ...ngs On Inside Of Skid Plate Courtesy of VOLVO CARS CORPORATION Locate the 2 markings on the inside of the Skid plate Mark the center with a scribe CAUTION Protect the connection s contact surfaces from paint Too many layers of paint can result in the function partially or totally disappearing 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 192: ...er drill bit Fig 143 Enlarging Holes In Bumper Casing Courtesy of VOLVO CARS CORPORATION Enlarge the holes in the bumper casing using a hole cutter Use special tool 9997234 Place the hole tool s support sleeve on the inside and the cutting part on the outside of the bumper cover 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 193: ...cated using isopropanol and wipe dry Fig 145 Applying Activator To Cleaned Surfaces Courtesy of VOLVO CARS CORPORATION Apply a thin and even layer of activator part no 8637076 to the cleaned surfaces and allow to dry for approx 10 min 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 194: ... Apply a thin and even layer of activator part no 8637076 on the cleaned surfaces and allow to dry for at least 10 min Fig 147 Brushing Hole Edges With Paint Courtesy of VOLVO CARS CORPORATION Carefully brush the hole edges with paint color 426 APPLIES TO ALL MODELS 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 195: ...de Wheel Arch Courtesy of VOLVO CARS CORPORATION Fig 149 Identifying Right Side Wheel Arch Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 196: ...shers Under Rear Bumper Courtesy of VOLVO CARS CORPORATION Fig 151 Identifying Rear Sill Plates Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 197: ...r Cover Courtesy of VOLVO CARS CORPORATION Remove the bumper cover from the body by carefully prying off the ends at the taped surface using a weatherstrip tool Pull off the cover under the tail lamp and from the rear edge of the wing on each side It is secured by four clips at the tail lamp and four in the rear edge of the rear wing Pull the bumper cover straight back Disconnect the connector for...

Page 198: ...RKING ASSISTANCE Fig 155 Disconnecting Connectors For Center Sensors Courtesy of VOLVO CARS CORPORATION Disconnect the connectors for the two center sensors NOTE Take care not to damage the bumper cover and Skid plate when working with them 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 199: ...nsors They are to be reused Fig 157 Identifying Clips Holding Cable Harness To Sensors Courtesy of VOLVO CARS CORPORATION Detach the four clips that hold the cable harness to the sensors in the holders in the existing Skid plate APPLIES TO ALL MODELS 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 200: ...kid plate it will not be reused APPLIES TO CARS WITH PARKING ASSISTANCE Fig 159 Identifying Protective Film Courtesy of VOLVO CARS CORPORATION Remove the protective film from one side of the double backed tape NOTE Take extra care when working with the bumper cover and Skid plate 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 201: ... 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 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 202: ...e Courtesy of VOLVO CARS CORPORATION Fig 163 Identifying Centering Tool Courtesy of VOLVO CARS CORPORATION Install the centering tool in the holder as shown 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 203: ...mper Cover Courtesy of VOLVO CARS CORPORATION Press the holders into place using the centering tool on the bumper cover APPLIES TO ALL MODELS NOTE The holders must be mounted turned against the holes as shown The holders must also be horizontal and in line with the bumper cover 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 204: ...engage APPLIES TO CARS WITH PARKING ASSISTANCE Fig 167 Identifying Clips For Sensor s Cable Harness Courtesy of VOLVO CARS CORPORATION Press the clips for the sensor s cable harness in the holders in the new Skid plate 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 205: ... Install the two sensors Fig 169 Connecting Connectors To Sensors Courtesy of VOLVO CARS CORPORATION Connect the connectors to the sensors APPLIES TO ALL MODELS 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 206: ...RATION Connect the connector to the number plate lighting and to the parking assistance connector if applicable Fig 171 Identifying Bumper Cover Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 207: ...g Screws Courtesy of VOLVO CARS CORPORATION Fig 173 Identifying Rear Sill Plates Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 208: ...de Wheel Arch Courtesy of VOLVO CARS CORPORATION Fig 175 Identifying Right Side Wheel Arch Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 209: ...e accessory s function according to service information in VIDA Volvo Scan Tool BODY KIT 2007 11 BODY KIT REMOVAL REAR BUMPER COVER Fig 177 Identifying Right Wheel Arch Lining And Screws Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 210: ...g And Screws Courtesy of VOLVO CARS CORPORATION Fig 179 Identifying Bolts And Washers Under Rear Bumper Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 211: ...dy by carefully prying off the ends using a weatherstrip tool Pull off the cover under the tail lamp and from the rear edge of the wing on each side It is secured by four clips at the tail lamp and four in the rear edge of the rear wing Pull the bumper cover straight back 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 212: ...3 Identifying Rear Fender s Panel Courtesy of VOLVO CARS CORPORATION Carefully bend loose the rear fender s panel starting at the trailing edge and then forward Bend with the weatherstrip tool right at the side of the clips The panel is fastened with a catch at the trailing edge and five clips all the way around The panel shall not be used again NOTE Do not damage the paint work 2012 Volvo C30 T 5...

Page 213: ...il the three clips release and then folding it down Remove the three clips in the fender liner s upper edge and all clips in the fender edge New clips are included in the kit Clean the fender edge Fig 185 Identifying Bumper Cover Screws Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 214: ... panel starting at the leading edge and then backward Bend with the weatherstrip tool right at the side of the clips The panel is fastened with a catch at the leading edge and seven clips all the way around The panel shall not be used again NOTE Do not damage the paint work 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 215: ...der edge New clips are included in the kit Clean the fender edge Repeat for the other side FRONT BUMPER COVER Fig 189 Identifying Panel To Left And Right Fog Light Courtesy of VOLVO CARS CORPORATION Remove the panel to the left and right fog light by carefully pressing in the catches in the panel s upper edge with a weatherstrip tool and pull it loose The panel is fastened with six catches 2012 Vo...

Page 216: ... screws from the engine splash guard Fig 191 Identifying Screws Holding Bumper Cover At Left Hand Wing Liner Courtesy of VOLVO CARS CORPORATION Remove the left front wheel Remove the five screws holding the bumper cover in the wing liner on the left and right hand sides 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 217: ...nt edge of the left hand wing liner up over the brake calliper Fig 193 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 frame Unplug the connectors 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 218: ...at the brake pipe and from clamps along the side member s underside Fig 195 Identifying Ground Lead With Screw And Toothed Washer Courtesy of VOLVO CARS CORPORATION Loosen the ground cable from the leading edge of the side member s outside 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 219: ...iator bracket APPLIES TO CARS WITH 5 CYLINDER ENGINE WHERE ELECTRIC ENGINE HEATER IS INSTALLED Fig 197 Identifying Engine Splash Guard Courtesy of VOLVO CARS CORPORATION Remove the seven screws from the engine splash guard 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 220: ...in the wing liner on the left and right hand sides Fig 199 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 Bend the front edge of the left hand wing liner up over the brake calliper 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessorie...

Page 221: ... Applies to cars for USA For cars to the USA there is no splice joint on the cable Then this is loosened instead by the engine heater Fig 201 Identifying Double Clamp Courtesy of VOLVO CARS CORPORATION Loosen the cable from the double clamp on the brake pipe on the right side in the engine compartment 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Acces...

Page 222: ...engine compartment Fig 203 Loosening Cable From Clips Along Metal Edge In Trailing Edge Of Engine Compartment Courtesy of VOLVO CARS CORPORATION Loosen the cable from the clips along the metal edge in the trailing edge of the engine compartment 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 223: ... the bulkhead on the left side Fig 205 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 underside 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 224: ...n the ground cable from the leading edge of the side member s outside Fig 207 Identifying Tie Strap Courtesy of VOLVO CARS CORPORATION Cut off the cable tie 1 that holds the cable to the left radiator bracket APPLIES TO ALL MODELS 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 225: ... Identifying Cover For Nozzles For Headlamp Washers Courtesy of VOLVO CARS CORPORATION Remove the covers for the nozzles for the headlamp washers on the right and left hand sides Carefully grip the cover Pull the cover out until the catch becomes accessible 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 226: ...sher nozzles Fig 211 Identifying Screws That Hold Bumper s Lower Part Courtesy of VOLVO CARS CORPORATION Remove the four screws that hold the bumper s lower part in the baffle Remove the spring nuts that hold the baffle in the bumper casing s lower part on both sides 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 227: ...With Air Baffle Courtesy of VOLVO CARS CORPORATION Remove the bumper cover with air baffle by grasping the ends and pulling forwards until the remaining hooks under the lamps release Disconnect the connectors for the fog lamps or parking assistance if applicable DOOR SILL PANEL NOTE Get help from a colleague for this procedure 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Insta...

Page 228: ... center pin in the clips on the underside of the bottom sill s panel On the two front clips the center pins may have to be drilled out to be able to remove the clips Turn loose the panel from the bottom sill s underside so that the clips come loose 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 229: ...the rubber strip from the panel Lay away the panel but the rubber strip is to be used again Repeat steps for the other side INSTALLATION REAR SPOILER Fig 217 Identifying Clips For Cable Harness For Reverse Warning s Sensors Courtesy of VOLVO CARS CORPORATION NOTE Do not damage the paint work 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 230: ...is procedure Place the bumper casing on a surface that will not damage the painted surface Carefully bend and pull loose the bumper s lower part from the upper part It is fastened with catches all the way around The lower part shall not be used again Fig 219 Identifying Rear Spoiler Courtesy of VOLVO CARS CORPORATION NOTE Do not damage the painted surface on the upper part 2012 Volvo C30 T 5 ACCES...

Page 231: ...sy 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 Fig 221 Identifying Reflector Courtesy of VOLVO CARS CORPORATION Press on the reflectors from the kit on the spoiler s ends NOTE Do not damage the painted surface on the upper part 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudfla...

Page 232: ...the towing eye s in the rectangular hole in the lower edge of the opening Press in the panel in the opening Fig 223 Pressing On Cover For Exhaust Pipe Opening Courtesy of VOLVO CARS CORPORATION Applies to cars where the end pipe is not to be visible Press on the cover for the exhaust pipe opening so that the catch at the top edge engages 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mud...

Page 233: ...To Number Plate Lighting Courtesy of VOLVO CARS CORPORATION Fig 225 Identifying Bumper Cover Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 234: ...s Courtesy of VOLVO CARS CORPORATION Fig 227 Identifying Rear Sill Plates Courtesy of VOLVO CARS CORPORATION FRONT SPOILER 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 235: ...CORPORATION Get help from a colleague for this procedure Place the bumper casing on a surface that will not damage the painted surface Carefully bend and pull loose the bumper s lower part from the upper part It is fastened with catches all the way around The lower part shall not be used again NOTE Do not damage the painted surface on the upper part 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bum...

Page 236: ...r where the anti chafing protector is to be located Use isopropanol Wipe dry Fig 231 Identifying Protective Tape Courtesy of VOLVO CARS CORPORATION Remove the protective tape from the anti chafing protector NOTE The unpainted spoiler must be painted first 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 237: ...ure the anti chafing protector along the edges of the spoiler at the rear edge Fig 233 Pressing Anti Chafing Protector Courtesy of VOLVO CARS CORPORATION Press the anti chafing protector at the rear edge forwards 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 238: ... 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 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 239: ...ve tape from the anti chafing protector Fig 237 Identifying Anti Chafing Protector Courtesy of VOLVO CARS CORPORATION Press the anti chafing protector into place Repeat for the other side 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 240: ...catches engage Fig 239 Identifying Bumper Cover Courtesy of VOLVO CARS CORPORATION Reinstall the bumper cover Make sure that the spoiler fits in the leading edge on the baffle NOTE Do not damage the painted surface on the upper part 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 241: ... the cable for the engine heater if applicable Route and clamp it in the same way as it was installed before Replace cut cable ties with new ones Remount the front wheel and tighten the wheel bolts to 90 Nm 66 lbf ft NOTE Do not clamp the cable directly to AC pipes fuel lines brake pipes or power steering hoses and pipes Make sure the cable does not chafe against sharp edges or moving parts in the...

Page 242: ...S CORPORATION Tighten the spoiler s brackets to the baffle Tighten the baffle s outer screw on both sides Fig 243 Identifying Fog Light Panel 1 Of 2 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 243: ...245 Identifying Bottom Sill Panel Courtesy of VOLVO CARS CORPORATION Get a new bottom sill panel and new clips from the kit Replace all clips Install the rubber strip from the old panel on the new 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 244: ... all catches engage Fig 247 Identifying Clips To Secure Panel In Lower Edge Courtesy of VOLVO CARS CORPORATION Get new clips from the kit and secure the panel in the lower edge Repeat steps for the other side WHEEL HOUSING EDGES 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 245: ...the fender edge from the kit Install new clips in the panel Fig 249 Identifying Clips And Fender Edge Courtesy of VOLVO CARS CORPORATION Get new clips from the kit and install these around the fender edge 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 246: ...r Press in the fender liner with clips in the fender edge s clips Make sure that the clips really snap into place Fig 251 Identifying Panel On Fender Edge Courtesy of VOLVO CARS CORPORATION Press in the new panel on the fender edge Make sure all catches engage 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 247: ...der Front Edge Courtesy of VOLVO CARS CORPORATION Fig 253 Identifying Screws On Front Fender Rear Edge Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 248: ...ORPORATION Fig 255 Identifying Screws On Rear Fender Rear Edge Courtesy of VOLVO CARS CORPORATION Repeat for all wheel housing edges MUD GUARDS FRONT 2007 09 MUD GUARDS FRONT 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 249: ...ifying Body Section Courtesy of VOLVO CARS CORPORATION Fig 257 Turning Wheel Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 250: ... Mudflap Is To Be Positioned Courtesy of VOLVO CARS CORPORATION Fig 259 Identifying Screws Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 251: ...anel Courtesy of VOLVO CARS CORPORATION Fig 261 Identifying Mud Guards Front Drilling Location Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 252: ...ying Body Section Courtesy of VOLVO CARS CORPORATION Fig 263 Identifying Wheel Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 253: ...nstallation Area Courtesy of VOLVO CARS CORPORATION Fig 265 Removing Fender Clips Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 254: ...ear Clips Courtesy of VOLVO CARS CORPORATION Fig 267 Identifying Drilling Location Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 255: ...ification Courtesy of VOLVO CARS CORPORATION MUDFLAPS 2010 12 MUDFLAPS Fig 269 Identifying Body Section Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 256: ...rn 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 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 257: ...g Screws Courtesy of VOLVO CARS CORPORATION Fig 273 Identifying Rivets And Panel Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 258: ...ole For Rivet Courtesy of VOLVO CARS CORPORATION Fig 275 Identifying Body Section Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 259: ...ourtesy of VOLVO CARS CORPORATION Fig 277 Identifying Rivets Courtesy of VOLVO CARS CORPORATION NOTE These will not be reused 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 260: ... 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 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 261: ...RS CORPORATION Install the clip Fig 281 Identifying Mudflap Courtesy of VOLVO CARS CORPORATION Fold the inner wing back and install the mudflap 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 262: ...ying Rivets Courtesy of VOLVO CARS CORPORATION Fig 283 Drilling Hole For Rivet Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 263: ...Hub Courtesy of VOLVO CARS CORPORATION Wheel to wheel hub tightening torque Step 1 Wheel to wheel hub 20 Nm Step 2 Wheel to wheel hub 110 Nm 2012 Volvo C30 T 5 ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps Installation Instructions Accessories ...

Page 264: ...ment 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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installat...

Page 265: ...TION VEHICLES WITH FRONT UNDERBODY AIR DEFLECTOR Fig 4 Identifying Front Underbody Air Deflector Attachment Screws Courtesy of VOLVO CARS CORPORATION VEHICLES WITHOUT UNDERBODY AIR DEFLECTORS 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 266: ...EHICLES Fig 6 Identifying Front Bumper Removal Points Courtesy of VOLVO CARS CORPORATION WARNING Be prepared to collect escaping fluid NOTE This step requires the aid of another technician 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 267: ...CORPORATION VEHICLES WITHOUT UNDERBODY AIR DEFLECTORS Fig 8 Identifying Underbody Air Deflector Attachment Screws Courtesy of VOLVO CARS CORPORATION ALL VEHICLES 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 268: ...ht washers see HEADLIGHT WASHERS Front fog lights see FRONT FOG LIGHTS radiator grille see RADIATOR GRILLE Fig 10 Identifying Lower Front Bumper Fasteners Courtesy of VOLVO CARS CORPORATION VEHICLES LATE VERSION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 269: ...N On both sides Fig 12 Identifying Bumper Attachment Screws On Front Frame Courtesy of VOLVO CARS CORPORATION CAUTION Take extra care not to damage the mating faces 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 270: ...n both sides VEHICLES WITH FRONT SIDE UNDERBODY AIR DEFLECTOR Fig 14 Identifying Rear Fender Splash Guard Attachment Screws Courtesy of VOLVO CARS CORPORATION VEHICLES WITH FRONT UNDERBODY AIR DEFLECTOR 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 271: ... of VOLVO CARS CORPORATION VEHICLES WITHOUT UNDERBODY AIR DEFLECTORS Fig 16 Identifying Under Carriage Bumper Attachment Screws Courtesy of VOLVO CARS CORPORATION ALL VEHICLES 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 272: ...des Fig 18 Identifying Fog Light Connector Cable Courtesy of VOLVO CARS CORPORATION On both sides VEHICLES WITHOUT UNDERBODY AIR DEFLECTORS NOTE This step requires the aid of another technician 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 273: ...ille see RADIATOR GRILLE Front fog lights see FRONT FOG LIGHTS Fig 20 Identifying Lower Front Bumper Fasteners Courtesy of VOLVO CARS CORPORATION INSTALLATION ALL VEHICLES To install reverse the removal procedure COVER BUMPER FRONT 2011 LATE 2012 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 274: ...ATION On both sides Fig 22 Identifying Bumper Attachment Screws On Front Frame Courtesy of VOLVO CARS CORPORATION CAUTION Take extra care not to damage the mating faces 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 275: ...n both sides VEHICLES WITH FRONT SIDE UNDERBODY AIR DEFLECTOR Fig 24 Identifying Rear Fender Splash Guard Attachment Screws Courtesy of VOLVO CARS CORPORATION VEHICLES WITH FRONT UNDERBODY AIR DEFLECTOR 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 276: ... of VOLVO CARS CORPORATION VEHICLES WITHOUT UNDERBODY AIR DEFLECTORS Fig 26 Identifying Under Carriage Bumper Attachment Screws Courtesy of VOLVO CARS CORPORATION ALL VEHICLES 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 277: ...Fog Light Connector Cable Courtesy of VOLVO CARS CORPORATION On both sides VEHICLES WITHOUT UNDERBODY AIR DEFLECTORS WARNING Be prepared to collect escaping fluid NOTE This step requires the aid of another technician 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 278: ... grille see RADIATOR GRILLE Front fog lights see FRONT FOG LIGHTS Fig 30 Identifying Lower Front Bumper Fasteners Courtesy of VOLVO CARS CORPORATION INSTALLATION To install reverse the removal procedure COVER BUMPER REAR 2007 2011 EARLY REMOVAL 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 279: ...ersions 1 Of 9 Courtesy of VOLVO CARS CORPORATION Fig 32 Removing Rear Bumper Cover All Versions 2 Of 9 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 280: ...rtesy of VOLVO CARS CORPORATION On both sides Fig 34 Removing Rear Bumper Cover All Versions 4 Of 9 Courtesy of VOLVO CARS CORPORATION VEHICLES EARLY VERSION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 281: ...ARS CORPORATION On both sides Fig 36 Early Version 2 Of 5 Courtesy of VOLVO CARS CORPORATION NOTE This step requires the aid of another technician 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 282: ... 3 Of 5 Courtesy of VOLVO CARS CORPORATION On both sides Fig 38 Early Version 4 Of 5 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 283: ... 40 Late Version 1 Of 8 Courtesy of VOLVO CARS CORPORATION On both sides Fig 41 Late Version 2 Of 8 Courtesy of VOLVO CARS CORPORATION NOTE This step requires the aid of another technician 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 284: ...Version 3 Of 8 Courtesy of VOLVO CARS CORPORATION Fig 43 Late Version 4 Of 8 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 285: ...O CARS CORPORATION Fig 45 Late Version 6 Of 8 Courtesy of VOLVO CARS CORPORATION Fig 46 Late Version 7 Of 8 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 286: ...esy of VOLVO CARS CORPORATION ALL VEHICLES Fig 48 Removing Rear Bumper Cover All Versions 5 Of 9 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 287: ...ersions 6 Of 9 Courtesy of VOLVO CARS CORPORATION Fig 50 Removing Rear Bumper Cover All Versions 7 Of 9 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 288: ...ON Fig 52 Removing Rear Bumper Cover All Versions 9 Of 9 Courtesy of VOLVO CARS CORPORATION INSTALLATION To install reverse the removal procedure COVER BUMPER REAR 2011 LATE 2012 REMOVAL 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 289: ...TION Fig 54 Removing Rear Bumper Cover 2 Of 17 Courtesy of VOLVO CARS CORPORATION Fig 55 Removing Rear Bumper Cover 3 Of 17 Courtesy of VOLVO CARS CORPORATION On both sides 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 290: ...ARS CORPORATION Fig 57 Removing Rear Bumper Cover 5 Of 17 Courtesy of VOLVO CARS CORPORATION On both sides NOTE This step requires the aid of another technician 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 291: ... Cover 6 Of 17 Courtesy of VOLVO CARS CORPORATION Fig 59 Removing Rear Bumper Cover 7 Of 17 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 292: ...ORPORATION Fig 61 Removing Rear Bumper Cover 9 Of 17 Courtesy of VOLVO CARS CORPORATION Fig 62 Removing Rear Bumper Cover 10 Of 17 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 293: ...Cover 11 Of 17 Courtesy of VOLVO CARS CORPORATION Fig 64 Removing Rear Bumper Cover 12 Of 17 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 294: ...ORPORATION Fig 66 Removing Rear Bumper Cover 14 Of 17 Courtesy of VOLVO CARS CORPORATION Fig 67 Removing Rear Bumper Cover 15 Of 17 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 295: ...N Fig 69 Removing Rear Bumper Cover 17 Of 17 Courtesy of VOLVO CARS CORPORATION INSTALLATION To install reverse the removal procedure REAR BUMPER COVER LOWER SECTION 2007 2009 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 296: ...VOLVO CARS CORPORATION Fig 71 Removing Rear Bumper Cover Lower Section 2 Of 9 Courtesy of VOLVO CARS CORPORATION Fig 72 Removing Rear Bumper Cover Lower Section 3 Of 9 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 297: ...LVO CARS CORPORATION Fig 74 Removing Rear Bumper Cover Lower Section 5 Of 9 Courtesy of VOLVO CARS CORPORATION NOTE This step requires assistance from another technician 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 298: ...VOLVO CARS CORPORATION Fig 76 Removing Rear Bumper Cover Lower Section 7 Of 9 Courtesy of VOLVO CARS CORPORATION Fig 77 Removing Rear Bumper Cover Lower Section 8 Of 9 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 299: ...ARS CORPORATION REAR BUMPER COVER LOWER SECTION 2010 2011 EARLY REMOVAL Fig 79 Removing Rear Bumper Cover Lower Section All Vehicles 1 Of 8 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 300: ...CLES WITH REAR UNDERBODY AIR DEFLECTOR Fig 81 Removing Rear Bumper Cover Lower Section Vehicles With Rear Underbody Air Deflector Courtesy of VOLVO CARS CORPORATION VEHICLES WITHOUT UNDERBODY AIR DEFLECTORS 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 301: ...y of VOLVO CARS CORPORATION ALL VEHICLES Fig 83 Removing Rear Bumper Cover Lower Section All Vehicles 3 Of 8 Courtesy of VOLVO CARS CORPORATION NOTE This step requires the aid of another technician 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 302: ...ARS CORPORATION Fig 85 Removing Rear Bumper Cover Lower Section All Vehicles 5 Of 8 Courtesy of VOLVO CARS CORPORATION Fig 86 Removing Rear Bumper Cover Lower Section All Vehicles 6 Of 8 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 303: ...ig 88 Removing Rear Bumper Cover Lower Section All Vehicles 8 Of 8 Courtesy of VOLVO CARS CORPORATION INSTALLATION To install reverse the removal procedure REAR BUMPER COVER UPPER SECTION 2007 2011 EARLY 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 304: ...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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 305: ...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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Bumpers And Mudflaps Removal replacement and installation ...

