FTV ZTs HNL 6 R14 M5 P

2007-2013 VOLVO C30 SERVICE
AND REPAIR MANUAL

2012 Volvo C30 T-5
ENGINE Engine Control - Removal, Replacement And Installation
ENGINE
Engine Control - Removal, Replacement And Installation
ACCELERATOR PEDAL
REMOVAL AND INSTALLATION
Fig. 1: Identifying Accelerator Pedal

Courtesy of VOLVO CARS CORPORATION
Torque: M6
10 Nm
2012 Volvo C30 T-5
ELECTRICAL Alternator And Regulator - Removal, Replacement And Installation
ELECTRICAL
Alternator And Regulator - Removal, Replacement And Installation
ALTERNATOR
GENERATOR (B5244S4; 2007-11)
REMOVAL
NOTE: Removal steps in this procedure may contain installation details.
Battery, disconnection. See BATTERY DISCONNECTING AND CONNECTING
Fig. 1: Identifying Bolts

Remove the auxiliaries belt. See ACCESSORY DRIVE BELT TENSIONER

2012 Volvo C30 T-5
Fig. 2: Identifying Generator B+ Terminal And Bolts

Remove the following items:
1. Torque: Generator B+ terminal
15 Nm
2. Torque: M8
24 Nm
INSTALLATION
To install, reverse the removal procedure.
GENERATOR (B5254T3; 2007, B5254T7; 2008-12)
REMOVAL
Fig. 3: Identifying Ignition In OFF Position

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

2012 Volvo C30 T-5
Fig. 4: Identifying Oil Stick Bracket Bolt

Fig. 5: Identifying Generator B+ Terminal And Nuts

1. Torque: Generator B+ terminal
15 Nm
2. Torque: M10
50 Nm
INSTALLATION

2012 Volvo C30 T-5
GENERATOR PULLEY, GENERATOR (B5244S4; 2007-11, B5254T7; 2008-12)
Special tools
999 7113 Spanner

Tool number: 999 7113
Tool description: Spanner
Tool boards: 30
Remove the alternator. See GENERATOR (B5254T3; 2007, B5254T7; 2008-12) or GENERATOR
(B5244S4; 2007-11)
Fig. 6: Identifying Spanner 9997113

see 9997113 see 9997113
CHARGE REGULATOR
CHARGE REGULATOR (B5244S4; 2007-11, B5254T3; 2007, B5254T7; 2008-12)
REMOVAL

2012 Volvo C30 T-5
Fig. 7: Identifying Nuts

Remove the generator (GEN). See GENERATOR (B5244S4; 2007-11) or GENERATOR (B5254T3; 2007,
B5254T7; 2008-12).
Fig. 8: Identifying M4 Generator Bolts

Torque: M4
3.5 Nm
INSTALLATION
To install, reverse the removal procedure

2012 Volvo C30 T-5
ELECTRICAL Battery And Mounting - Removal, Replacement And Installation
ELECTRICAL
Battery And Mounting - Removal, Replacement And Installation
BATTERY
REMOVAL
See SAFETY INFORMATION BATTERY AND CHARGING
Fig. 1: Identifying Underhood Torsion Rod, Nuts And Cover

Torque: M8
24 Nm
Fig. 2: View Of Battery And Cover

2012 Volvo C30 T-5
Perform battery disconnecting and connecting, see BATTERY DISCONNECTING AND CONNECTING
Fig. 3: Locating Battery Box And Terminal Connector Bolts

Fig. 4: Identifying Battery, Holder And Bolts

Torque: M6
10 Nm
INSTALLATION
VEHICLES WITH BATTERY MONITORING SENSOR (BMS)
Reset according to DIAGNOSTICS/VEHICLE COMMUNICATION/CEM/Advanced/Resetting information