Page 306: ...sy of VOLVO CARS CORPORATION Remove the accelerator pedal AP See ACCELERATOR PEDAL Fold the floor carpet out of the way Remove NOTE Manufacturer s terminology for this filter is passenger compartment air cleaner or particle filter 2012 Volvo C30 T 5 CABIN AIR FILTER Volvo C30 C70 2012 Volvo C30 T 5 CABIN AIR FILTER Volvo C30 C70 ...

Page 307: ...aise 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 INSTALLATION 2012 Volvo C30 T 5 CABIN AIR FILTER Volvo C30 C70 ...

Page 308: ...e rear edge Screw the cover into place at the front edge using the 3 screws Fold back the carpet Install the accelerator pedal AP See ACCELERATOR PEDAL 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 2012 Volvo C30 T 5 CABIN AIR FILTER ...

Page 309: ...e CAN net XXX E003 can be stored in all CAN connected control modules except in Central electronic module CEM The control modules on the CAN net listen for a message identity number that is sent out at regular intervals from Central electronic module CEM This diagnostic trouble code indicates that the control module has not received any identity number or that the expected number is not correct In...

Page 310: ... where the open circuit in the voltage supply occurred as the control module cannot store a diagnostic trouble code DTC when it is not supplied with power 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 2 Ignition Off And Disconnecting Battery N...

Page 311: ...and note if the resistance changes to detect intermittent short circuits or open circuit Remedy wiring as necessary Other information see BATTERY DISCONNECTING see CHECKING WIRING AND TERMINALS NOTE Resistance measurement measures only main lines in the CAN net in circuit where both terminating resistors are found not branches to certain control modules Open circuit on branching without a terminat...

Page 312: ...GROUND VOLTAGE IN CAN NET CHECKING THE TRAFFIC LOAD ON THE CAN CABLES Fig 4 Checking Traffic Load On CAN Cables Courtesy of VOLVO CARS CORPORATION Connect the battery Ignition on 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 2012 Volvo C30 T 5 ELECTRICAL Body Electrical ...

Page 313: ...ol module sending fault messages See tools 951 3010 as well as associated TJ 20402 Ignition on Connect DiCE to the diagnostics socket Note the blue LED indicator The indicator flashes to show detection of fault messages Cable fault Shake the cables lightly and pull lightly on the connections during the check to locate any fault Note the blue LED indicator Chatting control modules Chatting control ...

Page 314: ... Identifying PCM Wiring Terminals Courtesy of VOLVO CARS CORPORATION Was a fault detected YES Refer to IDENTIFYING A CONTROL MODULE IN THE CAN NETWORK NO Refer to CHECKING VOLTAGE DROP IN CABLE FOR CAN H AND CAN L RESPECTIVELY IDENTIFYING A CONTROL MODULE IN THE CAN NETWORK Fig 6 Checking Traffic Load On CAN Cables 2012 Volvo C30 T 5 ELECTRICAL Body Electrical ...

Page 315: ... the following connections on the OBDII box diagnostics socket 3 and 11 The average value of the voltage must be approximately 0 6 1 4 V The voltage shall normally be between 0 55 0 90 V A higher voltage may indicate increased traffic on the CAN net In case of fault in communication too high traffic on the CAN net the voltage is considerably higher than the above stated values In order to identify...

Page 316: ...ON NOTE Do not cut the power to the central electronic module CEM unless it is the last control module left to check NOTE After fault with control modules that interfere with communication other control modules may remain in Limp Home that is they work with reduced functionality even when the ignition has been turned off and on a few times For certain faults in the CAN net where control modules ha...

Page 317: ...diagnostic trouble code DTC for faulty communication return YES Refer to INFORMATION NO OKAY Troubleshooting has been completed CHECKING SHORT CIRCUITING TO GROUND VOLTAGE IN CAN NET Fig 10 Ignition Off And Disconnecting Battery Negative Lead Courtesy of VOLVO CARS CORPORATION Ignition off Disconnect the battery negative lead NOTE For certain faults in the CAN net where control modules have stoppe...

Page 318: ...bove 1 kohms 11 and 16 voltage The resistance should be above 1 kohms If resistance is below 1 kohms this indicates short circuiting between the CAN line and voltage cable Twist the cable harness and wiggle connectors where they can be accessed along the cable harness during every measurement and note if the resistance changes to detect intermittent short circuits or open circuit HINT Part the CAN...

Page 319: ...NG VOLTAGE DROP IN CABLE FOR CAN H AND CAN L RESPECTIVELY Fig 12 Checking Traffic Load On CAN Cables Courtesy of VOLVO CARS CORPORATION Connect the battery Ignition on 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 2012 Volvo C30 T 5 ELECTRICAL Body Electrical ...

Page 320: ...gnostics socket 3 and corresponding connection on relevant control module for CAN H The voltage shall be lower than 50 mV 11 and corresponding connection on relevant control module for CAN L The voltage shall be lower than 50 mV If voltage is too high this indicates too high contact resistance in cable connector or branching Check the circuit between the diagnostics socket and control module in qu...

Page 321: ... 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 Exit fault tracing for this diagnostic trouble code DTC or make another attempt 2012 Volvo C30 T 5 ELECTRICAL Body Electrical ...

Page 322: ...oose the door handle s small interior panel by positioning a weatherstrip in the joint between the top and bottom sections centered between the three retaining catches Removing the door handle panel with door module NOTE Wait at least five minutes before disassembling the connectors or removing other electrical equipment 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Interior Installation Instruction...

Page 323: ... module so that the six clips release and the cosmetic panel releases from the door panel Fig 3 View Of Door Module Connector Courtesy of VOLVO CARS CORPORATION Pull up the panel with door module and unplug the connector on the bottom 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Interior Installation Instructions Accessories ...

Page 324: ... the new panel from the kit and fasten the door module to it Connect the door module connector Press the new panel with door module into place Make sure all catches engage Refit the small interior panel Repeat steps for the other door SUN VISOR CHILD SEAT 2007 2011 SUN VISOR THE SUN VISOR IS SECURED WITH PRESS STUDS OR ELASTIC STRAPS 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Interior Installatio...

Page 325: ...OLVO CARS CORPORATION The sun visor can be attached to the top of the child seat with the press studs Fig 6 Child Seat Sun Visor 1 Of 3 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Interior Installation Instructions Accessories ...

Page 326: ...rest Fig 8 Child Seat Sun Visor 3 Of 3 Courtesy of VOLVO CARS CORPORATION Can also be folded to the side to protect against sunlight through the side window SUN BLIND LUGGAGE COMPARTMENT 2007 2012 SUN BLIND LUGGAGE COMPARTMENT SUN BLIND LUGGAGE COMPARTMENT 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Interior Installation Instructions Accessories ...

Page 327: ...age Compartment Windows Courtesy of VOLVO CARS CORPORATION INSTALLING Fig 10 Identifying Sun Blind Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Interior Installation Instructions Accessories ...

Page 328: ...dentifying 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 do not come loose 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Interior Installation Instructions Accessories ...

Page 329: ...dow 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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Interior Installation Instructions Accessories ...

Page 330: ...4 Courtesy of VOLVO CARS CORPORATION Fig 16 Folding Rear Window Sun Blind 4 of 4 Courtesy of VOLVO CARS CORPORATION SUN BLIND REAR SIDE WINDOW INSTALLING 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Interior Installation Instructions Accessories ...

Page 331: ...ide Window Sun Blind Courtesy of VOLVO CARS CORPORATION Fig 18 Installing Rear Side Window Sun Blind Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Interior Installation Instructions Accessories ...

Page 332: ...t Panel Courtesy of VOLVO CARS CORPORATION Remove the panel between the backrests in the rear seat by inserting your hands between the padding and brackets pressing the four catches and then pulling out the panel Place the panel to one side it shall not be used again 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Interior Installation Instructions Accessories ...

Page 333: ...lder Then at the front edge where it is secured by two holders Remove the seat cushion Fig 22 View Of Panel For The Backrest s Left Hand Mounting Courtesy of VOLVO CARS CORPORATION Fold the backrest forward Remove the panel for the backrest s left hand mounting 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Interior Installation Instructions Accessories ...

Page 334: ...ON Fig 24 Removing Backrest Courtesy of VOLVO CARS CORPORATION Fold the backrest away from the left hand mounting Pull it out from the mounting towards the right hand side INSTALL 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Interior Installation Instructions Accessories ...

Page 335: ...OLVO CARS CORPORATION Install the new bearing on the backrest s shaft journal Ensure that the control arm s lug 1 locates in the underneath of the shaft journal s hook 2 Press the control arm on the shaft journal until the hooks engage 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Interior Installation Instructions Accessories ...

Page 336: ... 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 Tighten the backrest and check that it is securely in its mountings Torque tighten the screw to 15 Nm 11 lbf ft 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Interior Installation Instructions Accessories ...

Page 337: ...ver Courtesy of VOLVO CARS CORPORATION Fig 30 Repositioning Backseat Courtesy of VOLVO CARS CORPORATION Repeat points for the other backrest 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Interior Installation Instructions Accessories ...

Page 338: ...n the central armrest s cut out 3 Then press the central armrest down at the rear edge so that the lugs 1 engage in the cut out 4 A click should be heard when the central armrest is secured Fig 32 Installing Rear Seat Cushion Courtesy of VOLVO CARS CORPORATION CHILD SEAT EYELETS 2007 2011 CHILD SEAT EYELETS REMOVE INSTALL 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Interior Installation Instructio...

Page 339: ...TION 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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Interior Installation Instructions Accessories ...

Page 340: ... and the seat rail while guiding the wings rearward Do the same on the right side of the seat Fig 36 View Of Eyelet Through The Square Hole Courtesy of VOLVO CARS CORPORATION Fit the eyelet through the square hole on the left seat wing Do the same on the right side 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Interior Installation Instructions Accessories ...

Page 341: ...d seat wings in a suitable spot so that they can be reinstalled if the child seat eyelets are removed WARNING Never place the child seat on the front passenger seat if the car is equipped with activated SRS Airbag on the passenger side If you have difficulties installing a child safety product contact the manufacturer for clearer installation instructions 2012 Volvo C30 T 5 ACCESSORIES AND BODY CA...

Page 342: ...9 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 Nm 7 5 lbf ft Reset the backrest CHILD SEAT MOUNTING KIT 2007 2011 MOUNTING KIT CHILD SEAT FRONT 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Interior Installation Instructions Accessories ...

Page 343: ...ON 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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Interior Installation Instructions Accessories ...

Page 344: ... tighten the screw to 24 Nm 18 lbf ft Fig 43 Identifying Floor Carpet Mounting Eyelet Marking Courtesy of VOLVO CARS CORPORATION Fold the floor carpet back under the mounting Mark with a pen where the mounting eyelet shall go through the carpet 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Interior Installation Instructions Accessories ...

Page 345: ... opposite the marking equally as wide as the mounting eyelet Fig 45 View Of Refit Carpet Over Mounting Eyelet Courtesy of VOLVO CARS CORPORATION Fold the carpet back over the mounting eyelet and refit it at the center console 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Interior Installation Instructions Accessories ...

Page 346: ...ve the screw in the mounting Fig 47 Identifying Mounting Screw Courtesy of VOLVO CARS CORPORATION Make a small T shape cut in the floor carpet equally as wide as the mounting eyelet on the mounting in the position as illustrated Use the mounting to mark where the small cut should be located 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Interior Installation Instructions Accessories ...

Page 347: ...mounting eyelet through the small cut in the floor carpet Position the mounting over the hole and the guide pin in the seat rail with the washer on top Reinstall the screw Torque tighten the screw to 50 Nm 37 lbf ft Reinstall the cover panel over the seat mounting 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Interior Installation Instructions Accessories ...

Page 348: ...the protective cushion and locate the child seat in its correct position with the protective cushion between the seat s backrest and the dashboard The lower edge of the protective cushion must be approximately edge to edge with the lower edge of the dashboard Mark out the lower edge of the protective cushion on the end face of the seat with a strip of tape 2012 Volvo C30 T 5 ACCESSORIES AND BODY C...

Page 349: ...f 30 washer fluid and 70 water as indicated by the marking Wipe dry Fig 53 Identifying Protective Cushion Velcro Strap Courtesy of VOLVO CARS CORPORATION Pull off one Velcro strap from the protective cushion NOTE Do not pull only on the white protective tape 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Interior Installation Instructions Accessories ...

Page 350: ...and according to the tape marking in the lower edge Press the protective cushion into the seat s backrest Remove the tape marking ISOFIX ATTACHMENT CHILD SEAT FRONT 2007 2012 ISOFIX ATTACHMENT CHILD SEAT FRONT REMOVE INSTALL Fig 55 Folding Backrest Forward On Front Passenger Side Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Interior Installation Instructions Acces...

Page 351: ...IX attachment to the SIPS tube with the four screws from the kit Tighten the screws to 10 Nm 7 5 lbf ft Reset the backrest ISOFIX GUIDE 2007 2012 ISOFIX GUIDE INSTALLING REMOVING THE ISOFIX GUIDE Illustration applies to the passenger seat and car models 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Interior Installation Instructions Accessories ...

Page 352: ...ss the Isofix guide 1 into place between the backrest and seat cushion Press it down to the Isofix mountings The Isofix mountings must be visible in the guide s 1 openings Check that the guide is correctly installed Removing the Isofix guide Grip the outer edges Carefully pull the guide outwards 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Interior Installation Instructions Accessories ...

Page 353: ... CORPORATION 1 Climate control unit ECC or MCC 2 Outside temperature sensor left hand side 3 Passenger compartment temperature sensor ECC 4 Sun sensor ECC NOTE The graphics in this service information are used for different model years and or models Some variation may occur However the essential information in the graphics is always correct 2012 Volvo C30 T 5 HVAC Climate Units Component Location ...

Page 354: ...ator 3 Fan motor 4 Damper motor module DMM air distribution 5 Damper motor module DMM temperature right hand 6 Damper motor module DMM temperature left hand 7 Damper motor module DMM recirculation 8 Damper motor module DMM defroster 9 Evaporator temperature sensor 10 Air cleaner ACL passenger compartment LOCATING COMPONENTS IN THE ENGINE COMPARTMENT 2012 Volvo C30 T 5 HVAC Climate Units Component ...

Page 355: ... Pipe hose between condenser and expansion valve 6 The pipe between the expansion valve and the evaporator 7 Service valve LT draining filling vacuum pumping 8 Pipe hose between evaporator and receiver 9 Receiver 10 Pipe hose between receiver and compressor 11 2 pressure sensors COMPONENT LOCATION CLIMATE CONTROL MODULE CCM 2007 LOCATION OF COMPONENTS 2012 Volvo C30 T 5 HVAC Climate Units Componen...

Page 356: ...S CORPORATION Overview passenger compartment 1 Climate control module CCM 2 Switch for STC DSTC 3 Passenger compartment temperature sensor with blower fan 4 Seat heating module SHM left 5 Seat heating module SHM right 2012 Volvo C30 T 5 HVAC Climate Units Component Location ...

Page 357: ...ht Only applies to vehicles equipped with ECC 3 Damper motor module DMM defroster 4 Damper motor module DMM air distribution 5 Damper motor module DMM temperature left 6 Air quality sensor AQS 7 Evaporator temperature sensor Only applies to vehicles equipped with ECC COMPONENT LOCATION CLIMATE CONTROL MODULE CCM 2008 12 COMPONENT LOCATION 2012 Volvo C30 T 5 HVAC Climate Units Component Location ...

Page 358: ...iew 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 Seat heating module SHM left 6 Seat heating module SHM right 2012 Volvo C30 T 5 HVAC Climate Units Component Location ...

Page 359: ... air distribution 5 Damper motor module DMM temperature left 6 Air quality sensor AQS 7 Evaporator temperature sensor Only applies to vehicles equipped with ECC AUXILIARY HEATER FUEL OPERATED FUEL FIRED BOOSTER HEATER NOTE The graphics in this service information are used for different model years and or models Some variation may occur However the essential information in the graphics is always co...

Page 360: ...nt heater with radiator hose connections exhaust system and external water pump D5WS and B5WS 2 Fuel pump FP with fuel hoses pipes to and from the fuel pump FP This is located in the rear axle behind the fuel tank 3 Fuel hoses pipes with suction hose on the fuel tank unit suction and pressure hoses to and from the fuel pump FP above the fuel tank 2 as well as pressure hoses pipes under the vehicle...

Page 361: ...Fig 9 Identifying Booster Heater Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 HVAC Climate Units Component Location ...

Page 362: ...n shroud 3 Fan motor 4 Heat exchanger together with housing 5 Water temperature sensor and overheat protection thermostat together cable harness 6 Combustion chamber 7 Flame sensor 8 Glow plugs COMPONENT LOCATION COMBUSTION PREHEATER MODULE CPM LOCATION OF COMPONENTS 2012 Volvo C30 T 5 HVAC Climate Units Component Location ...

Page 363: ...ng 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 3 Fuel pump FP 2012 Volvo C30 T 5 HVAC Climate Units Component Location ...

Page 364: ...lete control module that has many different functions in addition to controlling the climate functions REMOVAL NOTE The illustrations in this service information are used for different model years and or models Some variation may occur However the essential information is always correct 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation 2012 Volvo C30 T 5 HVAC Climate Units...

Page 365: ...ition 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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 366: ...ourtesy 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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 367: ...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 Remove the 2 connectors from the infotainment control module ICM the connector from the center console 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 368: ...move the panel See POWER SOCKET 12V 2007 or POWER SOCKET 12V 2008 2012 the 4 screws Unclip the gear selector lever boot Lift the center console up out REMOVING THE CLIMATE CONTROL MODULE CCM 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 369: ...Fig 6 Identifying Screws Courtesy of VOLVO CARS CORPORATION Remove the 8 screws 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 370: ...CCM Install the climate control module CCM on the front section of the center console the 4 x screws Tighten See TIGHTENING TORQUE the rear section of the center console the 8 screws Tighten See TIGHTENING TORQUE INSTALLING CENTER CONSOLE CAUTION Tighten the screws carefully There is a risk of cracks forming 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 371: ...JUSTING 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 AIR DISTRIBUTION DRIVER SIDE REGISTER 2010 2012 CENTER VENTILATION VENT REPLACING REMOVING THE CENTER VENTILATION VENT C30 30...

Page 372: ...tch TRANSFERRING COMPONENTS Transfer the switch for the hazard warning signal flashers to the new ventilation vent housing INSTALLING THE CENTER VENTILATION VENT Install the connector the vent housing Ensure that the hooks engage properly First locate the ventilation grilles in the outer mountings Then press the grilles into place OUTER VENTILATION VENTS REPLACING 2012 Volvo C30 T 5 HVAC Climate U...

Page 373: ...stall the vent housing Ensure that the hooks engage properly First locate the ventilation grilles in the inner mountings Then press the grilles into place POLLEN FILTER CLIMATE CONTROL SYSTEM 2007 PREPARATORY WORK 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 alw...

Page 374: ...OR 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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 375: ...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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 376: ...back the carpet Install the accelerator pedal AP See ACCELERATOR PEDAL POLLEN FILTER CLIMATE CONTROL SYSTEM 2008 2012 REMOVAL INSTALLATION 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 NOTE Removal steps in this procedure may contain ...

Page 377: ...3 Identifying Screws Courtesy of VOLVO CARS CORPORATION Torque M6 10 Nm Fig 14 Identifying Screw Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 378: ...ATION VENTILATION DUCT FOOT SPACE REAR REMOVE INSTALL 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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 379: ... Ducts Courtesy of VOLVO CARS CORPORATION AIR DISTRIBUTION UNIT DASHBOARD LOUDSPEAKER REPLACING REMOVING THE AIR DISTRIBUTION UNIT FROM THE DASHBOARD 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 380: ...e connector for the sun sensor alarm LED INSTALLING THE AIR DISTRIBUTION UNIT IN THE DASHBOARD Install the air distribution unit to the air ducts for the outer vents the cable duct using the 3 screws and 2 tie straps the connector for the sun sensor alarm LED the dashboard See DASHBOARD AIR DUCT OUTER VENT REPLACING REMOVING AIR DUCT OUTER VENT 2012 Volvo C30 T 5 HVAC Climate Units Removal Replace...

Page 381: ...ard upside down Remove the screw and pull the duct away from the air vent INSTALLING AIR DUCT OUTER VENT Install the duct for the outer air vents the screw the dashboard See DASHBOARD AIR DUCT FRONT FLOOR REPLACING REMOVING AIR DUCT FRONT FLOOR Remove 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 382: ...OR Install the air duct on the driver s side Press the air duct into place and finger tighten the screw the soundproofing panel on the driver s side See INSTRUMENT PANEL LOWER the air duct on the passenger side Press the air duct into place and finger tighten the screw the glove compartment See GLOVE COMPARTMENT the lower soundproofing panel on the passenger side using the 2 clips AIR DUCT FLOOR C...