2012 Volvo C30 T-5
when replacing battery (main battery) function. VIDA (Volvo Scan Tool) is necessary to perform this
procedure.
2012 Volvo C30 T-5
TRANSMISSION Manual Transmission
TRANSMISSION
Manual Transmission
TRANSMISSION
BEVEL GEAR
REMOVAL
Remove left-hand drive shaft, see DRIVESHAFT LEFT
Remove the right drive shaft, see DRIVE SHAFT RIGHT
Fig. 1: Identifying M7 Bolts

Torque: M7
17 Nm
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Fig. 2: Identifying Hose Strap

Fig. 3: Identifying Hose

Fig. 4: Identifying M8 And M10 Bolts

2012 Volvo C30 T-5
1. Torque: M8
24 Nm
2. Torque: M10
50 Nm

Torque: M10
50 Nm
Fig. 6: Removing Bevel Gear

2012 Volvo C30 T-5
Fig. 7: Identifying Bevel Gear

For information about transmission lubricants, see LUBRICANT TRANSMISSION

2012 Volvo C30 T-5
HVAC Automatic HVAC System
HVAC
Automatic HVAC System
HVAC
GLOW PLUG FUEL-POWERED PREHEATER
NOTE: The illustrations in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the illustrations is always correct.
PREPARATORY WORK
REMOVING THE COMBUSTION PREHEATER MODULE (CPM)
Remove the combustion preheater module (CPM). See: FUEL FIRED BOOSTER HEATER CONTROL
UNIT (TURBO) or FUEL FIRED BOOSTER HEATER CONTROL UNIT (NON-TURBO)
REMOVAL
REMOVING THE GLOW PLUG/PRESSURE EQUALIZER

2012 Volvo C30 T-5
Fig. 1: Identifying Screws For Cover Over Fan Housing

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 (TURBO) or
COOLANT PIPE FUEL-POWERED PREHEATER (NON-TURBO)
Fig. 2: Identifying Fan Housing

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
Fig. 3: Identifying Cable Terminals And Cables

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
Fig. 4: Identifying Flame Sensor And Pressure Equalizer

Disconnect the flame sensor (1) and with it the holder for the pressure equalizer (2).
Remove:
 the glow plug

 the pressure equalizer and the fuel pipe.
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.
INSTALLATION
NOTE: For tightening torques, see TIGHTENING TORQUE
INSTALLING THE GLOW PLUG / PRESSURE EQUALIZER
Install:
 the pressure equalizer

2012 Volvo C30 T-5
 the flame sensor together with the holder. Tighten

 the glow plug. Tighten.
Install the cable terminals and cables in the connectors.
- Flame sensor in positions 1 and 2 (blue and brown).
- Glow plug in positions 9 and 12 (white and brown).
NOTE: Route the cables behind the fan motor to the connector.
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
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 performance test of the engine's preheater. See: FUEL-POWERED PREHEATER, CHECKING
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Body Frame - Specifications, Mechanical
ACCESSORIES AND EQUIPMENT
Body Frame - Specifications, Mechanical
JACKING POINTS BODY
NOTE: The graphics in this service information are used for different model years
the graphics is always correct.
BODYWORK JACKING POINTS
LIFTING POINTS FOR LIFTING THE VEHICLE
Fig. 1: Identifying Lifting Points Of Vehicle

When lifting the vehicle, the lifting points indicated in the graphic must be used.
The jacking plate must have a rubber pad to prevent damage to the vehicle.
Do not lift at the front suspension, as there is a risk of the wheel alignment being altered.
2012 Volvo C30 T-5
FLOOR, FRAME SECTION, WHEEL HOUSING, BULKHEAD

SIDE MEMBERS REAR
NOTE: Some variation may occur. However, the essential information in the graphics is
always correct.
Fig. 2: View Of Symbol Numbers

Symbol legend
Measurement is given from centre
Measurement is given from an edge
Measurement is given from a cut marking
Fig. 3: Identifying Measurement Tools

2012 Volvo C30 T-5
For measuring, the recommendation is to use an electronic measuring device type Alvis Light or similar. A
deviation of +/- 2 mm is acceptable.
Fig. 4: Identifying Rear Measurements (1 Of 2)

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Fig. 5: Identifying Rear Measurements (2 Of 2)

SIDE MEMBERS, FRONT
always correct.

Symbol legend
Measurement is given from center
Fig. 7: Identifying Measurement Tools

2012 Volvo C30 T-5
For measuring, the recommendation is to use an electronic measuring device type Alvis Light or similar. A
deviation of +/- 2 mm is acceptable.
Fig. 8: Identifying Side Measurements (1 Of 3)

B1 = 1012 mm
B2 = 826 mm
B3 = 945 mm

B4 = 1198 mm
B5 = 1063 mm
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B6 = 1583 mm
B7 = 1421 mm
ROOF, WINDSHIELD AND REAR WINDSHIELD FRAME

ROOF

Symbol legend
Measurement is given from centre

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Fig. 12: Identifying Symbol Number 3 Measurement From The Bottom Of The Recess
Measurement 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

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Fig. 14: Identifying Windshield Frame Measurements

BODY SIDE

Explanation of symbols
As measured from centre
As measured from one edge

2012 Volvo C30 T-5
As measured from cut marking
Fig. 16: Identifying Symbol Number 3 Measurement From The Bottom Of The Recess
As measured 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)

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2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Body Frame - Removal, replacement and installation
ACCESSORIES AND BODY, CAB
Body Frame - Removal, replacement and installation
FLOOR, FRAME SECTION, WHEEL HOUSING, BULKHEAD

BUMPER RAIL, FRONT
REMOVAL
REMOVING THE FRONT BUMPER RAIL
Fig. 1: Removing Front Bumper Rail

Remove the front section. See: FRONT END .
Remove the bracket for the power steering. It is secured using 4 M8 screws.
2012 Volvo C30 T-5
Hang up the unit using wire.
Remove:
 the front screw, 1 x M6, for the washer reservoir

 the horn. It is secured using 2 M6 screws
 the cable harness and washer hose from the bumper rail.
NOTE: Note how the washer hose and cable are routed on the rail.
Support the radiator assembly. Detach the radiator. It is secured using 4 M8 screws.
Remove the remaining 6 M8 screws for the bumper rail. Remove the bumper rail.
INSTALLATION
NOTE: For tightening torques, see: TIGHTENING TORQUE .
INSTALLING THE FRONT BUMPER RAIL
Fig. 2: Installing Front Bumper Rail

2012 Volvo C30 T-5
Install:
 the bumper rail using the 6 M6 screws. Wait before installing the 2 screws for the servo unit
 the radiator using the 4 M8 screws
 the servo unit using the 4 M8 screws
 the cable harness and washer hose on the bumper rail
 the horn using the 2 M6 screws
 the washer reservoir using the 1 M6 screw
 the front section, seeFRONT END .
Rustproof. 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

2012 Volvo C30 T-5
Fig. 3: Aligning Front Wheel Arch

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
Fig. 4: Identifying Welding Locations For Replacement Part

Weld the replacement part into place. Lens diameter: Ø 4.5 mm.
Also, see WELDING, GENERAL .
Install components. See: FRONT SECTION, EXPOSING .
REAR BUMPER RAIL (2007-2009)
 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
Fig. 5: Removing Rear Bumper Rail

Torque: M8
24 Nm
Rust proof. See RUSTPROOFING .
Install in the reverse order.
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

2012 Volvo C30 T-5
Fig. 6: Removing Rear Bumper Rail

Torque: M8
24 Nm
For information about corrosion protection, see RUSTPROOFING
INSTALLATION
SIDE MEMBER REAR
PREPARATORY WORK
EXPOSING AND ASCERTAINING THE DAMAGE
When welding body components, see WELDING, GENERAL .
Remove the components, 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) .
2012 Volvo C30 T-5
REMOVAL
REMOVING THE REAR SIDE MEMBER
Fig. 7: Identifying The Cutting Point