Page 383: ...er Pull the duct forwards Detach the duct from the cross member INSTALLING CENTER AIR DUCT TO FLOOR REAR PASSENGER COMPARTMENT Install the duct in the cross member and the front section of the duct in the upper mounting the rear air vent the floor carpet the front sill trim panel see SILL EDGE the center console See INSTALLING CENTER CONSOLE the front seat as described in see FRONT SEAT AIR DUCT F...

Page 384: ...ottom edge and connect the 2 floor ducts Then connect it at the top edge the center console See INSTALLING CENTER CONSOLE SILL EDGE FRONT DOOR SILL TRIM PANEL REPLACING REMOVING THE SILL TRIM PANEL FROM THE FRONT SIDE DOOR 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 illustratio...

Page 385: ...G THE SILL TRIM PANEL FOR THE FRONT SIDE DOOR Secure the front mount against the dashboard Press the sill trim panel into place REAR DOOR SILL TRIM PANEL REPLACING REMOVING THE SILL TRIM PANEL FROM THE REAR SIDE DOOR CAUTION Ensure that the sill trim panel goes into the groove at the B pillar panel 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 386: ... panel INSTALLING THE SILL TRIM PANEL FOR THE REAR SIDE DOOR Secure the rear mount against the C post panel Press the sill trim panel into place SILL TRIM PANEL TRUNK LID REPLACING REMOVING THE SILL TRIM PANEL TRUNK LID CAUTION Ensure that the sill trim panel goes into the groove at the B pillar panel 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 387: ...traight up INSTALLING THE SILL TRIM PANEL TRUNK LID Press the sill trim panel into place Install the 2 screw clips Fold the cargo compartment floor down CLIMATE UNIT ACTUATOR DAMPER CLIMATE CONTROL SYSTEM DRIVER S SIDE NOTE The illustrations in this service information are used for different model years 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 388: ...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 and or models Some variation may occur However the essential information in the illustrations is always correct 2012 Volvo C30 T 5 HVAC Climate Units Removal Rep...

Page 389: ...R PREPARATORY WORK IMPORTANT INFORMATION The damper motor module DMM for air distribution is only on the left hand side REMOVING THE DASHBOARD Remove the dashboard See DASHBOARD REMOVAL REMOVING THE DAMPER MOTOR MODULE DMM FOR AIR DISTRIBUTION NOTE Identify the damper motor module DMM temperature See VIDA Volvo scan tool Vehicle communication NOTE The illustrations in this service information are ...

Page 390: ...t the lock Pull the connector off Remove the 3 screws the control module INSTALLATION INSTALLING THE DAMPER MOTOR MODULE DMM FOR AIR DISTRIBUTION Install the control module in position Adjust the shaft journal so that it goes in the 3 screws Tighten crosswise the switch the dashboard See DASHBOARD 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 391: ...PARTMENT REMOVAL REMOVING THE DAMPER MOTOR MODULE DMM FOR RECIRCULATION NOTE Identify the damper motor module DMM air distribution See VIDA Volvo scan tool Vehicle communication 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 2012 Volvo C30 T 5 HVAC ...

Page 392: ...lock Pull the connector off Remove the 4 screws the control module INSTALLATION INSTALLING THE DAMPER MOTOR MODULE DMM FOR RECIRCULATION Install the control module in position Adjust the shaft journal so that it goes in the 4 screws Tighten crosswise the switch the glove compartment See GLOVE COMPARTMENT 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 393: ...NG THE DASHBOARD Remove the dashboard See DASHBOARD REMOVAL REMOVING THE DAMPER MOTOR MODULE DMM FOR THE DEFROSTER NOTE Identify the damper motor module DMM recirculation See VIDA Volvo scan tool Vehicle communication 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...

Page 394: ... at the lock Pull the connector off Remove the 3 screws the control module INSTALLATION INSTALLING THE DAMPER MOTOR MODULE DMM FOR THE DEFROSTER Install the control module in position Adjust the shaft journal so that it goes in the 3 screws Tighten crosswise the switch the dashboard See DASHBOARD 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 395: ...Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Ignition off NOTE Identify the damper motor module DMM defroster See VIDA Volvo scan tool Vehicle communication 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 2012 Volvo C30 T 5 HVAC Climat...

Page 396: ...mately 60 degrees counter clockwise Disconnect the connector INSTALLATION INSTALLING THE AIR QUALITY SENSOR AQS Connect the connector Position the air quality sensor AQS in the groove Turn the air quality sensor AQS approximately 60 degrees clockwise until it stops Check that it is secure Install the glove compartment See GLOVE COMPARTMENT FINISHING Order software C30 30782266 TESTING THE AIR QUAL...

Page 397: ...g 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 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 2012 Volvo C30 T 5 HVAC Climate Units Removal...

Page 398: ...ality sensor is fault free the damper will gradually open after approximately 15 seconds FINISHING FINISHING 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 NOTE Only spray a little 20...

Page 399: ...D 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 CAUTION Do not touch the fan motor s fan rotor This is to avoid damage to the fan blades which can cause imbalance in the fan rotor NOTE Do not place the fan motor on the fan rotor 2012 Volvo C30 T 5 ...

Page 400: ...nector for the damper motor module DMM recirculation the damper motor module DMM recirculation See ACTUATOR RECIRCULATION the 3 screws for the air distribution damper cover the cover for the air distribution damper REMOVAL REMOVING THE BLOWER FAN MOTOR 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 401: ... 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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 402: ...ck 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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 403: ... Fan Motor Courtesy of VOLVO CARS CORPORATION Remove the fan motor from the passenger side Use see 9997115 INSTALLATION INSTALLING THE BLOWER FAN MOTOR 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 404: ...ition Connect the connector Install the cover for the air distribution damper using the 3 screws Tighten the damper motor module DMM recirculation See ACTUATOR RECIRCULATION the connector for the damper motor module DMM recirculation the air quality sensor AQS FINISHING TESTING THE FAN MOTOR NOTE Turn the fan motor to the position for installation 2012 Volvo C30 T 5 HVAC Climate Units Removal Repl...

Page 405: ...NG COMPONENTS 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 WARNING Follow the safety instructions for work on air conditioning systems See REFRIGERANT CAUTION Always use new O rings lubricated with compressor oil NOTE Plug the pipes and connection...

Page 406: ...on tank cap Raise the vehicle Remove the shield under the vehicle It is secured with 7 clips Install a hose on the nipple at the radiator Feed the hose down to a container Open the nipple Drain off the engine coolant 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 407: ...Identifying Dashboard Courtesy of VOLVO CARS CORPORATION Remove the dashboard See DASHBOARD REMOVAL REMOVING THE CLIMATE CONTROL UNIT 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 408: ...ead 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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 409: ...m 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 Pull the pipes off from the evaporator connection Separate the pipes to the heat exchanger see HEAT EXCHANGER 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 410: ...the right hand side under the heat exchanger housing the climate control unit INSTALLATION INSTALLING THE CLIMATE CONTROL UNIT Install the climate control unit the drainage hose from the heat exchanger housing Install the pipes to the heat exchanger See HEAT EXCHANGER NOTE For tightening torques see TIGHTENING TORQUE 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 411: ...diator Fill with coolant and warm up the engine until the thermostat opens Top up if necessary Check that the pipe coupling does not leak FINISHING ACCUMULATOR REPLACEMENT WITH FUNCTION CHECK AND LEAK DETECTION Replace ACCUMULATOR Vacuum pump the air conditioning A C system See VACUUM PUMPING Fill the AC system with refrigerant acc to REFRIGERANT FILLING Leak trace the air conditioning A C system ...

Page 412: ... COMPONENTS Read the instructions for slow and fast leaks acc to AC SYSTEM OIL REFILLING 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 WARNING Follow the safety instructions for work on air conditioning systems See REFRIGERANT 2012 Volvo C30 T 5 HV...

Page 413: ...EARLY or COVER BUMPER FRONT 2011 LATE 2012 Remove the front edge of the right hand fender liner the plastic nut x 1 the retaining clip against the engine cover under the vehicle REMOVAL REMOVING RECEIVER CAUTION Always use new O rings lubricated with compressor oil NOTE Plug the pipes and connections when working on the climate control system 2012 Volvo C30 T 5 HVAC Climate Units Removal Replaceme...

Page 414: ...ARS 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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 415: ...ntifying Pipe Hose Connector Courtesy of VOLVO CARS CORPORATION Disconnect the pipe hose connection to the receiver See the illustration 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 416: ...TION INSTALLING RECEIVER Fill the recommended volume of compressor oil See AC SYSTEM OIL REFILLING Install NOTE For tightening torques see TIGHTENING TORQUE NOTE Install the receiver within 5 10 minutes of the plugs having been removed This prevents the absorbent material absorbing moisture from the air 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 417: ...G ELECTRONIC LEAK TRACER 2008 09 INSTALLING COMPONENTS AND CHECKING PERFORMANCE Install the bumper cover See COVER BUMPER FRONT 2007 2011 EARLY or COVER BUMPER FRONT 2011 LATE 2012 right hand front headlamp See HEADLAMP BULB 2007 or HEADLAMP BULB 2008 2012 Carry out a performance test on the climate control unit See CLIMATE CONTROL SYSTEM CHECK ELECTRIC BOOSTER HEATER 2007 PREPARATORY WORK REMOVIN...

Page 418: ...rs Courtesy of VOLVO CARS CORPORATION Remove the cable harness from the mounting bracket This is secured with 2 clips the 4 screws Remove the right hand mounting bracket the 2 clamps for the cable harness the 3 connectors 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 419: ...e that it is situated horizontally and engages in the guide pins on the opposite side Install the 2 screws Tighten the 2 clamps for the cable harness WARNING Do not perform any work on the electrical preheater until the heating coil has cooled to ambient temperature NOTE For tightening torques see TIGHTENING TORQUE 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 420: ...n depends on the following factors The electrical preheater is only activated at ambient temperatures lower than 10 C When the coolant temperature reaches 70 C the preheater is disconnected It is subsequently only activated when the coolant temperature drops below 60 C The electrical preheater is activated depending on the capacity of the generator GEN ELECTRIC BOOSTER HEATER 2008 2012 PREPARATORY...

Page 421: ...rs Courtesy of VOLVO CARS CORPORATION Remove the cable harness from the mounting bracket This is secured with 2 clips the 4 screws Remove the right hand mounting bracket the 2 clamps for the cable harness the 3 connectors 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 422: ...e that it is situated horizontally and engages in the guide pins on the opposite side Install the 2 screws Tighten the 2 clamps for the cable harness WARNING Do not perform any work on the electrical preheater until the heating coil has cooled to ambient temperature NOTE For tightening torques see TIGHTENING TORQUE 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 423: ...r is regulated by the central electronic module CEM and regulation depends on the following factors The electrical preheater is only activated at ambient temperatures lower than 10 C When the coolant temperature reaches 70 C the preheater is disconnected It is subsequently only activated when the coolant temperature drops below 60 C The electrical preheater is activated depending on the capacity o...

Page 424: ...g Radiator Hoses Courtesy of VOLVO CARS CORPORATION Lower the vehicle Detach the radiator hoses from the engine compartment Turn the radiator hose connection counter clockwise to the end position and then pull off the radiator hose REMOVAL Remove the center console See REMOVING CENTER CONSOLE the glove compartment See GLOVE COMPARTMENT Detach the central electrical unit from its bracket but allow ...

Page 425: ...s for the cover Pull the cover at angle downwards backwards Heat exchanger See HEAT EXCHANGER Fig 55 Identifying Heat Exchanger Pipes Courtesy of VOLVO CARS CORPORATION NOTE The heat exchanger has pipes that are factory integrated These pipes must be cut in order to remove the unit The heat exchanger in the service kit has separate pipes however 2012 Volvo C30 T 5 HVAC Climate Units Removal Replac...

Page 426: ...e lead in s right half the section that holds the heat exchanger and evaporator pipes apart Pull the heat exchanger pipes through the seal Seal the pipes to the heat exchanger so that the remaining coolant cannot run out Angle the heat exchanger up at the rear edge Lift out the heat exchanger towards the passenger side INSTALLATION Install the heat exchanger NOTE Note how the seal is located on th...

Page 427: ...ips Courtesy of VOLVO CARS CORPORATION Install the clips so that they lock securely A click must be heard Fig 58 Identifying Screws For Cover Air Duct And Brackets On Both Sides Of Climate Control Units Courtesy of VOLVO CARS CORPORATION NOTE Use new O rings for the pipe ends NOTE The clips only fit one way in the pipe connection 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Instal...

Page 428: ... the firewall Tighten the drain nipple on the radiator Fill with coolant and warm up the engine until the thermostat opens Top up the coolant if necessary Check that the pipe coupling does not leak Install the glove compartment See GLOVE COMPARTMENT TEMPERATURE SENSOR PASSENGER COMPARTMENT PREPARATORY WORK COMPONENT OVERVIEW NOTE The illustrations in this service information are used for different...

Page 429: ...O 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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 430: ...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 REMOVAL REMOVING THE BLOWER FAN MOTOR PASSENGER COMPARTMENT TEMPERATURE SENSOR 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 431: ... FAN MOTOR PASSENGER COMPARTMENT TEMPERATURE SENSOR Install the blower fan with the passenger compartment temperature sensor the connector the driver s side soundproofing panel using the 3 screws and the clip the end cover the panel inside the center console COOLING UNIT AC COMPRESSOR 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 432: ...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 WARNING Follow the safety instructions for work on air conditioning systems See REFRIGERANT CAUTION Always use new O rings lubricated with compressor oil NOTE Plug the pipes and connections when working on the c...

Page 433: ...g Shield And Clips Courtesy of VOLVO CARS CORPORATION Remove the cover under the vehicle It is secured with 7 clips REMOVAL REMOVING COMPRESSOR 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 434: ...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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 435: ...y of VOLVO CARS CORPORATION the 3 mounting screws for the compressor Remove the compressor INSTALLATION INSTALLING THE COMPRESSOR NOTE For tightening torques see TIGHTENING TORQUE 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 436: ...ow the installation instruction to make sure of the AC compressor s position In case of wrong installation order the AC compressor ends up at an angle This leads to incorrect loading on the belt tensioner as well as displacement of the belt and subsequent belt failure Connect the connector Install the pipe connections 2 M8 1 and 2 Ensure that the O rings are securely located between the compressor...

Page 437: ...oning A C system See LEAK DETECTION TRACER AGENT LEAK TRACING ELECTRONIC LEAK TRACER 2007 2010 11 or LEAK TRACING ELECTRONIC LEAK TRACER 2008 2009 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 2012 Volvo C...

Page 438: ...f the right hand fender liner the plastic nut x 1 the retaining clip against the engine cover under the vehicle REMOVAL REMOVING RECEIVER 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 WARNING Follow the safety instructions for work on air condition...

Page 439: ...ARS 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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 440: ...ntifying Pipe Hose Connector Courtesy of VOLVO CARS CORPORATION Disconnect the pipe hose connection to the receiver See the illustration 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 441: ...TION INSTALLING RECEIVER Fill the recommended volume of compressor oil See AC SYSTEM OIL REFILLING Install NOTE For tightening torques see TIGHTENING TORQUE NOTE Install the receiver within 5 10 minutes of the plugs having been removed This prevents the absorbent material absorbing moisture from the air 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 442: ...the bumper cover See COVER BUMPER FRONT 2007 2011 EARLY or COVER BUMPER FRONT 2011 LATE 2012 right hand front headlamp See HEADLAMP BULB 2007 or HEADLAMP BULB 2008 2012 Carry out a performance test on the climate control unit See CLIMATE CONTROL SYSTEM CHECK CONDENSER B5244S4 B5254T3 PREPARATORY WORK DRAINING THE AIR CONDITIONING A C SYSTEM Read the instructions for slow and fast leaks acc to AC S...

Page 443: ... BUMPER FRONT 2011 LATE 2012 the left hand headlamp See HEADLAMP BULB 2007 or HEADLAMP BULB 2008 2012 the 2 screws 1 and 2 at the condenser connection see the illustration the air conditioning unit See RADIATOR B5244S4 or RADIATOR B5254T3 B5254T7 REMOVAL REMOVING THE CONDENSER NOTE Plug the pipes and connections when working on the climate control system 2012 Volvo C30 T 5 HVAC Climate Units Remov...

Page 444: ... the catch Carefully pry off both sides using a screwdriver Remove the condenser from the air conditioning unit INSTALLATION INSTALLING THE CONDENSER NOTE For tightening torques see TIGHTENING TORQUE 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 445: ...e condenser with oil See AC SYSTEM OIL REFILLING Press the condenser into the mounting points FINISHING CHECKING THE FUNCTION AND LEAK TRACING NOTE Ensure that both retaining clips secure the condenser 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 446: ...ill the AC system with refrigerant acc to REFRIGERANT FILLING 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 INSTALLING COMPONENTS Install the left hand headlamp See HEADLAMP BULB 2007 or HEADLAMP BULB 2008 2012 the bumper shell See COVER BUMPER FRONT 2011 LATE 2012 or COVE...

Page 447: ...ations 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 WARNING Follow the safety instructions for work on air conditioning systems See SAFETY INFORMATION COOLING SYSTEM CAUTION Always use new O rings lubricated with compressor oil NOTE Plug the pipes and connections when w...

Page 448: ...Fig 75 Identifying Screws And Cover From Frame Courtesy of VOLVO CARS CORPORATION Remove the 4 screws the cover from the frame 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 449: ... 76 Identifying Condenser Courtesy of VOLVO CARS CORPORATION Lift the condenser straight up INSTALLATION INSTALLING THE CONDENSER 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 450: ...for the frame the 4 screws INSTALLING THE COOLER UNIT Install the air conditioning aggregate See RADIATOR B5244S4 or RADIATOR B5254T3 B5254T7 FINISHING FILLING WITH REFRIGERANT AND LEAK TRACING Vacuum pump the air conditioning A C system See VACUUM PUMPING Fill the system See REFRIGERANT FILLING 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 451: ...ools see 9995596 see 9995598 see 9995599 see 9995600 see 9995597 see 9995602 PREPARATORY WORK REMOVING COMPONENTS 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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 452: ...Courtesy of VOLVO CARS CORPORATION Raise the vehicle Remove the shield under the vehicle It is secured with 7 clips See the illustration the right hand front wheel 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 453: ...ch the front edge of the right hand fender liner Fold the fender backwards See the illustration the right hand screw securing the air baffle the auxiliary unit belts acc to See ACCESSORY DRIVE BELT TENSIONER REMOVAL REMOVING THE MAGNETIC CLUTCH COMPRESSOR 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 454: ...80 Identifying Clutch Plate And Counterhold Courtesy of VOLVO CARS CORPORATION Remove the screw for the flex plate Use see 9995596 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 455: ...Fig 81 Identifying Shims Courtesy of VOLVO CARS CORPORATION the flex plate Use see 9995596 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 456: ...Fig 82 Identifying Snap Ring Courtesy of VOLVO CARS CORPORATION the snap ring 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 457: ...Fig 83 Identifying Puller And Socket Courtesy of VOLVO CARS CORPORATION Pull off the pulley Use see 9995598 and see 9995599 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 458: ... to the clip securing the cable above the compressor Tap it in out using a 3 mm drift INSTALLATION INSTALLING THE MAGNETIC CLUTCH FOR THE COMPRESSOR NOTE Note the position of the solenoid coils cable in relation to the compressor housing It should be located under cover panel 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 459: ...ve the cable from the solenoid coil connector Thread the cable between the belt tensioner and the top edge of the compressor Install the cable and the retaining clip See the illustration the compressor using the 3 M8 screws Tighten the cable to the connector Connect the connector 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 460: ...ON the solenoid coil using the 3 screws NOTE Make sure that the solenoid coils cable is located correctly in relation to the compressor housing The cable should be located under cover panel 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 461: ...d 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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 462: ...ims 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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 463: ...en 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 Replace the shims if the clearance is not within the stated values FINISHING INSTALLING COMPONENTS 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 464: ...front wheel the shield under the vehicle using the 7 clips See the illustration EVAPORATOR PREPARATORY WORK IMPORTANT INFORMATION Drain refrigerant from the A C system See REFRIGERANT DRAINING 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 2012 Volv...

Page 465: ... vehicle It is secured with 7 clips See the illustration Install a hose on the nipple at the radiator Feed the hose down to a container Open the nipple Drain off the engine coolant Disconnect the quick release connectors for the cooler hoses at the cowl panel in the engine compartment REMOVING COMPONENTS Remove 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 466: ...g 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 the bracket the heat exchanger See HEAT EXCHANGER 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation...

Page 467: ...crew securing the air conditioning A C pipes to the evaporator See the illustration Pull the pipes off from the evaporator connection REMOVAL REMOVING THE EVAPORATOR The evaporator has pipes that are integrated in the factory These pipes must be cut in order to remove the unit The evaporator in the service kit has separate pipes however 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And...

Page 468: ...rtesy of VOLVO CARS CORPORATION Remove the 2 screws and remove the right hand half of the lead in See the illustration the section that holds the heat exchanger and evaporator pipes apart 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 469: ...vaporator Pipes Courtesy of VOLVO CARS CORPORATION Cut off the evaporator pipes Pull and press out the pipes through the seal See the illustration 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 470: ...lternately at the top and bottom edges It may be hard to remove INSTALLATION INSTALLING THE EVAPORATOR Install a new seal using the removed evaporator as a template NOTE Note how the seal is located on the evaporator NOTE For tightening torques see TIGHTENING TORQUE 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 471: ...f the cover between the evaporator and the heater unit Tighten the 3 screws Install the loose pipe section between the evaporator and the connection in the engine compartment Start by inserting it through the lead in seal Then connect the block mounting to the evaporator using 2 M5 screws Tighten See TIGHTENING TORQUE 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 472: ...compartment See TIGHTENING TORQUE the heat exchanger See HEAT EXCHANGER the central electrical unit bracket using the 2 nuts Install the cable harness the central electrical unit on the bracket See CONTROL MODULE RELAY BOX PASSENGER COMPARTMENT the center console See INSTALLING CENTER CONSOLE NOTE Pull the insulation for the pipes as far in towards the evaporator as possible before installing the ...

Page 473: ...nditioning A C system See VACUUM PUMPING Fill the air conditioning A C system with refrigerant See REFRIGERANT FILLING 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 2012 Volvo C30 T 5 HVAC Clima...

Page 474: ...EMOVING THE EXPANSION VALVE ORIFICE 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 WARNING Follow the safety instructions for work on air conditioning systems See REFRIGERANT CAUTION Always use new O rings lubricated with compressor oil NOTE Plug th...

Page 475: ... See the illustration It is not screwed in place HINT The expansion valve can be removed using round nosed pliers INSPECTING THE FILTER SECTION OF THE EXPANSION VALVE NOTE Make a note of the position of the expansion valve in the pipe CAUTION Make sure that the expansion valve does not come off 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 476: ...e clogged B the compressor oil must be inspected If the filter is extremely clogged or if it contains a large volume of metal particles the compressor may need to be replaced If the compressor oil is black or very dirty replace the compressor If the compressor is dry replace the compressor INSTALLATION 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 477: ...ACING ELECTRONIC LEAK TRACER 2008 2009 or LEAK TRACING ELECTRONIC LEAK TRACER 2007 2010 11 CHECKING THE PERFORMANCE Carry out a performance test on the climate control unit See CLIMATE CONTROL SYSTEM CHECK LOW PRESSURE SWITCH CLIMATE CONTROL REMOVE INSTALL Fig 102 Identifying Low Pressure Switch Climate Control Courtesy of VOLVO CARS CORPORATION NOTE Make sure that the expansion valve is properly ...

Page 478: ...NT DRAINING REMOVAL REMOVING THE NEEDLE VALVE SERVICE VALVE NOTE For tightening torques see TIGHTENING TORQUE 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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 479: ...see 9511204 Use see 9811994 and tighten see TIGHTENING TORQUE FINISHING CHECKING THE FUNCTION AND LEAK TRACING Vacuum pump the air conditioning A C system See VACUUM PUMPING Fill the air conditioning A C system with refrigerant See REFRIGERANT FILLING NOTE Use only your finger and thumb when tightening the needle valve to avoid damage to the valve seal 2012 Volvo C30 T 5 HVAC Climate Units Removal...

Page 480: ...leaks acc to AC SYSTEM OIL REFILLING Drain the refrigerant from the AC system acc to REFRIGERANT DRAINING REMOVING THE SHIELD 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 WARNING Follow the safety instructions for work on air conditioning systems ...

Page 481: ...the vehicle Remove the shield under the vehicle It is secured with 7 clips PIPE HOSE BETWEEN COMPRESSOR AND CONDENSER PRESSURE SIDE REPLACING REMOVING THE PIPE HOSE BETWEEN THE COMPRESSOR AND THE CONDENSER 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 482: ...r pipe hose connector 1 on the compressor the front bumper cover See COVER BUMPER FRONT 2010 2011 EARLY COVER BUMPER FRONT 2011 LATE 2012 the lower connector for the charge air hose to the charge air cooler CAC on the right hand side 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 483: ...the pipe hose down to the compressor under the vehicle INSTALLING THE PIPE HOSE BETWEEN THE COMPRESSOR AND THE CONDENSER Place the pipe hose for the compressor in position by the upper connector to the condenser Install the pipe coupling 1 M8 Ensure that the O rings are securely located between the condenser and the pipe hose Tighten the screw NOTE For tightening torques see TIGHTENING TORQUE 2012...

Page 484: ...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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 485: ...pe hose down to the compressor under the vehicle INSTALLING THE PIPE HOSE BETWEEN THE COMPRESSOR AND THE RECEIVER Place the pipe hose for the compressor in position by the upper connector to the receiver Install the pipe coupling 1 M8 Ensure that the O rings are securely located between the receiver and the pipe hose Tighten the screw the upper connector for the charge air pipe NOTE For tightening...

Page 486: ...stem with refrigerant acc to REFRIGERANT FILLING 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 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: ... air conditioning A C system See REFRIGERANT DRAINING PIPE HOSE BETWEEN EVAPORATOR AND RECEIVER REPLACING REMOVING COMPONENTS 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 WARNING Follow the safety instructions for work on air conditioning systems ...

Page 488: ...ounting by pulling it upwards at an angle Remove the ground strip 3 from the connection at the right hand suspension turret the 2 switches 4 for the air conditioning A C system pressure sensor from the air conditioning A C pipes hoses the front bumper cover See COVER BUMPER FRONT 2010 2011 EARLY or COVER BUMPER FRONT 2011 LATE 2012 REMOVING THE PIPE HOSE BETWEEN THE EVAPORATOR AND THE RECEIVER 201...

Page 489: ...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 the plastic clip holding the mounting block the mounting block from the pipes 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 490: ...E EVAPORATOR AND THE RECEIVER Install the pipe coupling at the receiver using the M8 nut the right hand headlamp See HEADLAMP BULB 2007 or HEADLAMP BULB 2008 2012 Position the pipe hose next to the cowl panel in the engine compartment Install NOTE Plug the intake pipe for the receiver immediately after disconnection NOTE For tightening torques see TIGHTENING TORQUE 2012 Volvo C30 T 5 HVAC Climate ...

Page 491: ...nt 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 the power steering fluid reservoir and hoses 2 from its mounting by pulling it upwards at an angle Remove the ground strip 3 from the connection at the right hand suspension turret the 2 switches 4 for the air co...

Page 492: ...WEEN 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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 493: ...he condenser connection INSTALLING THE PIPE HOSE BETWEEN THE CONDENSER AND THE EXPANSION VALVE Install the cap nut for the expansion valve Install the M8 screw on the condenser connection the service valve Tighten See TIGHTENING TORQUE the service valve cover NOTE For tightening torques see TIGHTENING TORQUE 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 494: ... 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 See the illustration the plastic clip holding the mounting block the mounting block from the pipes 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacem...

Page 495: ...in the grooves on the pipe the plastic clip holding the mounting block the M8 screw securing the air conditioning A C pipes to the evaporator the cap nut for the expansion valve Press in the hose into the mounting below the right hand suspension turret Carry out finishing work FINISHING WORK THE SAME FOR ALL METHODS NOTE For tightening torques see TIGHTENING TORQUE 2012 Volvo C30 T 5 HVAC Climate ...

Page 496: ...he air conditioning A C system See VACUUM PUMPING Fill the air conditioning A C system with refrigerant See REFRIGERANT FILLING 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 SWITCH HIGH PRESSURE 2007 2011 REMOVE INSTALL Fig 118 Identifying High Pressure Switch Courtesy of ...

Page 497: ...o install reverse the removal procedure Perform climate unit checking see CLIMATE CONTROL SYSTEM CHECK TEMPERATURE SENSOR EVAPORATOR PREPARATORY WORK IGNITION OFF 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 2012 Volvo C30 T 5 HVAC Climate Units R...

Page 498: ...tifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Ignition off REMOVAL REMOVING THE TEMPERATURE SENSOR FOR THE EVAPORATOR 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 499: ...sensor straight out Remove the temperature sensor Remove the connector INSTALLATION INSTALLING THE TEMPERATURE SENSOR FOR THE EVAPORATOR Connect the connector Align the hooks for the temperature sensor in the opening so that the connector is turned down Place the temperature sensor down against the surface of the heater unit Turn the temperature sensor a 1 4 turn counter clockwise FINISHING 2012 V...

Page 500: ...ine coolant hose s from the pipe coupling s on the engine coolant heater HINT Mark out the internal location of the engine coolant hoses and the angle of the pipe couplings in relation to the cover REMOVAL REMOVING THE COVER OVER THE HEAT EXCHANGER NOTE The illustrations in this service information are used for different model years and or models Some variation may occur However the essential info...

Page 501: ...over heat exchanger It is secured using 4 screws Lift up the cover a little until the snap rings for the pipe couplings release Ease out and pull the pipe couplings upwards one at a time REMOVING PIPE COUPLING AND SNAP RING 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 502: ... that also hold the pipe couplings in place The snap rings are located in a groove on the pipe coupling Using a small screwdriver pry up 1 of the 2 grooves on each snap ring Remove the snap ring Remove the pipe INSTALLATION INSTALLING THE PIPE COUPLING AND COVER 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 503: ...lly Install the 4 screws Tighten HINT Lubricate the O rings for the pipes so that they can be inserted more easily into the openings in the heater exchanger Install the engine coolant hose s on the pipe coupling s on the engine coolant heater so that they are positioned according to the previous markings the engine coolant heater See FUEL FIRED BOOSTER HEATER B5244S4 FINISHING TESTING THE ENGINE C...

Page 504: ...he pipe coupling s on the engine coolant heater HINT Mark out the internal location of the engine coolant hoses and the angle of the pipe couplings in relation to the cover REMOVAL REMOVING THE COVER OVER THE HEAT EXCHANGER 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 illustrati...

Page 505: ...over heat exchanger It is secured using 4 screws Lift up the cover a little until the snap rings for the pipe couplings release Ease out and pull the pipe couplings upwards one at a time REMOVING PIPE COUPLING AND SNAP RING 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 506: ... that also hold the pipe couplings in place The snap rings are located in a groove on the pipe coupling Using a small screwdriver pry up 1 of the 2 grooves on each snap ring Remove the snap ring Remove the pipe INSTALLATION INSTALLING THE PIPE COUPLING AND COVER 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 507: ...Install the 4 screws Tighten HINT Lubricate the O rings for the pipes so that they can be inserted more easily into the openings in the heater exchanger Install the engine coolant hose s on the pipe coupling s on the engine coolant heater so that they are positioned according to the previous markings the engine coolant heater See FUEL FIRED BOOSTER HEATER B5254T3 B5254T7 FINISHING TESTING THE ENGI...

Page 508: ...eheater module CPM See FUEL FIRED BOOSTER HEATER CONTROL UNIT B5244S4 REMOVAL REMOVING THE FAN MOTOR FOR THE ENGINE COOLANT HEATER Fig 128 Identifying Screws For Cover Over Fan Housing 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 2012 Volvo C30 T ...

Page 509: ...OLVO CARS CORPORATION Carefully pull the fan housing straight out viewed from the shorter side of the engine coolant heater See the illustration NOTE The nearest connection pipe may need to be adjusted in order to remove the cover See COOLANT PIPE FUEL POWERED PREHEATER B5244S4 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 510: ...erminals 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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 511: ...motor away from the heat exchanger TRANSFERRING COMPONENTS TRANSFERRING FLAME TRAP Transfer the flame trap See FLAME SENSOR FUEL POWERED PREHEATER B5244S4 INSTALLATION INSTALLING THE FAN MOTOR FOR THE ENGINE COOLANT HEATER 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 512: ...ug is above the hole in the combustion chamber the fan motor Ensure that the molded gasket is positioned correctly in the recess Tighten the 3 screws on the fan motor Install the cable terminals and wiring for the fan motor in positions 13 and 14 black and brown in the 14 pin connector the fan motor housing NOTE The molded gasket 3 has a small tab that must fit in the corresponding mating faces on...

Page 513: ...FIRED BOOSTER HEATER CONTROL UNIT B5244S4 the auxiliary heater acc to FUEL FIRED BOOSTER HEATER B5244S4 FINISHING TESTING THE ENGINE COOLANT HEATER Carry out a performance test of the engine coolant heater See FUEL POWERED PREHEATER CHECKING FAN MOTOR FUEL POWERED PREHEATER B5254T3 B5254T7 NOTE The illustrations in this service information are used for different model years 2012 Volvo C30 T 5 HVAC...

Page 514: ...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 the illustrations is always correct NOTE The nearest connection pipe may need to be adjusted in order to remove the cover See COOLANT PIPE FUEL POWERED PREHEATER B5254T3 B5254T7 2012 Volvo C30 T 5 HVAC Climate...

Page 515: ... 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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 516: ...erminals 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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 517: ...fan motor away from the heat exchanger TRANSFERRING COMPONENTS TRANSFERRING FLAME TRAP Transfer the flame trap See FLAME SENSOR FUEL POWERED PREHEATER INSTALLATION INSTALLING THE FAN MOTOR FOR THE ENGINE COOLANT HEATER 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 518: ...ug is above the hole in the combustion chamber the fan motor Ensure that the molded gasket is positioned correctly in the recess Tighten the 3 screws on the fan motor Install the cable terminals and wiring for the fan motor in positions 13 and 14 black and brown in the 14 pin connector the fan motor housing NOTE The molded gasket 3 has a small tab that must fit in the corresponding mating faces on...

Page 519: ...54T7 Install the control module See FUEL FIRED BOOSTER HEATER CONTROL UNIT B5254T3 B5254T7 the auxiliary heater acc to FUEL FIRED BOOSTER HEATER B5254T3 B5254T7 FINISHING TESTING THE ENGINE COOLANT HEATER Carry out a performance test of the engine coolant heater See FUEL POWERED PREHEATER CHECKING FLAME SENSOR FUEL POWERED PREHEATER B5244S4 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement...

Page 520: ...the 4 screws for the cover over the fan housing Remove the cover 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 NOTE The nearest connection pipe may need to be adjusted in order to remove the cover See COOLANT PIPE FUEL POWERED PREHEATER B5244S4 201...

Page 521: ... 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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 522: ...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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 523: ...e cable terminals and cables in the connectors See Flame sensor in positions 1 and 2 blue and brown Carefully push the fan housing into place Ensure that the connector is not trapped that the cable seal on the water pump is correctly positioned and that the cable runs behind the fan motor NOTE Route the cables behind the fan motor to the connector 2012 Volvo C30 T 5 HVAC Climate Units Removal Repl...

Page 524: ...ERED PREHEATER CHECKING FLAME SENSOR FUEL POWERED PREHEATER B5254T3 B5254T7 PREPARATORY WORK REMOVING THE COMBUSTION PREHEATER MODULE CPM Remove the control module See FUEL FIRED BOOSTER HEATER CONTROL UNIT B5254T3 B5254T7 REMOVAL REMOVING THE FLAME SENSOR NOTE The illustrations in this service information are used for different model years and or models Some variation may occur However the essent...

Page 525: ... 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 See COOLANT PIPE FUEL POWERED PREHEATER B5254T3 B5254T7 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 526: ... 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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 527: ...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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 528: ...e cable terminals and cables in the connectors See Flame sensor in positions 1 and 2 blue and brown Carefully push the fan housing into place Ensure that the connector is not trapped that the cable seal on the water pump is correctly positioned and that the cable runs behind the fan motor NOTE Route the cables behind the fan motor to the connector 2012 Volvo C30 T 5 HVAC Climate Units Removal Repl...

Page 529: ...a performance test of the engine coolant heater See FUEL POWERED PREHEATER CHECKING FUEL FIRED BOOSTER HEATER B5244S4 Special tools see 9512619 PREPARATORY WORK REMOVING COMPONENTS AND DRAINING THE ENGINE COOLANT 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 alwa...

Page 530: ...move the shield under the vehicle It is secured with 7 clips See the illustration Install a hose on the nipple at the radiator Feed the hose down to a container Open the nipple Drain off the engine coolant REMOVAL REMOVING THE ENGINE COOLANT HEATER 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 531: ...engine coolant heater to collect any engine coolant spillage Remove the connector 2 for the engine coolant heater the fuel line 3 from the clip below the heater Open the holder 4 for the radiator hoses behind the engine to expose the lower radiator hose running down to the water pump Remove the exhaust pipe from the engine coolant heater See FUEL FIRED BOOSTER HEATER EXHAUST PIPE B5244S4 2012 Volv...

Page 532: ...nnector for the water pump HINT Mark the location of the upper hose on the water pump Position a container below the water pump to collect any spilled engine coolant Disconnect the upper hose as illustrated Plug the opening 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 533: ...Angle out the top edge of the engine coolant heater Place paper around the upper fuel connection on the engine coolant heater Disconnect the fuel hose HINT Use see 9512619 to detach and secure the clamps Lift up the engine coolant heater TRANSFERRING COMPONENTS TRANSFERRING ENGINE COOLANT HOSES Transfer the engine coolant hoses 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installa...

Page 534: ...r See FUEL FIRED BOOSTER HEATER EXHAUST PIPE B5244S4 the radiator hose for the water pump in its holder the fuel line in the clip below the engine coolant heater the connector for the engine coolant heater the radiator hose into the passenger compartment Tighten the drain nipple on the radiator Fill with coolant and warm up the engine until the thermostat opens Top up if necessary FINISHING TESTIN...

Page 535: ... clips FUEL FIRED BOOSTER HEATER B5254T3 B5254T7 Special tools see 9512619 PREPARATORY WORK REMOVING COMPONENTS AND DRAINING THE ENGINE COOLANT 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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement ...

Page 536: ...r hose 1 from the intake manifold the intake manifold 2 between the air cleaner and the turbocharger Remove the hose clamps at the mass air flow MAF sensor the hose clamps at the turbocharger TC the screws for the intake manifold in the cylinder head 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 537: ...move the shield under the vehicle It is secured with 7 clips See the illustration Install a hose on the nipple at the radiator Feed the hose down to a container Open the nipple Drain off the engine coolant REMOVAL REMOVING THE ENGINE COOLANT HEATER 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 538: ...the engine coolant heater to collect any engine coolant spillage Remove the connector 2 for the engine coolant heater the fuel line 3 from the clip below the heater Open the holder 4 for the radiator hoses behind the engine to expose the lower radiator hose running down to the water pump Remove the exhaust pipe from the engine coolant heater See FUEL FIRED BOOSTER HEATER EXHAUST PIPE 2012 Volvo C3...

Page 539: ...nnector for the water pump HINT Mark the location of the upper hose on the water pump Position a container below the water pump to collect any spilled engine coolant Disconnect the upper hose as illustrated Plug the opening 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 540: ...Angle out the top edge of the engine coolant heater Place paper around the upper fuel connection on the engine coolant heater Disconnect the fuel hose HINT Use see 9512619 to detach and secure the clamps Lift up the engine coolant heater TRANSFERRING COMPONENTS TRANSFERRING ENGINE COOLANT HOSES Transfer the engine coolant hoses 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installa...

Page 541: ... line in the clip below the engine coolant heater the connector for the engine coolant heater the radiator hose into the passenger compartment Install the screws for the intake manifold in the cylinder head the hose clamps at the turbocharger TC the hose clamps at the mass air flow MAF sensor the intake manifold between the air cleaner ACL and the turbocharger TC the hose for the EVAP canister fro...

Page 542: ...clips FUEL FIRED BOOSTER HEATER CONTROL UNIT B5244S4 PREPARATORY WORK REMOVING THE ENGINE COOLANT HEATER Remove the Combustion Preheater Module See FUEL FIRED BOOSTER HEATER B5244S4 IMPORTANT INFORMATION 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 correc...

Page 543: ...EMOVAL 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 Position a small screwdriver between the control module connector and its 2 catches Turn the screwdriver carefully to re...

Page 544: ... PREPARATORY WORK REMOVING THE ENGINE COOLANT HEATER Remove the engine coolant heater See FUEL FIRED BOOSTER HEATER B5254T3 B5254T7 IMPORTANT INFORMATION If the combustion preheater module CPM is to be moved from one vehicle to another note down any diagnostic trouble codes DTCs and operating times before removing the control module from the vehicle Always check that the pins or sockets in the con...

Page 545: ...een the control module connector and its 2 catches Turn the screwdriver carefully to release the catches Pull off the control module 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 Tighten the 4 screws crosswise 2012 Volvo ...

Page 546: ... while the repair was carried out FUEL FIRED BOOSTER HEATER EXHAUST PIPE B5244S4 REMOVAL REMOVING THE EXHAUST PIPE FOR THE ENGINE COOLANT HEATER Fig 161 Identifying Upper Mounting Courtesy of VOLVO CARS CORPORATION 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 al...

Page 547: ...ig 162 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 Disconnect the water pump See WATER PUMP FUEL DRIVEN AUXILIARY HEATER 2007 2009 Leave the water pump hanging from its hoses 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 548: ...l 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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 549: ...TALLING THE EXHAUST PIPE FOR THE ENGINE COOLANT HEATER Position the exhaust pipe Carry out the work from the right hand wheel arch Screw the nut into place loosely on the lower mounting Do not tighten yet Install the fuel hose pipe at the quick release connector under the vehicle Secure the upper mounting Tighten See TIGHTENING TORQUE Position the intake hose FINISHING 2012 Volvo C30 T 5 HVAC Clim...

Page 550: ...a performance test of the engine coolant heater See FUEL POWERED PREHEATER CHECKING FUEL FIRED BOOSTER HEATER EXHAUST PIPE B5254T3 B5254T7 PREPARATORY WORK REMOVING COMPONENTS 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 2012 Volvo C30 T 5 HVAC Cl...

Page 551: ...e intake manifold 2 between the air cleaner ACL and the turbocharger TC Remove the hose clamps at the mass air flow MAF sensor the hose clamps at the turbocharger TC the screws for the intake manifold in the cylinder head REMOVAL REMOVING THE EXHAUST PIPE FOR THE ENGINE COOLANT HEATER 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 552: ...CORPORATION 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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 553: ...ehicle Remove the right hand front wheel the shield under the vehicle It is secured with 7 clips Disconnect the water pump See WATER PUMP FUEL DRIVEN AUXILIARY HEATER Leave the water pump hanging from its hoses 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 554: ...l 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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 555: ...STALLING THE EXHAUST PIPE FOR THE ENGINE COOLANT HEATER Position the exhaust pipe Carry out the work from the right hand wheel arch Screw the nut into place loosely on the lower mounting Do not tighten yet Install the fuel hose pipe at the quick release connector under the vehicle Secure the upper mounting Tighten See TIGHTENING TORQUE Position the intake hose Install 2012 Volvo C30 T 5 HVAC Clima...

Page 556: ...INISHING 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 the shield under the vehicle using the 7 clips Carry out a performance test of the engine coolant heater See FUEL POWERED PREHEATER CHECKING ...

Page 557: ...ER HEATER CONTROL UNIT B5254T3 B5254T7 or FUEL FIRED BOOSTER HEATER CONTROL UNIT B5244S4 the cover and the pipe couplings See COOLANT PIPE FUEL POWERED PREHEATER B5254T3 B5254T7 or COOLANT PIPE FUEL POWERED PREHEATER B5244S4 the cover for the fan motor It is secured using 4 screws NOTE The illustrations in this service information are used for different model years and or models Some variation may...

Page 558: ...INE 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 those for the overheat protection thermostat at positions 5 and 6 red cables those for the engine coolant tempe...

Page 559: ...ation to the fan motor cover 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 Glow plug in positions 9 and 12 white and brown Water pump in positions 10 and 11 brown and violet Fan motor in positions 13 ...

Page 560: ...FUEL FIRED BOOSTER HEATER B5244S4 or FUEL FIRED BOOSTER HEATER B5254T3 B5254T7 FINISHING TESTING THE ENGINE COOLANT HEATER Carry out a performance test of the engine coolant heater See FUEL POWERED PREHEATER CHECKING FUEL FIRED BOOSTER HEATER WATER IN FUEL SENSOR B5254T3 B5254T7 PREPARATORY WORK REMOVING COMPONENTS NOTE The illustrations in this service information are used for different model yea...