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
Fig. 8: Installing Rear Side Member

Spot-weld the replacement part. Tip diameter: Ø 4.5 mm.
See the illustration for the location of the spot welds.
Apply rustproofing. See RUSTPROOFING .
Install the components, seeREAR SECTION, 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
2012 Volvo C30 T-5
PREPARATORY WORK (COMMON TO BOTH METHODS)
PREPARATORY WORK
Fig. 9: Identifying Cut Points

When welding body components, see: WELDING, GENERAL .
Remove components. See: FRONT SECTION, EXPOSING .
Determine the extent of the damage. See: SIDE MEMBERS, FRONT and FRONT END .
METHOD CONTENTS
This method consists of:
 see SIDE MEMBER LOWER, REPLACEMENT

 see SIDE MEMBER, UPPER, REPLACING.
SIDE MEMBER LOWER, REPLACEMENT

2012 Volvo C30 T-5
REMOVING THE OUTER SECTION OF THE LOWER SIDE MEMBER
Fig. 10: Identifying Side Member Cutting Area

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
Fig. 11: Identifying Cutting Points

Cutting point (1)
This cutting point 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
Fig. 12: Removing Upper Part Of Side Member Extension

If the member is cut at cutting point (2), remove the upper part of the side member extension.
2012 Volvo C30 T-5
Fig. 13: Removing Outer Part Of Cross Member Cowl Panel

Remove the outer part of the cross member cowl panel.
INSTALLING THE INNER SECTION OF THE LOWER SIDE MEMBER

2012 Volvo C30 T-5
Fig. 14: Installing Inner Section Of Lower Side Member (1 Of 2)

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.

2012 Volvo C30 T-5
Fig. 15: Installing Inner Section Of Lower Side Member (2 Of 2)

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
Fig. 16: Installing Outer Section Of Lower Side Member

Grind clean.
For location of the spot-weld, see below.
LOCATION OF THE SPOT-WELD

2012 Volvo C30 T-5
Fig. 17: Identifying Spot-Weld Location

INSTALLING COMPONENTS
2012 Volvo C30 T-5
Fig. 18: Identifying Seam-Weld Area On Collar

Seam-weld the collar into place using 8 welding seams each measuring 30 mm. 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
Fig. 19: Removing Outer Section Of Upper Side Member

Drill or grind out the spot welds.
The member can also be joined at (1).
NOTE: If the inner section is joined, the distance between the joins must be at least
50mm.
REMOVING THE INNER SECTION OF THE UPPER SIDE MEMBER

2012 Volvo C30 T-5
Fig. 20: Removing Inner Section Of Upper Side Member

Drill or grind out the spot welds.
INSTALLING THE INNER SECTION OF THE UPPER SIDE MEMBER
Grind clean.
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
INSTALLING THE OUTER SECTION OF THE UPPER SIDE MEMBER
Grind clean.
Secure the upper side member.
FINISHING WORK (COMMON TO BOTH METHODS)
SUPPLEMENTARY WORK AND INSTALLING COMPONENTS
Seal. See: BODY SEAL, SEALING DIAGRAM .
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)

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2012 Volvo C30 T-5
Install the outer back piece. See TAIL SECTION EXTERNAL
Seal. See BODY SEAL, SEALING DIAGRAM
Rust proof. See RUSTPROOFING
WHEEL ARCH REAR
Welding body components. 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)

Fig. 26: Removing Rear Wheel Arch (2 Of 2)

2012 Volvo C30 T-5
ROOF, WINDSHIELD AND REAR WINDSHIELD FRAME

CANT RAIL/ROOF SIDE
INFORMATION
PRINCIPLES OF JOINING
Fig. 27: Identifying Cutting Points For C And D-Posts