Page 561: ...UEL POWERED PREHEATER B5254T3 B5254T7 or COOLANT PIPE FUEL POWERED PREHEATER B5244S4 the cover for the fan motor It is secured using 4 screws the housing around the fan motor IMPORTANT INFORMATION The engine coolant temperature sensor blue cables and the overheat protection thermostat red cables cannot be replaced separately They must be replaced together with the cable harness and the 14 pin conn...

Page 562: ...those for the engine coolant temperature sensor at positions 3 and 4 blue cables The connector is supplied with the replacement part INSTALLATION INSTALLING THE OVERHEAT PROTECTION THERMOSTAT ENGINE COOLANT TEMPERATURE SENSOR Install the sensors and position the cable harness along the recesses for the heat exchanger Ensure that the cable grommet is correctly located in relation to the fan motor c...

Page 563: ... black and brown 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 B5244S4 or COOLANT PIPE FUEL POWERED PREHEATER B5254T3 B5254T7 the control module See FUEL FIRED BOOSTER HEATER CONTROL UNIT B5244S4 or FUEL FIRED BOOSTER HEATER CONTROL UNIT B5254T3 B5254T7 the auxiliary heater acc to...

Page 564: ...OVING THE FRONT FUEL LINE 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 WARNING Use protective gloves and protective goggles during all operations due to the risk of fuel spills NOTE There must be no dirt present when handling fuel line connections...

Page 565: ... 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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 566: ...EATER EXHAUST PIPE B5244S4 Remove the fuel pipe 3 from the clip mounting the mounting screw 4 Angle the engine coolant heater out slightly Place paper around the upper fuel connection on the engine coolant heater Disconnect the fuel hose HINT Use see 9512619 to release the clamps Lift up and remove the fuel line INSTALLING THE FRONT FUEL LINE 2012 Volvo C30 T 5 HVAC Climate Units Removal Replaceme...

Page 567: ...ng work FUEL LINE CENTER REPLACING REMOVING THE CENTER FUEL LINE Raise the vehicle Remove the front and rear quick release connectors for the fuel line Disconnect the fuel line from the mounting points Route the fuel line back under the front SIPS member INSTALLING THE CENTER FUEL LINE Route the fuel line under the front SIPS member Secure the fuel line in the mounting points Install the front and...

Page 568: ...Fig 180 Identifying Fuel Pump Connector Courtesy of VOLVO CARS CORPORATION Remove the fuel tank See FUEL TANK 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 569: ...ick release connector to the suction pipe Lift the suction pipe INSTALLING THE SUCTION PIPE Press down the suction hose Connect the quick release connector for the fuel line A click must be clearly heard Reinstall the fuel tank See FUEL TANK Carry out finishing work FINISHING NOTE Wipe up any fuel spills 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 570: ...VING THE FRONT FUEL LINE 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 WARNING Use protective gloves and protective goggles during all operations due to the risk of fuel spills NOTE There must be no dirt present when handling fuel line connections ...

Page 571: ...ing 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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 572: ... 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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 573: ...ER HEATER EXHAUST PIPE Remove the fuel pipe 3 from the clip mounting the mounting screw 4 Angle the engine coolant heater out slightly Place paper around the upper fuel connection on the engine coolant heater Disconnect the fuel hose HINT Use see 9512619 to release the clamps Lift up and remove the fuel line INSTALLING THE FRONT FUEL LINE 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement A...

Page 574: ...ork FUEL LINE CENTER REPLACING REMOVING THE CENTER FUEL LINE Raise the vehicle Remove the front and rear quick release connectors for the fuel line Disconnect the fuel line from the mounting points Route the fuel line back under the front SIPS member INSTALLING THE CENTER FUEL LINE Route the fuel line under the front SIPS member Secure the fuel line in the mounting points Install the front and rea...

Page 575: ...Fig 185 Identifying Fuel Pump Connector Courtesy of VOLVO CARS CORPORATION Remove the fuel tank See FUEL TANK 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 576: ...ick release connector to the suction pipe Lift the suction pipe INSTALLING THE SUCTION PIPE Press down the suction hose Connect the quick release connector for the fuel line A click must be clearly heard Reinstall the fuel tank See FUEL TANK Carry out finishing work FINISHING NOTE Wipe up any fuel spills 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 577: ...RS CORPORATION 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 WARNING Use protective gloves and protective goggles during all operations due to the risk of fuel spills NOTE There must be no dirt present when handling the fuel lines connections 2012 ...

Page 578: ...her with the bracket from the rear sub frame 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 REMOVAL REMOVING THE FUEL PUMP FP 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 579: ... the fuel tank unit Remove the fuel lines from the fuel pump FP on top of the fuel tank the fuel pump FP and hoses running back over the rear axle INSTALLATION INSTALLING THE FUEL PUMP FP Thread the fuel pump FP hoses above the rear axle and over the fuel tank Install NOTE Wipe up any fuel spills NOTE For tightening torques see TIGHTENING TORQUE 2012 Volvo C30 T 5 HVAC Climate Units Removal Replac...

Page 580: ...bracket FINISHING TESTING THE ENGINE COOLANT HEATER Carry out a performance test of the engine coolant heater See FUEL POWERED PREHEATER CHECKING FUEL PUMP FUEL DRIVEN AUXILIARY HEATER B5254T3 B5254T7 PREPARATORY WORK IMPORTANT INFORMATION NOTE The illustrations in this service information are used for different model years and or models Some variation may occur However the essential information i...

Page 581: ...t rear wheel the connector for the fuel pump FP the fuel pump FP together with the bracket from the rear sub frame WARNING Use protective gloves and protective goggles during all operations due to the risk of fuel spill NOTE There must be no dirt present when handling fuel line connections 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 582: ...S 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 REMOVAL REMOVING THE FUEL PUMP FP 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 583: ... the fuel tank unit Remove the fuel lines from the fuel pump FP on top of the fuel tank the fuel pump FP and hoses running back over the rear axle INSTALLATION INSTALLING THE FUEL PUMP FP Thread the fuel pump FP hoses above the rear axle and over the fuel tank Install NOTE Wipe up any fuel spills NOTE For tightening torques see TIGHTENING TORQUE 2012 Volvo C30 T 5 HVAC Climate Units Removal Replac...

Page 584: ...bracket FINISHING TESTING THE ENGINE COOLANT HEATER Carry out a performance test of the engine coolant heater See FUEL POWERED PREHEATER CHECKING WATER PUMP FUEL DRIVEN AUXILIARY HEATER B5244S4 PREPARATORY WORK DRAINING THE ENGINE COOLANT 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...

Page 585: ...to expose the lower radiator hose to the water pump Raise the vehicle Remove the shield under the vehicle It is secured with 7 clips Install a hose on the nipple at the radiator Feed the hose down to a container Open the nipple and drain off the coolant REMOVAL REMOVING THE WATER PUMP 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 586: ...INT Mark the location of the hoses at a suitable point on the water pump Install hose clips on both coolant hoses as close to the water pump as possible Position a container under the water pump Disconnect the hoses INSTALLATION INSTALLING THE WATER PUMP NOTE For tightening torques see TIGHTENING TORQUE 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 587: ...ding to any markings Remove the hose clips the water pump and mounting 1 x M6 Tighten HINT Hook the lower reverse of the rubber mounting in the mounting This facilitates locating the thread hole and correct mounting the connector Close the drain nipple Remove the hose Fill with coolant Run the engine until the thermostat opens Top up if necessary FINISHING ADJUSTING AND CHECKING 2012 Volvo C30 T 5...

Page 588: ... of VOLVO CARS CORPORATION Install the cover It is secured with 7 clips Lower the vehicle WATER PUMP FUEL DRIVEN AUXILIARY HEATER B5254T3 B5254T7 PREPARATORY WORK 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 2012 Volvo C30 T 5 HVAC Climate Units R...

Page 589: ...nd the engine to expose the lower radiator hose to the water pump Raise the vehicle Remove the shield under the vehicle It is secured with 7 clips Install a hose on the nipple at the radiator Feed the hose down to a container Open the nipple and drain off the coolant REMOVAL REMOVING THE WATER PUMP 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 590: ...INT Mark the location of the hoses at a suitable point on the water pump Install hose clips on both coolant hoses as close to the water pump as possible Position a container under the water pump Disconnect the hoses INSTALLATION INSTALLING THE WATER PUMP NOTE For tightening torques see TIGHTENING TORQUE 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 591: ...ding to any markings Remove the hose clips the water pump and mounting 1 x M6 Tighten HINT Hook the lower reverse of the rubber mounting in the mounting This facilitates locating the thread hole and correct mounting the connector Close the drain nipple Remove the hose Fill with coolant Run the engine until the thermostat opens Top up if necessary FINISHING ADJUSTING AND CHECKING 2012 Volvo C30 T 5...

Page 592: ...k 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 2012 Volvo C30 T 5 HVAC Climate Units Removal Replacement And Installation ...

Page 593: ... Tool number 999 7446 Tool description Bleeding tool Tool boards 40 Materials Designation Part number Brake fluid 9437430 WARNING Only use new specified brake fluid from airtight containers CAUTION The fluid level must remain between the MAX and MIN marks 2012 Volvo C30 T 5 TRANSMISSION Clutch Cleaning Inspection And Adjustment 2012 Volvo C30 T 5 TRANSMISSION Clutch Cleaning Inspection And Adjustm...

Page 594: ...Use Brake fluid 9437430 Fig 2 Identifying Bleeding Tool Courtesy of VOLVO CARS CORPORATION see 9997446 2012 Volvo C30 T 5 TRANSMISSION Clutch Cleaning Inspection And Adjustment ...

Page 595: ...h Bleeding Procedure 1 Of 11 Courtesy of VOLVO CARS CORPORATION Fig 4 Clutch Bleeding Procedure 2 Of 11 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 TRANSMISSION Clutch Cleaning Inspection And Adjustment ...

Page 596: ...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 2012 Volvo C30 T 5 TRANSMISSION Clutch Cleaning Inspection And Adjustment ...

Page 597: ...h Bleeding Procedure 5 Of 11 Courtesy of VOLVO CARS CORPORATION Fig 8 Clutch Bleeding Procedure 6 Of 11 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 TRANSMISSION Clutch Cleaning Inspection And Adjustment ...

Page 598: ...Fig 9 Clutch Bleeding Procedure 7 Of 11 Courtesy of VOLVO CARS CORPORATION Fig 10 Clutch Bleeding Procedure 8 Of 11 2012 Volvo C30 T 5 TRANSMISSION Clutch Cleaning Inspection And Adjustment ...

Page 599: ...TION 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 2012 Volvo C30 T 5 TRANSMISSION Clutch Cleaning Inspection And Adjustment ...

Page 600: ...ig 13 Clutch Bleeding Procedure 11 Of 11 Courtesy of VOLVO CARS CORPORATION INSTALLATION To install reverse the removal procedure 2012 Volvo C30 T 5 TRANSMISSION Clutch Cleaning Inspection And Adjustment ...

Page 601: ...ol number 999 5662 Tool description Compression tool clutch P200 V40 Tool boards 40 999 5663 Centering tool clutch plate P200 V40 Tool number 999 5663 Tool description Centering tool clutch plate P200 V40 Tool boards 40 999 5675 Socket centering clutch plate used with 9995663 Tool number 999 5675 Tool description Socket centering clutch plate used with 9995663 Tool boards 40 Materials Designation ...

Page 602: ...120 Courtesy of VOLVO CARS CORPORATION see 9997068 see 9997120 Fig 2 Locating Counterhold Tool Stop Pin Courtesy of VOLVO CARS CORPORATION NOTE Note the position of the component before removal 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 603: ...ntifying Centering Tool 999 5663 And Socket Tool 999 5675 Attached To Clutch Disc Courtesy of VOLVO CARS CORPORATION see 9995663 see 9995675 CAUTION The cone on the special tool must only be tightened finger tight to prevent damage to the clutch disc 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 604: ...ing agent 1161721 Fig 6 Identifying Compression Tool 9995662 Attached To Pressure Plate Courtesy of VOLVO CARS CORPORATION Torque M8 24 Nm WARNING Take care not to trap any fingers when removing the special tool 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 605: ...n Counterhold Tool boards 43 999 7120 Gear sector Tool number 999 7120 Tool description Gear sector Tool boards 21 999 5662 Compression tool clutch P200 V40 Tool number 999 5662 Tool description Compression tool clutch P200 V40 Tool boards 40 999 5663 Centering tool clutch plate P200 V40 Tool number 999 5663 Tool description Centering tool clutch plate P200 V40 Tool boards 40 2012 Volvo C30 T 5 TR...

Page 606: ...068 see 9997120 999 5675 Socket centering clutch plate used with 9995663 Tool number 999 5675 Tool description Socket centering clutch plate used with 9995663 Tool boards 40 Materials Designation Part number Cleaning agent 1161721 NOTE Note the position of the component before removal 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 607: ...ALLATION Fig 10 Identifying Centering Tool 999 5663 And Socket Tool 999 5675 Attached To Clutch Disc Courtesy of VOLVO CARS CORPORATION CAUTION The cone on the special tool must only be tightened finger tight to prevent damage to the clutch disc 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 608: ...ON Use Cleaning agent 1161721 Fig 12 Identifying Compression Tool 9995662 Attached To Pressure Plate Courtesy of VOLVO CARS CORPORATION Torque M8 24 Nm WARNING Take care not to trap any fingers when removing the special tool 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 609: ...UTCH CONTROL B5244S4 CLUTCH SLAVE CYLINDER REMOVAL Remove the transaxle See TRANSMISSION REMOVING Fig 14 Identifying Removal Of Retaining Pin To Link Arm Courtesy of VOLVO CARS CORPORATION NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 610: ...SMISSION INSTALLING TRANSMISSION REMOVING Special tools see 9985972 see 9995463 see 9995972 see 9997077 see 9997101 see 9997103 NOTE As the illustrations in this service information are used for different model years and or models some variation may occur However the essential information is always correct 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 611: ...porator hose by releasing the quick release lock the air cleaner ACL Disconnect the air cleaner ACL from the rubber mountings Pull the air cleaner ACL straight up PREVENTING SPILLAGES Open the bleed screw on the clutch cylinder Install the hose from the bleeding equipment on the bleed screw Slowly press the clutch pedal all the way down Lock the pedal Use a pedal jack REMOVAL REMOVING THE GROUND L...

Page 612: ...PORATION 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 REMOVING THE BRACKET 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 613: ...Locating Bracket Bolts Courtesy of VOLVO CARS CORPORATION Remove the bracket from the transmission REMOVING THE GEAR SELECTOR CABLES 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 614: ... of VOLVO CARS CORPORATION Remove the ball joints Use see 9997077 the sleeves for the gear selector cables from the transmission cable bracket Tie up the cables REMOVING THE CLUTCH LINE 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 615: ... nipple from the terminal Remove the rubber bushing from its bracket on the transmission Tie up the clutch line higher than the brake fluid reservoir Remove the 4 screws from the heat shield for the three way catalytic converter TWC REMOVING THE UPPER SCREWS 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 616: ...tween the engine and transmission LOWERING THE ENGINE AND TRANSMISSION Lower the engine 10 mm by turning see 9997103 HINT 10 mm corresponds to 6 revolutions on the screw REMOVING THE TORQUE ROD NOTE One screw is located against the heat shield for the three way catalytic converter TWC 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 617: ...lts 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 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 618: ...l 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 REMOVING THE LOWER SCREWS 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 619: ...ousing Bolts Courtesy of VOLVO CARS CORPORATION There are 7 screws between the engine and transmission Remove 5 screws leaving 2 screws in position 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 620: ...E FIXTURE ON THE MOBILE JACK AND TRANSMISSION 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 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 621: ...Align see 9997101 and 7101 1 together with their screws on the fixture and the transmission HINT First raise the jack to the transmission until all the mountings are at the correct angle for the transmission Then tighten all the screwed joints REMOVING SCREWS NOTE Tighten all the screws to the fixtures 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 622: ... 9997089 NOTE Ensure that the transmission is taken straight out in relation to the engine NOTE Lower the transmission slightly when removing so that it will pass the side member NOTE As the illustrations in this service information are used for different model years and or models some variation may occur However the essential information 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement ...

Page 623: ... AND LUBRICATING THE INPUT SHAFT The input shaft must be lubricated before a manual transmission is installed See INPUT SHAFT CLEANING CHECKING BEFORE INSTALLING Check that the transmission and engine mating surfaces are absolutely clean Also check that the guide sleeves towards the engine are in position and are free of faults Lubricate the holes in the transmission for the guide pins Use a littl...

Page 624: ...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 INSTALLING ENGINE MOUNTING 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 625: ...n 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 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 626: ...st the transmission in the engine pad Install the M14 screw for the engine mounting Remove the lifting beams and the lifting hook INSTALLING THE SCREWS IN THE TRANSMISSION ENGINE Fig 31 Identifying Starter Motor And Screws For Transmission Engine 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 627: ...TCH LINE Fig 32 Identifying Clutch Line Courtesy of VOLVO CARS CORPORATION Use a new O ring for the clutch line Install the clutch line Lock using the locking pin Remove the pedal jack if applicable Lift up the clutch pedal Bleed the clutch INSTALLING THE BRACKET 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 628: ...er Bracket And Coolant Hose Courtesy of VOLVO CARS CORPORATION Install the bracket holder the bracket and the coolant hose INSTALLING THE GEAR SELECTOR CABLE 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 629: ...nd levers Adjust the transmission cable See TRANSMISSION CABLE ADJUSTING INSTALLING THE AIR CLEANER ACL MODULE Fig 35 Identifying Air Cleaner ACL Module And Rubber Hose For Throttle Housing Courtesy of VOLVO CARS CORPORATION Install the air cleaner ACL module See INSTALLING COMPONENTS NOTE Ensure that the cable and sleeve do not crack or break 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replace...

Page 630: ...ORPORATION Secure the sub frame against the fixture plate using a retaining strap Lift the sub frame Align the sub frame in the front mountings in the side members Install the screws loosely 4 5 threads Allow the sub frame to hang down at the rear edge and to rest on the mobile jack Remove the temporary mounting for the steering gear Allow the steering gear to rest on the sub frame INSTALLING THE ...

Page 631: ...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 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 632: ...th sides Carefully raise the sub frame so that the adjustment tools are lined up with the holes in the side members INSTALLING THE SCREWS Fig 40 Identifying Screws For Rear Mounting Of Sub Frame Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 633: ...b 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 Tightening is performed later from the engine compartment FINISHING INSTALLING THE BEVEL GEAR Install the bevel gear See BEVEL GEAR INSTALLING THE LEFT DRIVE SHAFT Install the left hand drive shaft See DRIVESHAFT LEFT CHECKING ...

Page 634: ...sy of VOLVO CARS CORPORATION Tighten the two M12 screws for the steering gear INSTALLING THE BATTERY LEAD Fig 43 Identifying Battery Box Courtesy of VOLVO CARS CORPORATION Install the box for the battery the battery negative lead See BATTERY DISCONNECTING AND CONNECTING 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 635: ...EAR CABLE 800 Tool number 999 5511 Tool description PRESS TOOL BALL SEAT GEAR CABLE 800 Tool boards 43 999 7172 Wrench Tool number 999 7172 Tool description Wrench Tool boards 43 999 7119 Mounting Tool number 999 7119 Tool description Mounting Tool boards 21 Materials Designation Part number Anti squeak tape 1161842 Silicone grease 1161687 NOTE Removal steps in this procedure may contain installat...

Page 636: ... Identifying Clutch Pedal Courtesy of VOLVO CARS CORPORATION Fig 45 Removing Clutch Pedal Spring Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 637: ...EDAL ENGINE COMPARTMENT Fig 47 Identifying Connector Removal 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 WARNING Be prepared to collect escaping fluid 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 638: ...ove the following items Lighting switch see LIGHTING SWITCH Panel steering column see PANEL STEERING COLUMN Stoplamp switch see STOPLAMP SWITCH WARNING Be prepared to collect escaping fluid CAUTION Make sure the open end of the hose is secured above the fluid level in the reservoir 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 639: ...ARS CORPORATION Torque steering column to steering gear steering shaft joint 25 Nm Fig 51 Locating Connectors Courtesy of VOLVO CARS CORPORATION NOTE Make sure that a new component is installed 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 640: ...Courtesy of VOLVO CARS CORPORATION Fig 53 Identifying Steering Column To Dashboard Bolts Courtesy of VOLVO CARS CORPORATION Torque Steering column to dashboard 24 Nm 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 641: ... 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 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 642: ...EHICLES MANUFACTURED FROM CHASSIS NUMBER 22095 Remove the collision warning control module see COLLISION WARNING CONTROL MODULE ALL VEHICLES Fig 57 Identifying Bracket Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 643: ...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 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 644: ...tch 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 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 645: ... CARS CORPORATION INSTALLATION Fig 63 Identifying Bracket Courtesy of VOLVO CARS CORPORATION NOTE Use a new seal NOTE This step is not necessary when installing a new component 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 646: ...re to Cut Courtesy of VOLVO CARS CORPORATION Fig 65 Visually Inspecting That Bracket Is At 90Degrees Courtesy of VOLVO CARS CORPORATION see 9997119 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 647: ...1161842 Courtesy of VOLVO CARS CORPORATION Use Anti squeak tape 1161842 Fig 67 Identifying Silicone grease 1161687 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 648: ...REMOVAL Remove battery see BATTERY Fig 68 Identifying Removal Of M6 Screws Courtesy of VOLVO CARS CORPORATION Torque M6 Special tools 999 7172 Wrench Tool number 999 7172 Tool description Wrench Tool boards 43 NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 649: ...nector Courtesy of VOLVO CARS CORPORATION Fig 70 Identifying Connector Removal Courtesy of VOLVO CARS CORPORATION WARNING Be prepared to collect escaping fluid 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 650: ...ng items Panel steering column see PANEL STEERING COLUMN Combined instrument panel see COMBINED INSTRUMENT PANEL Start Inhibit Switch see START INHIBIT SWITCH WARNING Be prepared to collect escaping fluid CAUTION Make sure the open end of the hose is secured above the fluid level in the reservoir 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 651: ... CORPORATION Torque steering column to steering gear steering shaft joint 25 Nm WARNING The steering column may contain pyrotechnic components NOTE Make sure that the road wheels are in the straight ahead position NOTE Make sure that a new component is installed 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 652: ...nt Point Courtesy of VOLVO CARS CORPORATION Fig 76 Locating Clutch Line Steering Wheel Connectors Courtesy of VOLVO CARS CORPORATION Fig 77 Identifying Connector 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 653: ...Courtesy of VOLVO CARS CORPORATION Fig 79 Identifying Steering Column To Dashboard Bolts Courtesy of VOLVO CARS CORPORATION Torque Steering column to dashboard 24 Nm 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 654: ...Clutch Line Fasteners Courtesy of VOLVO CARS CORPORATION Fig 81 Identifying Clutch Piston Attachment Clips Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 655: ...lts Courtesy of VOLVO CARS CORPORATION Torque M8 24 Nm Fig 83 Identifying Wrench 9997172 To Adjust Clutch Tension Courtesy of VOLVO CARS CORPORATION see 9997172 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 656: ...ARS CORPORATION INSTALLATION To install reverse the removal procedure Perform clutch system venting see BLEEDING THE CLUTCH SYSTEM START INHIBIT SWITCH REMOVAL NOTE Use a new seal 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 657: ... VOLVO CARS CORPORATION Fig 86 Removing Connector Courtesy of VOLVO CARS CORPORATION Fig 87 Identifying Start Inhibit Switch Courtesy of VOLVO CARS CORPORATION INSTALLATION 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 658: ...ITION SENSOR CLUTCH PEDAL ENGINE COMPARTMENT REMOVAL Remove battery see BATTERY Special tools 999 7402 Installer Tool number 999 7402 Tool description Installer Tool boards 40 NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 659: ...emoval Of M6 Screws Courtesy of VOLVO CARS CORPORATION Torque M6 10 Nm Fig 90 Identifying Removal Of Connector Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 660: ...ATION see 9997402 INSTALLATION To install reverse the removal procedure CLUTCH CONTROL B5254T3 CLUTCH SLAVE CYLINDER REMOVAL Remove transmission see TRANSMISSION NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 661: ...93 Locating Bolt For Clutch Slave Cylinder Courtesy of VOLVO CARS CORPORATION Torque M6 10 Nm INSTALLATION To install reverse the removal procedure MASTER CYLINDER CLUTCH see MASTER CYLINDER CLUTCH CLUTCH CONTROL B5254T7 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 662: ...ON 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 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 663: ...itch Courtesy of VOLVO CARS CORPORATION INSTALLATION Fig 96 Identifying Start Inhibit Switch Courtesy of VOLVO CARS CORPORATION To install reverse the removal procedure 2012 Volvo C30 T 5 TRANSMISSION Clutch Removal replacement and installation ...