Roof pillars must be joined as shown in the illustration unless otherwise indicated in the method.
Cut the different panel sections with a 50 mm offset. This applies when replacing all roof pillars.
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.
2012 Volvo C30 T-5
REMOVAL
REMOVING THE CANTRAIL / ROOF SIDE
Fig. 28: Removing Cantrail / Roof Side

Remove components. See: ROOF SECTION, EXPOSING (2007-2009) or ROOF SECTION, EXPOSING
(2010-2012) .
Pull or press out the damaged section to make it easier to re-align internal components.
Determine the extent of the damage. See BODY SIDE and ROOF .
NOTE: Do not replace too small a section of the cant rail/roof side since the damage
may have spread.
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.
2012 Volvo C30 T-5
If replacing the cantrail without replacing the roof panel, the cantrail must be cut from front to rear at the top
edge and then bead welded back together.
Grind and drill out the spot welds and bead welds.
Pry off the cantrail.
Grind clean.
INSTALLATION
INSTALLING THE CANTRAIL / ROOF SIDE
Fig. 29: Installing Cantrail / Roof Side

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
Take care not to damage the internal reinforcements when sawing.
Secure the edges of the joints by tack welding.
Complete the welding. See also: WELDING, GENERAL .
Seal to the roof panel. See: ROOF PANEL.
Rust-proof. See: RUSTPROOFING .
Install components. See: ROOF SECTION, EXPOSING (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

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
Designation Part number

2-component foam 3M 08463
Masking tape 9511050-8
Seal 3M 08115
REMOVAL
Follow the instructions regarding welding, general, see WELDING, GENERAL
Remove roof section, exposing, see ROOF SECTION, EXPOSING (2007-2009) or ROOF SECTION,
EXPOSING (2010-2012) .
For information about roof, see ROOF
INSTALLATION
Fig. 31: Installing Roof Panel (1 Of 8)


2012 Volvo C30 T-5

Use: 2-component foam, 3M 08463

2012 Volvo C30 T-5

Use: Masking tape, 9511050-8
For information about body sealant, sealing diagram, see BODY SEAL, SEALING DIAGRAM

2012 Volvo C30 T-5

NOTE: Make sure that the seal is correctly located.

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
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Materials:
Insulation foam 3M 08463
Welding body components. See WELDING, GENERAL .
Remove the side section. See SIDE SECTION, EXPOSING .
Fig. 39: Removing/Installing A-Pillar (1 Of 8)

2012 Volvo C30 T-5

Use: Insulation foam, 3M 08463

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2012 Volvo C30 T-5

Install the side door's hinges. See DOOR HALF HINGE
Seal the A-pillar. See BODY SEAL, SEALING DIAGRAM .
Rustproof the A-pillar. See RUSTPROOFING .
Install the side section. See SIDE SECTION, EXPOSING .
B-POST
Materials:
 rear fender. See FENDER

 sill molding. See BODY SILL REINFORCEMENT

2012 Volvo C30 T-5
Fig. 47: 2-component foam, 3M 08463

BODY SIDE INNER
 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
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Fig. 48: Removing Body Side Inner Section (1 Of 3)



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BODY SILL REINFORCEMENT
Remove. See SIDE SECTION, EXPOSING
Fig. 51: Alternative Sill Molding Cutting Points

Alternative sill molding cutting points.
Fig. 52: View Of Sill Molding Reinforcement Assembly

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replaced.
 Rear fender. See FENDER

 A-pillar. See A-PILLAR
Alternative cutting points.
Fig. 53: Identifying Body Sill Weld Points (1 of 2)

Fig. 54: Identifying Body Sill Weld Points (2 of 2)

Install the following items:

 A-pillar. See A-PILLAR
2012 Volvo C30 T-5
 Rear fender. See FENDER
Seal. See BODY SEAL, SEALING DIAGRAM .
Install the side section. See SIDE SECTION, EXPOSING .
REAR SECTION, REAR SHELF