Page 664: ...ment panel see COMBINED INSTRUMENT PANEL Fig 1 View of Collision Warning Control Module Courtesy of VOLVO CARS CORPORATION Torque M6 10 Nm NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES EQUIPMENT Collision Avoidance 2012 Volvo C30 T 5 ACCESSORIES EQUIPMENT Collision Avoidance ...

Page 665: ...O CARS CORPORATION Torque M6 10 Nm INSTALLATION To install reverse the removal procedure CAUTION Take extra care not to damage the clips NOTE Make sure that the component terminals are not bent or damaged 2012 Volvo C30 T 5 ACCESSORIES EQUIPMENT Collision Avoidance ...

Page 666: ...Second Step tighten to 130 Nm Battery see BATTERY MARKING Brakes Bleeding Sequence see BRAKE SYSTEM BLEEDING Disc Brakes Service Specifications see WHEEL BRAKE SPECIFICATIONS MECHANICAL Torque see SUMMARY OF SPECIFIC COMPONENTS AND TIGHTENING TORQUES Charging Torque see SUMMARY OF TIGHTENING TORQUES FOR SPECIFIC COMPONENTS Drive Belts Adjustment Drive Belt is self adjusting Drive Belt Routing See ...

Page 667: ...l Flex Plate Drive Plate Torque 33 ft lb 45 N m and then angle tighten an additional 65 degrees NOTE For more information about angle tightening see SCREWED JOINT TORQUE ANGLE TIGHTENING Fuel System Pressure Specification Relative Pressure 300 kPa Absolute Pressure 400 kPa Checking Fuel Pressure see FUEL SYSTEM PRESSURE CHECKING B5254T7 Fuel Filter R I see FUEL FILTER B5254T7 Ignition Firing Order...

Page 668: ...eel 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 Stage 2 140 Nm 2012 Volvo C30 T 5 COMMON SPECS PROCEDURES C30 ...

Page 669: ...ying Secondary Lock Released Using Electrician s Screwdriver NOTE The graphics in this service information are used for different model years and or models Some variation may occur However the essential information in the graphics is always correct 2012 Volvo C30 T 5 ELECTRICAL Cables And Fuses Removal Replacement And Installation 2012 Volvo C30 T 5 ELECTRICAL Cables And Fuses Removal Replacement ...

Page 670: ...as shown At the same time pull the cable carefully backwards ASSEMBLY CAUTION Disconnect and work with only one cable at a time to minimize the risk of mixing them up NOTE Wheel sensor cables are twisted pair positive and negative signal cables for each wheel It is important that paired cables are twinned in the same way when they are reinstalled in the connector The cables must be twisted approxi...

Page 671: ...the secondary lock into place CONNECTOR CONTROL MODULE EXTRA SAFETY SYSTEM Special tools see 9512812 see 9512637 DISASSEMBLY DISASSEMBLING SECONDARY LOCK NOTE The graphics in this service information are used for different model years and or models Some variation may occur However the essential information in the graphics is always correct 2012 Volvo C30 T 5 ELECTRICAL Cables And Fuses Removal Rep...

Page 672: ...active catches on both sides of the socket housing and slide out the receptacle housings DISASSEMBLING PRIMARY LOCK CAUTION Disconnect and work with only one cable at a time to minimize the risk of mixing them up 2012 Volvo C30 T 5 ELECTRICAL Cables And Fuses Removal Replacement And Installation ...

Page 673: ...12 or tool see 9512637 as shown ASSEMBLY 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 ASSEMBLING SECONDARY LOCK Press the secondary lock into place ELECTRICAL DISTRIBUTION BOX FUSE BOX ACCESSORY CONTROL MODULE AEM 2012 Volvo C30 T 5 ELECTRICAL Cables An...

Page 674: ... 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 2012 Volvo C30 T 5 ELECTRICAL Cables And Fuses Removal Replacement And Installation ...

Page 675: ...VOLVO CARS CORPORATION Fig 8 Identifying Accessory Control Module AEM Removal Procedure 3 Of 8 Courtesy of VOLVO CARS CORPORATION Fig 9 Identifying Accessory Control Module AEM Removal Procedure 4 Of 8 2012 Volvo C30 T 5 ELECTRICAL Cables And Fuses Removal Replacement And Installation ...

Page 676: ...emoval 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 2012 Volvo C30 T 5 ELECTRICAL Cables And Fuses Removal Replacement And Installation ...

Page 677: ... Of 8 Courtesy of VOLVO CARS CORPORATION INSTALLATION To install reverse the removal procedure Order and download software according to 30664885 CABLE BATTERY TO GENERATOR B5244S4 2007 11 REMOVAL NOTE Some variation may occur However the essential information in the graphics is always correct 2012 Volvo C30 T 5 ELECTRICAL Cables And Fuses Removal Replacement And Installation ...

Page 678: ...ECTING the air cleaner ACL connection to battery Torque Battery lead to battery lead terminal 14 Nm nut on starter motor Torque Starter motor B terminal 15 Nm the clamp x1 1 clip the lead INSTALLATION To install reverse the removal procedure CABLE BATTERY TO GENERATOR B5254T3 2007 B5254T7 2008 12 REMOVAL 2012 Volvo C30 T 5 ELECTRICAL Cables And Fuses Removal Replacement And Installation ...

Page 679: ...battery Torque Battery lead to battery lead terminal 14 Nm nut on starter motor Torque Starter motor B terminal 15 Nm the clamp x1 1 clip the lead INSTALLATION To install reverse the removal procedure CONTROL MODULE RELAY BOX PASSENGER COMPARTMENT NOTE Some variation may occur However the essential information in the graphics is always correct 2012 Volvo C30 T 5 ELECTRICAL Cables And Fuses Removal...

Page 680: ...y Box Clip Courtesy of VOLVO CARS CORPORATION CAUTION The control module must be removed reinstalled and downloaded with software before the control module is replaced NOTE This module contains customer parameters 2012 Volvo C30 T 5 ELECTRICAL Cables And Fuses Removal Replacement And Installation ...

Page 681: ... Identifying Control Module Relay Box Tilted Down Courtesy of VOLVO CARS CORPORATION Fig 19 Identifying Control Module Relay Box Pulled Forward And Down Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ELECTRICAL Cables And Fuses Removal Replacement And Installation ...

Page 682: ...O CARS CORPORATION INSTALLATION To install reverse the removal procedure Order and download software according to 30667203 Set the clock LEAD BATTERY TO CENTRAL ELECTRICAL UNIT ENGINE COMPARTMENT NOTE Make sure that the component terminals are not bent or damaged Special Tool 2012 Volvo C30 T 5 ELECTRICAL Cables And Fuses Removal Replacement And Installation ...

Page 683: ...Tool number T9512636 Tool description TERMINAL REMOVAL TOOL COLOR CODE BLUE Tool boards T9512852 TERMINAL REMOVAL TOOL Tool number T9512852 Tool description REMOVAL TOOL Tool boards NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ELECTRICAL Cables And Fuses Removal Replacement And Installation ...

Page 684: ...r Courtesy of VOLVO CARS CORPORATION Fig 23 Identifying Battery Lead To Battery Lead Terminal 14 Nm Courtesy of VOLVO CARS CORPORATION Torque Battery lead to battery lead terminal 14 Nm 2012 Volvo C30 T 5 ELECTRICAL Cables And Fuses Removal Replacement And Installation ...

Page 685: ...ifying Position Of Relays Courtesy of VOLVO CARS CORPORATION For the location of the relays and fuses see decals at each respective relay and fuse box in the vehicle Pocket Data Booklet Remove the front secondary catch lift with a screwdriver NOTE Note the position of the relays Remove relays and fuses from the relay fuse holder as needed 2012 Volvo C30 T 5 ELECTRICAL Cables And Fuses Removal Repl...

Page 686: ...ORPORATION 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 see 9512852 INSTALLATION Install in reverse order 2012 Volvo C30 T 5 ELECTRICAL Cables And Fuses Removal Replacement And Installation ...

Page 687: ...C 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 2012 Volvo C30 T 5 ENGINE Cooling System Removal Replacement And Installation 2012 Volvo C30 T 5 ENGINE Cooling System Removal Replacement And Installation ...

Page 688: ...RPORATION Remove the following items screw engine compartment panel Fig 3 Locating Mounting Screws Courtesy of VOLVO CARS CORPORATION Remove the following items screw radiator mounting 2012 Volvo C30 T 5 ENGINE Cooling System Removal Replacement And Installation ...

Page 689: ...under any strain Fig 5 Locating Mounting Screws Courtesy of VOLVO CARS CORPORATION the screws for the upper radiator mounting 2 pcs on both sides bracket under air conditioning aggregate radiator downwards INSTALLATION INSTALLING THE ENGINE COOLING FAN FC NOTE Tighten See TIGHTENING TORQUE 2012 Volvo C30 T 5 ENGINE Cooling System Removal Replacement And Installation ...

Page 690: ...ON 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 2012 Volvo C30 T 5 ENGINE Cooling System Removal Replacement And Installation ...

Page 691: ... CORPORATION Install the following items engine compartment panel screws M6 Fig 9 Identifying Mobile Jack Courtesy of VOLVO CARS CORPORATION Install a mobile jack under the radiator 2012 Volvo C30 T 5 ENGINE Cooling System Removal Replacement And Installation ...

Page 692: ...54T7 2008 12 REMOVAL REMOVING THE ENGINE COOLING FAN FC Remove the electric cooling fan See ENGINE COOLING FAN FC B5254T7 2011 LATE 12 or ENGINE COOLING FAN FC B5244S4 2007 09 B5254T3 2007 B5254T7 2008 11 INSTALLING THE BRACKET FOR THE RADIATOR Fig 11 Re installing Radiator Bracket with Fan Removed 2012 Volvo C30 T 5 ENGINE Cooling System Removal Replacement And Installation ...

Page 693: ...07 09 B5254T3 2007 B5254T7 2008 11 or CHARGE AIR COOLER B5254T7 2011 LATE 2012 REMOVING THE ENGINE COMPARTMENT PANEL Fig 12 Identifying Panel And Screws Courtesy of VOLVO CARS CORPORATION Remove screws the engine compartment panel REMOVING THE UPPER RADIATOR MOUNTING 2012 Volvo C30 T 5 ENGINE Cooling System Removal Replacement And Installation ...

Page 694: ...tor 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 REMOVING THE RADIATOR 2012 Volvo C30 T 5 ENGINE Cooling System Removal Replacement And Installation ...

Page 695: ...des the bracket under the air conditioning aggregate the radiator downwards INSTALLATION INSTALLING THE RADIATOR Fig 16 Re installing Radiator Bracket with Fan Removed Courtesy of VOLVO CARS CORPORATION NOTE For tightening torques see TIGHTENING TORQUE 2012 Volvo C30 T 5 ENGINE Cooling System Removal Replacement And Installation ...

Page 696: ...g 2 on both sides Fig 18 Identifying Panel And Screws Courtesy of VOLVO CARS CORPORATION the engine compartment panel the screws M6 Install the charge air cooler CAC See CHARGE AIR COOLER B5244S4 2007 09 B5254T3 2007 B5254T7 2008 11 EARLY or CHARGE AIR COOLER B5254T7 2011 LATE 2012 2012 Volvo C30 T 5 ENGINE Cooling System Removal Replacement And Installation ...

Page 697: ...tifying Radiator Bracket Courtesy of VOLVO CARS CORPORATION Remove the bracket Install the electric cooling fan See ENGINE COOLING FAN FC B5244S4 2007 09 B5254T3 2007 B5254T7 2008 11 EARLY or ENGINE COOLING FAN FC B5254T7 2011 LATE 12 COOLANT PUMP AND THERMOSTAT COOLANT PUMP 2012 Volvo C30 T 5 ENGINE Cooling System Removal Replacement And Installation ...

Page 698: ...ATION To install reverse the removal procedure THERMOSTAT B5244S4 2007 10 REMOVAL Drain cooling system draining filling and bleeding See COOLING SYSTEM DRAINING CHARGING AND BLEEDING NOTE Removal steps in this procedure may contain installation details WARNING Be prepared to collect escaping fluid NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ENGINE Cooli...

Page 699: ...rtesy of VOLVO CARS CORPORATION Torque M6 10 Nm Fig 23 Identifying Thermostat Courtesy of VOLVO CARS CORPORATION INSTALLATION To install reverse the removal procedure WARNING Be prepared to collect escaping fluid 2012 Volvo C30 T 5 ENGINE Cooling System Removal Replacement And Installation ...

Page 700: ...ND BLEEDING Remove the air filter housing See AIR CLEANER HOUSING Fig 24 Identifying Water Outlet Courtesy of VOLVO CARS CORPORATION Torque M6 10 Nm NOTE Removal steps in this procedure may contain installation details WARNING Be prepared to collect escaping fluid 2012 Volvo C30 T 5 ENGINE Cooling System Removal Replacement And Installation ...

Page 701: ...procedure COOLING FAN ENGINE COOLING FAN FC B5244S4 2007 10 B5254T3 2007 08 B5254T7 2008 11 EARLY REMOVAL REMOVING THE BUMPER Remove the bumper cover Drain coolant See COOLING SYSTEM DRAINING CHARGING AND BLEEDING REMOVING COMPONENTS 2012 Volvo C30 T 5 ENGINE Cooling System Removal Replacement And Installation ...

Page 702: ...O 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 2012 Volvo C30 T 5 ENGINE Cooling System Removal Replacement And Installation ...

Page 703: ...to vehicles with automatic transmissions Remove the screws for the transmission s oil cooler Place the oil cooler to one side Fig 29 Identifying Premair Sensor Courtesy of VOLVO CARS CORPORATION Only applies to vehicles with premair sensors Remove the connector for the premair sensor 2012 Volvo C30 T 5 ENGINE Cooling System Removal Replacement And Installation ...

Page 704: ...emove 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 REMOVING THE ENGINE COOLING FAN 2012 Volvo C30 T 5 ENGINE Cooling System Removal Replacement And Installation ...

Page 705: ... 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 2012 Volvo C30 T 5 ENGINE Cooling System Removal Replacement And Installation ...

Page 706: ...rneath Hook the engine cooling fan FC into the upper and lower mountings the 2 x coolant hoses close the drain screw the bracket for the air conditioning aggregate the 4 x M8 screws Remove the air conditioning aggregate the splash guard under the engine using the 7 x screws NOTE When removing the engine cooling fan FC ensure that no cables are damaged NOTE For tightening torques see TIGHTENING TOR...

Page 707: ...nsmission the bolt Applies to all versions Install the connector to the engine cooling fan FC the 2 x hoses in the clips the cover for the brake control module BCM Top up the coolant See COOLING SYSTEM DRAINING CHARGING AND BLEEDING Run the engine until the thermostat opens Top up if necessary Install the bumper cover ENGINE COOLING FAN FC B5254T7 2011 LATE 12 REMOVAL 2012 Volvo C30 T 5 ENGINE Coo...

Page 708: ...ee 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 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ENGINE Cooling System Removal Replacement And Installation ...

Page 709: ...nly applies to vehicles with automatic transmissions Remove the screws for the transmission s oil cooler Place the oil cooler to one side Fig 39 Identifying Premair Sensor Courtesy of VOLVO CARS CORPORATION Only applies to vehicles with premair sensors Remove the connector for the premair sensor 2012 Volvo C30 T 5 ENGINE Cooling System Removal Replacement And Installation ...

Page 710: ...emove 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 REMOVING THE ENGINE COOLING FAN 2012 Volvo C30 T 5 ENGINE Cooling System Removal Replacement And Installation ...

Page 711: ... 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 2012 Volvo C30 T 5 ENGINE Cooling System Removal Replacement And Installation ...

Page 712: ...erneath Hook the engine cooling fan FC into the upper and lower mountings the 2x coolant hoses close the drain screw the bracket for the air conditioning aggregate the 4 x M8 screws Remove the air conditioning aggregate the splash guard under the engine using the 7x screws NOTE When removing the engine cooling fan FC ensure that no cables are damaged NOTE For tightening torques see TIGHTENING TORQ...

Page 713: ... all versions Install the connector to the engine cooling fan FC the 2 x hoses in the clips the cover for the brake control module BCM Top up the coolant See COOLING SYSTEM DRAINING CHARGING AND BLEEDING Run the engine until the thermostat opens Top up if necessary Install the bumper cover See COVER BUMPER FRONT 2010 11 EARLY or COVER BUMPER FRONT 2011 LATE 2012 CHARGE AIR COOLER WITH CONNECTION 2...

Page 714: ...OLER CAC Fig 46 Identifying Screw Locations Courtesy of VOLVO CARS CORPORATION Remove the switch the hoses the 2 screws NOTE The graphics in this service information are used for different model years and or models Some variation may occur However the essential information in the graphics is always correct 2012 Volvo C30 T 5 ENGINE Cooling System Removal Replacement And Installation ...

Page 715: ...E AIR COOLER B5254T7 2011 LATE 2012 PREPARATORY WORK The bumper cover See COVER BUMPER FRONT REMOVAL REMOVING THE UPPER SCREWS FOR THE LOWER AIR BAFFLE NOTE For tightening torques see TIGHTENING TORQUE NOTE The graphics in this service information are used for different model years and or models Some variation may occur However the essential information in the graphics is always correct 2012 Volvo...

Page 716: ...Fig 47 Locating Screws Courtesy of VOLVO CARS CORPORATION Remove the screws on both sides REMOVING THE CHARGE AIR COOLER CAC 2012 Volvo C30 T 5 ENGINE Cooling System Removal Replacement And Installation ...

Page 717: ...the charge air cooler CAC INSTALLATION INSTALLING THE CHARGE AIR COOLER CAC Thread on the right hand charge air pipe and hook the charge air cooler CAC into the upper mountings Install the 2 M6 screws the hoses NOTE For tightening torques see TIGHTENING TORQUE 2012 Volvo C30 T 5 ENGINE Cooling System Removal Replacement And Installation ...

Page 718: ...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 2012 Volvo C30 T 5 ENGINE Cooling System Removal Replacement And Installation ...

Page 719: ...Link Connector OBD II Courtesy of VOLVO CARS CORPORATION 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 2012 Volvo C30 T 5 ELECTRICAL Body Electrical 2012 Volvo C30 T 5 ELECTRICAL Body Electrical ...

Page 720: ...ng 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 2012 Volvo C30 T 5 ELECTRICAL Body Electrical ...

Page 721: ...esy of VOLVO CARS CORPORATION see 9512636 INSTALLATION To install reverse the removal procedure NOTE Make sure that the component terminals are not bent or damaged NOTE Only work on 1 cable at a time 2012 Volvo C30 T 5 ELECTRICAL Body Electrical ...

Page 722: ...DOOR REMOVAL AND INSTALLATION Fig 1 Door Latch Fuel Filler Door Remove Install Components 1 Of 3 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 723: ...ig 3 Door Latch Fuel Filler Door Remove Install Components 3 Of 3 Courtesy of VOLVO CARS CORPORATION FUEL TANK FILLER DOOR NOTE The illustrations in this service information are used for different model years 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 724: ...ORATION Remove the 2 screws the holder for the fuel tank filler cap 1 INSTALLATION INSTALLING THE FUEL TANK FILLER COVER Install and or models Some variation may occur However the essential information in the illustrations is always correct 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 725: ...emove 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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 726: ...of VOLVO CARS CORPORATION Fig 8 Removing Front Door Latch 4 Of 4 Courtesy of VOLVO CARS CORPORATION DOOR LATCH GLOVE COMPARTMENT REMOVAL AND INSTALLATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 727: ... GLOVE COMPARTMENT Fig 9 Removing Pins Courtesy of VOLVO CARS CORPORATION Fig 10 Identifying Handle Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 728: ...CABLE REMOVAL Remove the following items Window front door See WINDOW FRONT DOOR Handle outer door front see HANDLE OUTER DOOR FRONT NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 729: ...rior Handle Cable 2 Of 7 Courtesy of VOLVO CARS CORPORATION Fig 14 Removing Front Door Interior Handle Cable 3 Of 7 Courtesy of VOLVO CARS CORPORATION Remove the following items 1 Torque Door latch to door 8 Nm 2 Torque M6 10 Nm 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 730: ...f VOLVO CARS CORPORATION Fig 16 Removing Front Door Interior Handle Cable 5 Of 7 Courtesy of VOLVO CARS CORPORATION Fig 17 Removing Front Door Interior Handle Cable 6 Of 7 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 731: ...RONT DOOR OUTER HANDLE Disconnect the battery ground cable See BATTERY DISCONNECTING AND CONNECTING Fig 19 Removing Front Door Outer Handle 1 Of 3 Courtesy of VOLVO CARS CORPORATION NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 732: ... KVM 3 Nm Torque Door lock cylinder to external handle vehicles with keyless vehicle module KVM 4 Nm Fig 21 Removing Front Door Outer Handle 3 Of 3 Courtesy of VOLVO CARS CORPORATION Only vehicles with KVM keyless vehicle module NOTE Slacken off the screw by 4 turns only 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 733: ...ATION Fig 23 Identifying Door Lock Cylinder Courtesy of VOLVO CARS CORPORATION OUTER TAILGATE TRUNK LID HANDLE REMOVAL AND INSTALLATION NOTE Make sure that the connector fastens in the park position during dismantling NOTE Do not loosen the bolt more than 4 turns 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 734: ...esy of VOLVO CARS CORPORATION Torque Exterior handle to tailgate luggage compartment lid 3 Nm Fig 25 Removing Outer Tailgate Trunk Lid Handle 2 Of 2 Courtesy of VOLVO CARS CORPORATION TRUNK LID TAILGATE LOCK MECHANISM REMOVAL 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 735: ...f VOLVO CARS CORPORATION Torque Door latch to luggage compartment lid 20 Nm INSTALLATION To install reverse the removal procedure ROOF HATCH NOTE Removal steps in this procedure may contain installation details NOTE Note the position of the component before removal 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 736: ...n molding backwards Release the top edge and unhook the bottom edge of the apron molding Remove the apron molding 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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacem...

Page 737: ... GUTTER Fig 29 Pressing Out The Front Mounting Courtesy of VOLVO CARS CORPORATION Press out the front mounting for the gutter on both sides 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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Rem...

Page 738: ...rom the sunroof frame Repeat the procedure on the other side INSTALLATION INSTALLING THE GUTTER Fig 31 Identifying Clips Courtesy of VOLVO CARS CORPORATION Install the 2 new clips on the gutter NOTE Ensure that the clips are positioned correctly on the gutter see illustration 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 739: ... the other Fig 33 Installing The Gutter Courtesy of VOLVO CARS CORPORATION Press both front mountings for the gutter into place FINISHING CAUTION Ensure that the clips are in the correct position NOTE Do not damage or loosen the clips 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 740: ...nner cover back as far as possible Remove the inner cover See APRON MOLDING SUNROOF the 4 screws for the glass cover 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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and in...

Page 741: ... ROOF Fig 35 Identifying Weatherstripping Courtesy of VOLVO CARS CORPORATION Press the weatherstrip into place in the T groove INSTALLATION INSTALLING THE GLASS SUN ROOF Install NOTE The join for the weatherstrip must be in the middle of the rear edge of the sunroof 1 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 742: ...of VOLVO CARS CORPORATION Ignition off Remove the key from the ignition switch Wait 1 minute before starting work REMOVAL REMOVING THE SUN ROOF 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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids...

Page 743: ...dlining as described in see HEADLINING WITH SUN ROOF Remove the 4 drain hoses the connector from the electric motor sun roof module SRM Remove the electric motor sun roof module SRM 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 744: ...COMPONENTS Remove the sun roof glass See GLASS SUN ROOF the wind deflector See WIND DEFLECTOR SUNROOF the sun visor inner sun roof See SUN VISOR INNER COVER SUN ROOF INSTALLATION INSTALLING SUN ROOF NOTE Note the position and dimensions of all spacers and screws NOTE 2 people are required for this task 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 745: ...h nylon washer 4 1 M6x16 with nylon washer 5 1 M6x25 with nylon washer and spacer 20x6 5x6 6 1 M6x25 with nylon washer and spacer 20x6 5x6 7 1 M6x35 with nylon washer and spacer 20x6 5x20 8 1 M6x35 with nylon washer and spacer 20x6 5x20 9 1 M6x35 with nylon washer and spacer 20x6 5x20 10 1 M6x35 with nylon washer and spacer 20x6 5x20 NOTE 2 people are required for this task 2012 Volvo C30 T 5 ACCE...

Page 746: ... ROOF Install the headlining See HEADLINING WITH SUN ROOF NEW CALIBRATION OF 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 RECALIBRATION OF ELECTRIC MOTOR SUN ROOF MODULE SRM When installing a previously used electric motor control module perform recalibration See RECALIBRATIO...

Page 747: ...See GLASS SUN ROOF Pull the sun visor inner cover forwards Remove the 2 screws at the front mounting the 2 front slides Pull the sun visor inner cover further forwards Remove the 2 screws at the rear mounting the 2 rear slides INSTALLATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 748: ...UN ROOF FINISHING ADJUSTING THE LENS AND INSTALLING COMPONENTS Adjust the lens See SUN ROOF Install the apron molding See APRON MOLDING SUNROOF THE ELECTRIC MOTOR SUN ROOF MODULE SRM PREPARATORY WORK IGNITION OFF 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 alwa...

Page 749: ...on off REMOVAL REMOVING ELECTRIC MOTOR SUN ROOF MODULE SRM Move the sun visors to one side Remove the snap fasteners for the sun visors the front courtesy lighting See LIGHTING INTERNAL FRONT 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 750: ...ng Connector Courtesy of VOLVO CARS CORPORATION the connector Slacken off the 3 screws for the interior lighting frame 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 751: ...odule INSTALLATION INSTALLING ELECTRIC MOTOR SUN ROOF MODULE SRM Install the electric motor control module the 3 screws Tighten Tighten the 3 screws for the interior lighting frame Install the connector the front courtesy lighting See LIGHTING INTERNAL FRONT 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 752: ...installing a previously used electric motor control module perform recalibration See RECALIBRATION OF THE ELECTRIC MOTOR SUN ROOF MODULE SRM WIND DEFLECTOR SUNROOF REMOVAL REMOVING WIND DEFLECTOR SUN ROOF 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 corre...

Page 753: ...e grooves on the sides and past the lock grooves in the rear edge Bend the wind deflector down and position the locking tabs in under the edge of the panel Ensure that the ends have engaged in the lock grooves FINISHING RECALIBRATION OF THE ELECTRIC MOTOR SUN ROOF MODULE SRM Recalibrate of the electric motor control module See RECALIBRATION OF THE ELECTRIC MOTOR SUN ROOF MODULE SRM SIDE DOOR WITH ...

Page 754: ... See WELDING GENERAL Remove the side door See SIDE DOOR Materials Designation Part number Bodywork adhesive 1161524 PUR adhesive 1161821 Body putty 1161767 NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 755: ... Use PUR adhesive 1161821 Fig 47 Body putty 1161767 Courtesy of VOLVO CARS CORPORATION Use Body putty 1161767 Seal See BODY SEAL SEALING DIAGRAM Rust proof See RUSTPROOFING Install the side door See SIDE DOOR DOOR STOP FRONT SIDE DOOR 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 756: ...ATION Fig 49 Removing Door Stop From Front Side Door 2 Of 2 Courtesy of VOLVO CARS CORPORATION Remove the following items 1 Torque M6 10 Nm 2 Torque M8 24 Nm NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 757: ...rearview mirror external 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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 758: ... in reverse order Seal See BODY SEAL SEALING DIAGRAM Rust proof See RUSTPROOFING TRUNK LID TAILGATE WITH HINGE AND SUPPORT TAILGATE AND TRUNK LID HINGES Remove the following items NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 759: ...runk 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 Torque M6 10 Nm Install in the reverse order TAILGATE 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 760: ...lar 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 NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 761: ...ION Fig 58 Removing Tailgate 3 Of 5 Courtesy of VOLVO CARS CORPORATION Fig 59 Removing Tailgate 4 Of 5 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 762: ...r an unpainted body No max or min measurements are given since there must be harmony between the gaps on the visual surface If a black unpainted front fender is fitted on a white vehicle it will be much harder to see the size of the gap between the fender and the door LEVEL ADJUSTMENT APPLIES WHEN ADJUSTING DOORS FENDERS AND HATCHES NOTE The measurements vary from one vehicle to another This list ...

Page 763: ...nt part must be positioned above the part behind it see illustration partly to overlap in case of a collision partly to reduce wind noise Measurement M1 0 5 mm MEASUREMENTS ENGINE HOOD 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 764: ...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 F6 3 0 mm F7 3 3 mm F8 2 8 mm F9 0 7 mm MEASUREMENTS DOORS 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 765: ... 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 S6 2 2 mm S7 2 7 mm 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 766: ...CARS CORPORATION Measurements apply without rubber strip on the door arch S8 8 0 mm S9 9 0 mm S10 9 3 mm S11 9 2 mm S12 9 2 mm S13 9 1 mm MEASUREMENTS TRUNK LID 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 767: ...g Trunk Lid Measurements Courtesy of VOLVO CARS CORPORATION V50 R1 4 5 mm R2 6 1 mm R3 0 7 mm R4 4 0 mm R5 4 0 mm R6 4 0 mm 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 768: ...R7 3 3 mm R8 3 1 mm R9 0 8 mm R10 1 3 mm R11 4 0 mm WINDOW LIFT FRONT DOOR WINDOW LIFT MECHANISM ELECTRIC MOTOR REMOVAL NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 769: ...nism Electric Motor 2 Of 2 Courtesy of VOLVO CARS CORPORATION Torque M6 10 Nm INSTALLATION To install reverse the removal procedure Order and download software according to 30669920 Order and download software according to 30669923 Perform power window motor initiation see DOOR WINDOW MOTOR INITIALIZATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installati...

Page 770: ...ONT 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 NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 771: ...sm 3 Of 9 Courtesy of VOLVO CARS CORPORATION Torque M6 10 Nm Fig 72 Removing Front Door Window Lift Mechanism 4 Of 9 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 772: ...f VOLVO CARS CORPORATION Fig 74 Removing Front Door Window Lift Mechanism 6 Of 9 Courtesy of VOLVO CARS CORPORATION Fig 75 Removing Front Door Window Lift Mechanism 7 Of 9 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 773: ... 77 Removing Front Door Window Lift Mechanism 9 Of 9 Courtesy of VOLVO CARS CORPORATION INSTALLATION To install reverse the removal procedure Perform power window motor initiation see DOOR WINDOW MOTOR INITIALIZATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Doors And Lids Removal replacement and installation ...

Page 774: ...moving 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 NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Remov...

Page 775: ...RS CORPORATION Remove the following items the gear selector cables from the levers see 9997077 the gear selector cables from the brackets to prevent bending them when removing the lever NOTE As 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 2012 Volvo C3...

Page 776: ... lever Fig 5 Identifying Back Up Lamp Switch Connector Courtesy of VOLVO CARS CORPORATION Remove the following items the connector from the back up lamp switch the back up light switch see 9995543 INSTALLATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 777: ...ew 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 see 9512853 NOTE For tightening torques see TIGHTENING TORQUE 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 778: ...r with cables to the existing wiring See JOINING CABLES INSTALLING THE CONNECTOR Fig 9 Identifying Tie Strap Installed Courtesy of VOLVO CARS CORPORATION Install the connector with the wiring on the back up lamp switch Install a tie strap as shown in the illustration so that the cable harness is not in contact with the gear selector cable 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrica...

Page 779: ... to press in the pin the gear selector cables in the bracket selector cables to levers Install the air cleaner ACL housing Check the function CONTROL STALK LEFT REMOVAL Remove panel steering column see PANEL STEERING COLUMN 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 780: ...O CARS CORPORATION INSTALLATION To install reverse the removal procedure CONTROL STALK RIGHT REMOVAL Remove panel steering column see PANEL STEERING COLUMN Fig 13 Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 781: ...LLATION To install reverse the removal procedure DATA LINK CONNECTOR OBD II REMOVAL AND INSTALLATION Fig 15 Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 782: ...of VOLVO CARS CORPORATION Fig 17 Identifying Data Link Connector OBD II Release Tab Courtesy of VOLVO CARS CORPORATION Fig 18 Removing Data Link Connector 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 783: ...RPORATION Fig 19 Inserting Terminal Removal Tool Courtesy of VOLVO CARS CORPORATION NOTE Only work on 1 cable at a time 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 784: ...sy of VOLVO CARS CORPORATION Remove panel side door front see PANEL FRONT DOOR Fig 22 Identifying Driver Door Module DDM Screws Courtesy of VOLVO CARS CORPORATION Torque M6 10 Nm NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 785: ...Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION NOTE Make sure that the component terminals are not bent or damaged 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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical E...

Page 786: ...CTRICAL SOCKET Fig 24 View Of Ashtray Panel Courtesy of VOLVO CARS CORPORATION Remove the rear panel Disconnect the connector from the ashtray panel 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 787: ...screwdriver Press out the cigarette lighter electrical socket INSTALLATION INSTALLING THE CIGARETTE LIGHTER ELECTRICAL SOCKET Install the cigarette lighter electrical socket the connector the cover EXTRA POWER SOCKET 12V 2008 2012 REMOVAL AND INSTALLATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 788: ...S CORPORATION Fig 27 Extra Power Socket Remove Install Components 2 of 2 Courtesy of VOLVO CARS CORPORATION EXTRA POWER SOCKET 12V LUGGAGE COMPARTMENT 2008 2009 AND 2011 2012 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 789: ...TION FRONT POSITION SENSOR HEADLAMP 2007 2009 REMOVAL Fig 30 Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Follow instructions for lifting points body frame see JACKING POINTS BODY NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 790: ... 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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 791: ...ructions for lifting points body frame see JACKING POINTS BODY Fig 33 Identifying Front Position Sensor Headlamp Screws Courtesy of VOLVO CARS CORPORATION Torque M6 10 Nm INSTALLATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 792: ...E 2012 REMOVAL Fig 34 Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Follow instructions for lifting points body frame see JACKING POINTS BODY NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 793: ...rse 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 Tool boards 80 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 794: ... Fig 36 Removing Instrument Panel Console Switch Knob Courtesy of VOLVO CARS CORPORATION see 9814071 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 795: ...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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 796: ...tion In OFF Position Courtesy of VOLVO CARS CORPORATION Fig 40 Identifying Lighting Switch in OFF Position Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 797: ...ch Screws Courtesy of VOLVO CARS CORPORATION INSTALLATION To install reverse the removal procedure PASSENGER DOOR MODULE PDM REMOVAL NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 798: ...r Door Module DDM Screws Courtesy of VOLVO CARS CORPORATION Torque M6 10 Nm INSTALLATION To install reverse the removal procedure Order and download software according to 30669923 NOTE Make sure that the component terminals are not bent or damaged 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 799: ...VOLVO CARS CORPORATION Follow instructions for lifting points body frame see JACKING POINTS BODY Fig 46 Identifying Position Sensor Rear Headlamp Screws Courtesy of VOLVO CARS CORPORATION Torque M6 10 Nm NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 800: ...n OFF Position Courtesy of VOLVO CARS CORPORATION Follow instructions for lifting points body frame see JACKING POINTS BODY Fig 48 Identifying Position Sensor Rear Headlamp Screws Courtesy of VOLVO CARS CORPORATION NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 801: ...DLAMP 2011 LATE 2012 REMOVAL Fig 49 Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Follow instructions for lifting points body frame see JACKING POINTS BODY NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 802: ...ATION 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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 803: ...LVO CARS CORPORATION INSTALLATION To install reverse the removal procedure POWER SOCKET 12V 2008 2012 REMOVAL AND INSTALLATION Remove floor console see FLOOR CONSOLE REAR DOOR WINDOW REGULATOR ROTARY SWITCH REMOVAL 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 804: ...sy of VOLVO CARS CORPORATION Fig 55 Window Regulator Rotary Switch Rear Door Remove Install Components 1 Of 3 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 805: ...ve Install Components 3 of 3 Courtesy of VOLVO CARS CORPORATION INSTALLATION To install reverse the removal procedure ROTARY SWITCH FRONT DOOR WINDOW REGULATOR 2007 2011 EARLY REMOVAL Fig 58 Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 806: ...e Panel Courtesy of VOLVO CARS CORPORATION Fig 60 Identifying Door Handle Panel Clips Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 807: ...ION To install reverse the removal procedure ROTARY SWITCH FRONT DOOR WINDOW REGULATOR 2011 LATE 2012 REMOVAL Fig 62 Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 808: ...Panel Courtesy of VOLVO CARS CORPORATION Fig 64 Prying Up Front Side Switch Panel Frame Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 809: ...nel Frame Courtesy of VOLVO CARS CORPORATION Fig 66 Identifying Window Regulator Rotary Switch Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 810: ...ch Screws Courtesy of VOLVO CARS CORPORATION INSTALLATION Fig 68 Installing Front Door Switch Panel 1 of 2 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 811: ...N ROOF 2007 2011 REMOVAL CAUTION Only use moderate force CAUTION Make sure that equal pressure is applied to the full length of the component CAUTION Take extra care when handling the component 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 812: ...ORPORATION INSTALLATION To install reverse the removal procedure ROTARY SWITCH SUN ROOF 2012 PREPARATORY WORK 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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement a...

Page 813: ...sy of VOLVO CARS CORPORATION Ignition off REMOVAL REMOVING THE INTERIOR LIGHTING Remove the interior lighting See LIGHTING INTERNAL FRONT REMOVING THE SWITCH 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 814: ...TALLATION INSTALLING THE SWITCH Press in the conductive strap Lock in place Correctly position the rear of the switch and press the switch into place INSTALLING THE INTERIOR LIGHTING Install the interior lighting See LIGHTING INTERNAL FRONT STEERING WHEEL CONTROL MODULE 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 815: ...K LEFT Fig 74 Identifying Steering Wheel Control Module Bolts Courtesy of VOLVO CARS CORPORATION Torque Steering wheel control module to steering column 0 9 Nm NOTE Removal steps in this procedure may contain installation details CAUTION Make sure that the clockspring pins are not bent or damaged 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and install...

Page 816: ...stall reverse the removal procedure Order and download software according to 30667218 SWITCH CENTRAL LOCKING SYSTEM REMOVAL Fig 76 Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Remove panel side door front see PANEL FRONT DOOR 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 817: ...dure SWITCH HAZARD WARNING FLASHERS REMOVAL Remove inner ventilation nozzle see DRIVER SIDE REGISTER Fig 78 Identifying Hazard Warning Flashers Release Courtesy of VOLVO CARS CORPORATION INSTALLATION To install reverse the removal procedure 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 818: ...E Fig 79 Identifying Tunnel Compartment Switches Courtesy of VOLVO CARS CORPORATION Fig 80 View Of Tunnel Compartment Switch Tabs Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 819: ...iate switch using VIDA Volvo scan tool INSTALLATION To install reverse the removal procedure COLLISION AVOIDANCE DISTANCE SENSORS PARKING ASSISTANCE REAR 2007 2011 EARLY REMOVAL 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 820: ... Bumper Cover Upper Section see REAR BUMPER COVER UPPER SECTION 2007 2011 EARLY Fig 83 Removing Rear Parking Assistance Distance Sensors 1 Of 2 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 821: ...Of 2 Courtesy of VOLVO CARS CORPORATION INSTALLATION Fig 85 Installing Rear Parking Assistance Distance Sensors 1 Of 2 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 822: ...TANCE SENSORS PARKING ASSISTANCE REAR 2011 LATE 2012 REMOVAL Fig 87 Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Remove casing bumper rear see COVER BUMPER REAR 2007 2011 EARLY or COVER BUMPER REAR 2011 LATE 2012 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 823: ...LVO CARS CORPORATION Fig 89 Removing Rear Parking Assistance Distance Sensors 2 Of 2 Courtesy of VOLVO CARS CORPORATION INSTALLATION Follow instructions for paint see PAINT 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 824: ...king Assistance Distance Sensors 2 Of 2 Courtesy of VOLVO CARS CORPORATION To install reverse the removal procedure PARKING ASSISTANCE MODULE REMOVAL Remove the right side panel cargo compartment see SIDE PANEL LOADSPACE 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 825: ...removal procedure Order and download software according to 30786805 DOOR LOCKS ANTI THEFT SYSTEMS ANTENNA LOCKING SYSTEM KEYLESS ENTRY FRONT NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 826: ...of VOLVO CARS CORPORATION Remove the following items the 2 x nuts the antenna the connector Install in reverse order ANTENNA LOCKING SYSTEM KEYLESS ENTRY LUGGAGE COMPARTMENT Remove the center arm rest See CENTER ARMREST REAR 2007 2011 or CENTER ARMREST REAR 2012 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 827: ...646 2 Fig 96 Identifying Ignition Switch In OFF Position Courtesy of VOLVO CARS CORPORATION Remove casing bumper rear See REAR BUMPER COVER LOWER SECTION 2007 2009 or REAR BUMPER COVER LOWER SECTION 2010 2011 EARLY NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 828: ...tall in reverse order ANTENNA LOCKING SYSTEM KEYLESS ENTRY REAR 2011 LATE 2012 REMOVAL Fig 98 Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Remove casing bumper rear see COVER BUMPER REAR 2007 2011 EARLY or COVER BUMPER REAR 2011 LATE 2012 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 829: ...Of 2 Courtesy of VOLVO CARS CORPORATION Fig 100 Removing Keyless Entry Locking System Rear Antenna 2 Of 2 Courtesy of VOLVO CARS CORPORATION INSTALLATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 830: ...OLVO CARS CORPORATION Remove the plenum cover see PLENUM CHAMBER Fig 102 Identifying Anti Theft Protection Siren Bolts Courtesy of VOLVO CARS CORPORATION Torque M6 10 Nm NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 831: ...urtesy of VOLVO CARS CORPORATION Remove the plenum cover see PLENUM CHAMBER Fig 104 Locating Anti Theft Protection Siren Courtesy of VOLVO CARS CORPORATION Torque M6 NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 832: ... Siren 2 of 2 Courtesy of VOLVO CARS CORPORATION INSTALLATION To install reverse the removal procedure FRONT INTRUSION SENSOR 2007 2011 REMOVAL Make sure that the vehicle is modified See MASS MOVEMENT SENSOR MMS MODIFICATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 833: ...In OFF Position Courtesy of VOLVO CARS CORPORATION Fig 108 Front Intrusion Sensor Cover Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 834: ...ctor Courtesy of VOLVO CARS CORPORATION INSTALLATION To install reverse the removal procedure FRONT INTRUSION SENSOR 2012 REMOVAL 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 835: ...ver Courtesy of VOLVO CARS CORPORATION Fig 111 Front Intrusion Sensor Connector Courtesy of VOLVO CARS CORPORATION INSTALLATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 836: ...ying 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 REMOVING THE KEYLESS VEHICLE MODULE KVM 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 837: ...s the control module INSTALLATION INSTALLING THE KEYLESS VEHICLE MODULE KVM Install the control module the 2 x screws the 5 connectors CAUTION The pins on the control module are fragile Press the connectors in carefully 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 838: ...7 REMOVAL REMOVING THE COMBINED INSTRUMENT PANEL Remove the combined instrument panel See COMBINED INSTRUMENT PANEL REMOVING RECEIVER LOCK SYSTEM Fig 114 View Of Instrument Panel Screws NOTE Is the vehicle equipped with keyless entry system see RECEIVER LOCK SYSTEM KEYLESS ENTRY RKE 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 839: ...nstall the combined instrument panel See COMBINED INSTRUMENT PANEL LOCKING SYSTEM RECEIVER 2008 2012 REMOVAL Detach front edge of headlining with roof hatch see HEADLINING WITH SUN ROOF Fig 115 Locating Locking System Receiver Courtesy of VOLVO CARS CORPORATION Materials Designation Part number Melting adhesive 1161656 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal ...

Page 840: ...LVO CARS CORPORATION INSTALLATION Fig 117 Identifying Adhesive Courtesy of VOLVO CARS CORPORATION CAUTION Take extra care not to crease the headliner 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 841: ...VOLVO CARS CORPORATION To install reverse the removal procedure RECEIVER LOCK SYSTEM KEYLESS ENTRY RKE REMOVAL Detach front edge of headlining with roof hatch see HEADLINING WITH SUN ROOF Materials Designation Part number Melting adhesive 1161656 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 842: ...RS CORPORATION Fig 121 Removing Locking System Receiver Courtesy of VOLVO CARS CORPORATION INSTALLATION CAUTION Take extra care not to crease the headliner 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 843: ...tesy of VOLVO CARS CORPORATION Fig 123 Melting Adhesive 1161656 Courtesy of VOLVO CARS CORPORATION Use Melting adhesive 1161656 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 844: ...Courtesy of VOLVO CARS CORPORATION Remove the sun sensor alarm LED Use a weather strip tool the connector x 1 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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement a...

Page 845: ...dlamps see HEADLAMPS 2007 2009 HEADLAMPS 2010 2011 EARLY or 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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 846: ...VO CARS CORPORATION INSTALLATION To install reverse the removal procedure Fig 128 Installing Headlight Washer Courtesy of VOLVO CARS CORPORATION RAIN SENSOR REMOVAL 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 847: ...sy of VOLVO CARS CORPORATION Fig 130 Removing Rain Sensor 2 Of 3 Courtesy of VOLVO CARS CORPORATION Fig 131 Removing Rain Sensor 3 Of 3 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 848: ...mponent CAUTION The silicon surface must not be touched any contamination of the surface will damage the sensor Special tools 998 7693 UNIVERSAL SEPARATOR B75 MM L80 MM Tool number 998 7693 Tool description UNIVERSAL SEPARATOR B75 MM L80 MM Tool boards 08 NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Rem...

Page 849: ... Courtesy of VOLVO CARS CORPORATION see 9987693 Fig 133 Removing Rear Wiper Motor 2 Of 2 Courtesy of VOLVO CARS CORPORATION Torque M6 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 850: ...RS CORPORATION Remove casing bumper front see COVER BUMPER FRONT 2007 2011 EARLY For information on component position washer reservoir see LOCATION OF COMPONENTS WASHER RESERVOIR 2007 2011 EARLY NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 851: ...install reverse the removal procedure WASHER FLUID RESERVOIR 2011 LATE 2012 REMOVAL WARNING Be prepared to collect escaping fluid NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 852: ...asher reservoir see LOCATION OF COMPONENTS WASHER RESERVOIR 2011 LATE 2012 Remove casing bumper front see COVER BUMPER FRONT 2011 LATE 2012 Fig 137 View Of Washer Reservoir Screw Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 853: ...CARS CORPORATION Fig 139 Identifying Reservoir Tank Components Courtesy of VOLVO CARS CORPORATION WARNING Be prepared to collect escaping fluid 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 854: ...Torque M6 10 Nm INSTALLATION To install reverse the removal procedure WIPER ARM Special tools 981 4088 Puller Tool number 981 4088 Tool description Puller Tool boards 80 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 855: ...ove Key From Ignition Courtesy of VOLVO CARS CORPORATION CAUTION Make sure that the motor is in the park position 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 856: ...VOLVO CARS CORPORATION Torque Windshield wiper arm 21 Nm Fig 143 View Of Special Tool 9814088 Courtesy of VOLVO CARS CORPORATION see 9814088 INSTALLATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 857: ... From Ignition Courtesy of VOLVO CARS CORPORATION Remove the plenum cover see PLENUM CHAMBER NOTE Removal steps in this procedure may contain installation details CAUTION Make sure that the motor is in the park position 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 858: ...ON To install reverse the removal procedure WIPER MOTOR FRONT REMOVAL NOTE Removal steps in this procedure may contain installation details CAUTION Make sure that the motor is in the park position 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 859: ...TION Remove the wiper mechanism windscreen see WIPER MECHANISM WINDSHIELD Fig 148 Identifying Wiper Motor Front Components Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 860: ... of VOLVO CARS CORPORATION Torque M6 10 Nm INSTALLATION To install reverse the removal procedure NOTE Note the position of the component before removal NOTE Make sure that this component is installed to the noted removal position 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 861: ...moving 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 NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Remov...

Page 862: ...RS CORPORATION Remove the following items the gear selector cables from the levers see 9997077 the gear selector cables from the brackets to prevent bending them when removing the lever NOTE As 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 2012 Volvo C3...

Page 863: ... lever Fig 5 Identifying Back Up Lamp Switch Connector Courtesy of VOLVO CARS CORPORATION Remove the following items the connector from the back up lamp switch the back up light switch see 9995543 INSTALLATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 864: ...ew 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 see 9512853 NOTE For tightening torques see TIGHTENING TORQUE 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 865: ...r with cables to the existing wiring See JOINING CABLES INSTALLING THE CONNECTOR Fig 9 Identifying Tie Strap Installed Courtesy of VOLVO CARS CORPORATION Install the connector with the wiring on the back up lamp switch Install a tie strap as shown in the illustration so that the cable harness is not in contact with the gear selector cable 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrica...

Page 866: ... to press in the pin the gear selector cables in the bracket selector cables to levers Install the air cleaner ACL housing Check the function CONTROL STALK LEFT REMOVAL Remove panel steering column see PANEL STEERING COLUMN 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 867: ...O CARS CORPORATION INSTALLATION To install reverse the removal procedure CONTROL STALK RIGHT REMOVAL Remove panel steering column see PANEL STEERING COLUMN Fig 13 Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 868: ...LLATION To install reverse the removal procedure DATA LINK CONNECTOR OBD II REMOVAL AND INSTALLATION Fig 15 Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 869: ...of VOLVO CARS CORPORATION Fig 17 Identifying Data Link Connector OBD II Release Tab Courtesy of VOLVO CARS CORPORATION Fig 18 Removing Data Link Connector 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 870: ...RPORATION Fig 19 Inserting Terminal Removal Tool Courtesy of VOLVO CARS CORPORATION NOTE Only work on 1 cable at a time 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 871: ...sy of VOLVO CARS CORPORATION Remove panel side door front see PANEL FRONT DOOR Fig 22 Identifying Driver Door Module DDM Screws Courtesy of VOLVO CARS CORPORATION Torque M6 10 Nm NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 872: ...Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION NOTE Make sure that the component terminals are not bent or damaged 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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical E...

Page 873: ...CTRICAL SOCKET Fig 24 View Of Ashtray Panel Courtesy of VOLVO CARS CORPORATION Remove the rear panel Disconnect the connector from the ashtray panel 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 874: ...screwdriver Press out the cigarette lighter electrical socket INSTALLATION INSTALLING THE CIGARETTE LIGHTER ELECTRICAL SOCKET Install the cigarette lighter electrical socket the connector the cover EXTRA POWER SOCKET 12V 2008 2012 REMOVAL AND INSTALLATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 875: ...S CORPORATION Fig 27 Extra Power Socket Remove Install Components 2 of 2 Courtesy of VOLVO CARS CORPORATION EXTRA POWER SOCKET 12V LUGGAGE COMPARTMENT 2008 2009 AND 2011 2012 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 876: ...TION FRONT POSITION SENSOR HEADLAMP 2007 2009 REMOVAL Fig 30 Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Follow instructions for lifting points body frame see JACKING POINTS BODY NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 877: ... 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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 878: ...ructions for lifting points body frame see JACKING POINTS BODY Fig 33 Identifying Front Position Sensor Headlamp Screws Courtesy of VOLVO CARS CORPORATION Torque M6 10 Nm INSTALLATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 879: ...E 2012 REMOVAL Fig 34 Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Follow instructions for lifting points body frame see JACKING POINTS BODY NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 880: ...rse 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 Tool boards 80 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 881: ... Fig 36 Removing Instrument Panel Console Switch Knob Courtesy of VOLVO CARS CORPORATION see 9814071 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 882: ...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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 883: ...tion In OFF Position Courtesy of VOLVO CARS CORPORATION Fig 40 Identifying Lighting Switch in OFF Position Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 884: ...ch Screws Courtesy of VOLVO CARS CORPORATION INSTALLATION To install reverse the removal procedure PASSENGER DOOR MODULE PDM REMOVAL NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 885: ...r Door Module DDM Screws Courtesy of VOLVO CARS CORPORATION Torque M6 10 Nm INSTALLATION To install reverse the removal procedure Order and download software according to 30669923 NOTE Make sure that the component terminals are not bent or damaged 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 886: ...VOLVO CARS CORPORATION Follow instructions for lifting points body frame see JACKING POINTS BODY Fig 46 Identifying Position Sensor Rear Headlamp Screws Courtesy of VOLVO CARS CORPORATION Torque M6 10 Nm NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 887: ...n OFF Position Courtesy of VOLVO CARS CORPORATION Follow instructions for lifting points body frame see JACKING POINTS BODY Fig 48 Identifying Position Sensor Rear Headlamp Screws Courtesy of VOLVO CARS CORPORATION NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 888: ...DLAMP 2011 LATE 2012 REMOVAL Fig 49 Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Follow instructions for lifting points body frame see JACKING POINTS BODY NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 889: ...ATION 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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 890: ...LVO CARS CORPORATION INSTALLATION To install reverse the removal procedure POWER SOCKET 12V 2008 2012 REMOVAL AND INSTALLATION Remove floor console see FLOOR CONSOLE REAR DOOR WINDOW REGULATOR ROTARY SWITCH REMOVAL 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 891: ...sy of VOLVO CARS CORPORATION Fig 55 Window Regulator Rotary Switch Rear Door Remove Install Components 1 Of 3 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 892: ...ve Install Components 3 of 3 Courtesy of VOLVO CARS CORPORATION INSTALLATION To install reverse the removal procedure ROTARY SWITCH FRONT DOOR WINDOW REGULATOR 2007 2011 EARLY REMOVAL Fig 58 Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 893: ...e Panel Courtesy of VOLVO CARS CORPORATION Fig 60 Identifying Door Handle Panel Clips Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 894: ...ION To install reverse the removal procedure ROTARY SWITCH FRONT DOOR WINDOW REGULATOR 2011 LATE 2012 REMOVAL Fig 62 Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 895: ...Panel Courtesy of VOLVO CARS CORPORATION Fig 64 Prying Up Front Side Switch Panel Frame Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 896: ...nel Frame Courtesy of VOLVO CARS CORPORATION Fig 66 Identifying Window Regulator Rotary Switch Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 897: ...ch Screws Courtesy of VOLVO CARS CORPORATION INSTALLATION Fig 68 Installing Front Door Switch Panel 1 of 2 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 898: ...N ROOF 2007 2011 REMOVAL CAUTION Only use moderate force CAUTION Make sure that equal pressure is applied to the full length of the component CAUTION Take extra care when handling the component 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 899: ...ORPORATION INSTALLATION To install reverse the removal procedure ROTARY SWITCH SUN ROOF 2012 PREPARATORY WORK 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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement a...

Page 900: ...sy of VOLVO CARS CORPORATION Ignition off REMOVAL REMOVING THE INTERIOR LIGHTING Remove the interior lighting See LIGHTING INTERNAL FRONT REMOVING THE SWITCH 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 901: ...TALLATION INSTALLING THE SWITCH Press in the conductive strap Lock in place Correctly position the rear of the switch and press the switch into place INSTALLING THE INTERIOR LIGHTING Install the interior lighting See LIGHTING INTERNAL FRONT STEERING WHEEL CONTROL MODULE 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 902: ...K LEFT Fig 74 Identifying Steering Wheel Control Module Bolts Courtesy of VOLVO CARS CORPORATION Torque Steering wheel control module to steering column 0 9 Nm NOTE Removal steps in this procedure may contain installation details CAUTION Make sure that the clockspring pins are not bent or damaged 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and install...

Page 903: ...stall reverse the removal procedure Order and download software according to 30667218 SWITCH CENTRAL LOCKING SYSTEM REMOVAL Fig 76 Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Remove panel side door front see PANEL FRONT DOOR 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 904: ...dure SWITCH HAZARD WARNING FLASHERS REMOVAL Remove inner ventilation nozzle see DRIVER SIDE REGISTER Fig 78 Identifying Hazard Warning Flashers Release Courtesy of VOLVO CARS CORPORATION INSTALLATION To install reverse the removal procedure 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 905: ...E Fig 79 Identifying Tunnel Compartment Switches Courtesy of VOLVO CARS CORPORATION Fig 80 View Of Tunnel Compartment Switch Tabs Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 906: ...iate switch using VIDA Volvo scan tool INSTALLATION To install reverse the removal procedure COLLISION AVOIDANCE DISTANCE SENSORS PARKING ASSISTANCE REAR 2007 2011 EARLY REMOVAL 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 907: ... Bumper Cover Upper Section see REAR BUMPER COVER UPPER SECTION 2007 2011 EARLY Fig 83 Removing Rear Parking Assistance Distance Sensors 1 Of 2 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 908: ...Of 2 Courtesy of VOLVO CARS CORPORATION INSTALLATION Fig 85 Installing Rear Parking Assistance Distance Sensors 1 Of 2 Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 909: ...TANCE SENSORS PARKING ASSISTANCE REAR 2011 LATE 2012 REMOVAL Fig 87 Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Remove casing bumper rear see COVER BUMPER REAR 2007 2011 EARLY or COVER BUMPER REAR 2011 LATE 2012 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 910: ...LVO CARS CORPORATION Fig 89 Removing Rear Parking Assistance Distance Sensors 2 Of 2 Courtesy of VOLVO CARS CORPORATION INSTALLATION Follow instructions for paint see PAINT 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 911: ...king Assistance Distance Sensors 2 Of 2 Courtesy of VOLVO CARS CORPORATION To install reverse the removal procedure PARKING ASSISTANCE MODULE REMOVAL Remove the right side panel cargo compartment see SIDE PANEL LOADSPACE 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 912: ...removal procedure Order and download software according to 30786805 DOOR LOCKS ANTI THEFT SYSTEMS ANTENNA LOCKING SYSTEM KEYLESS ENTRY FRONT NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 913: ...of VOLVO CARS CORPORATION Remove the following items the 2 x nuts the antenna the connector Install in reverse order ANTENNA LOCKING SYSTEM KEYLESS ENTRY LUGGAGE COMPARTMENT Remove the center arm rest See CENTER ARMREST REAR 2007 2011 or CENTER ARMREST REAR 2012 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 914: ...646 2 Fig 96 Identifying Ignition Switch In OFF Position Courtesy of VOLVO CARS CORPORATION Remove casing bumper rear See REAR BUMPER COVER LOWER SECTION 2007 2009 or REAR BUMPER COVER LOWER SECTION 2010 2011 EARLY NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 915: ...tall in reverse order ANTENNA LOCKING SYSTEM KEYLESS ENTRY REAR 2011 LATE 2012 REMOVAL Fig 98 Identifying Ignition In OFF Position Courtesy of VOLVO CARS CORPORATION Remove casing bumper rear see COVER BUMPER REAR 2007 2011 EARLY or COVER BUMPER REAR 2011 LATE 2012 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 916: ...Of 2 Courtesy of VOLVO CARS CORPORATION Fig 100 Removing Keyless Entry Locking System Rear Antenna 2 Of 2 Courtesy of VOLVO CARS CORPORATION INSTALLATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 917: ...OLVO CARS CORPORATION Remove the plenum cover see PLENUM CHAMBER Fig 102 Identifying Anti Theft Protection Siren Bolts Courtesy of VOLVO CARS CORPORATION Torque M6 10 Nm NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 918: ...urtesy of VOLVO CARS CORPORATION Remove the plenum cover see PLENUM CHAMBER Fig 104 Locating Anti Theft Protection Siren Courtesy of VOLVO CARS CORPORATION Torque M6 NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 919: ... Siren 2 of 2 Courtesy of VOLVO CARS CORPORATION INSTALLATION To install reverse the removal procedure FRONT INTRUSION SENSOR 2007 2011 REMOVAL Make sure that the vehicle is modified See MASS MOVEMENT SENSOR MMS MODIFICATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 920: ...In OFF Position Courtesy of VOLVO CARS CORPORATION Fig 108 Front Intrusion Sensor Cover Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 921: ...ctor Courtesy of VOLVO CARS CORPORATION INSTALLATION To install reverse the removal procedure FRONT INTRUSION SENSOR 2012 REMOVAL 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 922: ...ver Courtesy of VOLVO CARS CORPORATION Fig 111 Front Intrusion Sensor Connector Courtesy of VOLVO CARS CORPORATION INSTALLATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 923: ...ying 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 REMOVING THE KEYLESS VEHICLE MODULE KVM 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 924: ...s the control module INSTALLATION INSTALLING THE KEYLESS VEHICLE MODULE KVM Install the control module the 2 x screws the 5 connectors CAUTION The pins on the control module are fragile Press the connectors in carefully 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 925: ...7 REMOVAL REMOVING THE COMBINED INSTRUMENT PANEL Remove the combined instrument panel See COMBINED INSTRUMENT PANEL REMOVING RECEIVER LOCK SYSTEM Fig 114 View Of Instrument Panel Screws NOTE Is the vehicle equipped with keyless entry system see RECEIVER LOCK SYSTEM KEYLESS ENTRY RKE 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 926: ...nstall the combined instrument panel See COMBINED INSTRUMENT PANEL LOCKING SYSTEM RECEIVER 2008 2012 REMOVAL Detach front edge of headlining with roof hatch see HEADLINING WITH SUN ROOF Fig 115 Locating Locking System Receiver Courtesy of VOLVO CARS CORPORATION Materials Designation Part number Melting adhesive 1161656 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal ...

Page 927: ...LVO CARS CORPORATION INSTALLATION Fig 117 Identifying Adhesive Courtesy of VOLVO CARS CORPORATION CAUTION Take extra care not to crease the headliner 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 928: ...VOLVO CARS CORPORATION To install reverse the removal procedure RECEIVER LOCK SYSTEM KEYLESS ENTRY RKE REMOVAL Detach front edge of headlining with roof hatch see HEADLINING WITH SUN ROOF Materials Designation Part number Melting adhesive 1161656 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 929: ...RS CORPORATION Fig 121 Removing Locking System Receiver Courtesy of VOLVO CARS CORPORATION INSTALLATION CAUTION Take extra care not to crease the headliner 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 930: ...tesy of VOLVO CARS CORPORATION Fig 123 Melting Adhesive 1161656 Courtesy of VOLVO CARS CORPORATION Use Melting adhesive 1161656 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 931: ...Courtesy of VOLVO CARS CORPORATION Remove the sun sensor alarm LED Use a weather strip tool the connector x 1 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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement a...

Page 932: ...dlamps see HEADLAMPS 2007 2009 HEADLAMPS 2010 2011 EARLY or 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 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 933: ...VO CARS CORPORATION INSTALLATION To install reverse the removal procedure Fig 128 Installing Headlight Washer Courtesy of VOLVO CARS CORPORATION RAIN SENSOR REMOVAL 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 934: ...sy of VOLVO CARS CORPORATION Fig 130 Removing Rain Sensor 2 Of 3 Courtesy of VOLVO CARS CORPORATION Fig 131 Removing Rain Sensor 3 Of 3 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 935: ...mponent CAUTION The silicon surface must not be touched any contamination of the surface will damage the sensor Special tools 998 7693 UNIVERSAL SEPARATOR B75 MM L80 MM Tool number 998 7693 Tool description UNIVERSAL SEPARATOR B75 MM L80 MM Tool boards 08 NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Rem...

Page 936: ... Courtesy of VOLVO CARS CORPORATION see 9987693 Fig 133 Removing Rear Wiper Motor 2 Of 2 Courtesy of VOLVO CARS CORPORATION Torque M6 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 937: ...RS CORPORATION Remove casing bumper front see COVER BUMPER FRONT 2007 2011 EARLY For information on component position washer reservoir see LOCATION OF COMPONENTS WASHER RESERVOIR 2007 2011 EARLY NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 938: ...install reverse the removal procedure WASHER FLUID RESERVOIR 2011 LATE 2012 REMOVAL WARNING Be prepared to collect escaping fluid NOTE Removal steps in this procedure may contain installation details 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 939: ...asher reservoir see LOCATION OF COMPONENTS WASHER RESERVOIR 2011 LATE 2012 Remove casing bumper front see COVER BUMPER FRONT 2011 LATE 2012 Fig 137 View Of Washer Reservoir Screw Courtesy of VOLVO CARS CORPORATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 940: ...CARS CORPORATION Fig 139 Identifying Reservoir Tank Components Courtesy of VOLVO CARS CORPORATION WARNING Be prepared to collect escaping fluid 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 941: ...Torque M6 10 Nm INSTALLATION To install reverse the removal procedure WIPER ARM Special tools 981 4088 Puller Tool number 981 4088 Tool description Puller Tool boards 80 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 942: ...ove Key From Ignition Courtesy of VOLVO CARS CORPORATION CAUTION Make sure that the motor is in the park position 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

Page 943: ...VOLVO CARS CORPORATION Torque Windshield wiper arm 21 Nm Fig 143 View Of Special Tool 9814088 Courtesy of VOLVO CARS CORPORATION see 9814088 INSTALLATION 2012 Volvo C30 T 5 ACCESSORIES AND BODY CAB Other Electrical Equipment Removal replacement and installation ...

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