BACK PIECE INNER
PREPARATORY WORK
REMOVING COMPONENTS AND ASCERTAINING THE DAMAGE
Remove:
 parts according to: REAR SECTION, EXPOSING (2007-2009) or REAR SECTION, EXPOSING
(2010-2012) .
 the outer rear section, see TAIL SECTION EXTERNAL
 the rear bumper rail. See: REAR BUMPER RAIL.
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

2012 Volvo C30 T-5
Fig. 55: Installing Inner Rear Section

Spot-weld the replacement part. Tip diameter Ø 4, 5 mm.
Weld the load eyelets into place.
Install:
 the rear bumper rail, see REAR BUMPER RAIL

 the outer rear section, see TAIL SECTION EXTERNAL.
Install components. See: REAR SECTION, EXPOSING (2007-2009) or REAR SECTION, EXPOSING
(2010-2012) .
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TAIL SECTION EXTERNAL
Materials:
Insulation foam 3M 08643
Remove the rear section. See REAR SECTION, EXPOSING (2007-2009) or REAR SECTION,
EXPOSING (2010-2012) .
Fig. 56: Removing External Tail Section (1 Of 3)

Alternative cutting points.

2012 Volvo C30 T-5

Use: Insulation foam, 3M 08643

Seal, see BODY SEAL, SEALING DIAGRAM
Apply rustproofing agent. See RUSTPROOFING .
Check the vehicle's whiplash system. See COLLISION PROTECTION UNIT FROM BEHIND FRONT
SEAT CHECK
TAIL SECTION, SIDE
PREPARATORY WORK
REMOVING COMPONENTS AND ASCERTAINING THE DAMAGE
Remove:
(2010-2012) .
 the rear bumper rail, see: REAR BUMPER RAIL.
Determine the extent of the damage. See REAR SECTION .

2012 Volvo C30 T-5
REMOVING THE REAR SECTION SIDE
Fig. 59: Removing Rear Section Side

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
Fig. 60: Installing Side Rear Section

Secure the replacement part.
Spot-weld the replacement part. Tip diameter: Ø 4.5 mm.
Seam-weld as shown in the illustration:
(1) = 65 mm
(2) = 85 mm
Rust-proof. See: RUSTPROOFING .
Install:
2012 Volvo C30 T-5
 the rear bumper rail. See: REAR BUMPER RAIL.

(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 - General Information
Body Frame - General Information
BODY REPAIR
BODY SEAL, SEALING DIAGRAM
Materials:
Seal 1161767
Spray sealant 1161651
Seal 3M 08115
Soundproofing 68117640
SEALING PRODUCTS
Fig. 1: Using Seal, 1161767

1. Weatherstrip
When replacing sheet metal parts, the joints between the different sheet metal parts shall be sealed according to
illustration
Use: Seal, 1161767

2012 Volvo C30 T-5
Fig. 2: Spray sealant, 1161651

2. Spray sealant
The putty can be applied in a bead, be sprayed in a thin layer or brushed on with a paintbrush.
Use: Spray sealant, 1161651
When applying in 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

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
3M 08115 is not approved as a substitute for Volvo bodywork adhesive.
If 3M 08115 is not available, then sealing compound with the following properties should be used:
 -flows out without running

 -has the correct hardness
 -can be sanded when hardened
 -has the correct flexibility.
Fig. 4: Soundproofing, 68117640

4. Foam rubber replacement soft (soundproofing foam)
Soundproofing foam is installed in hollow spaces to counteract propagation of sound in the body. There are 2
types of approved soundproofing foam:
Volvo's soundproofing foam consists of a wax-treated cylinder 50x50 mm. It can be compressed for
installation between metal parts. Several cylinders can be used if one is not enough.
Use: Soundproofing, 68117640
3M ' 2-component foam starts to foam when the components are mixed. The foam is suitable for filling of
larger hollow spaces and can be applied between the roof bow and the roof panel. Follow the supplier's
instructions for application.
RUSTPROOFING
Special tool
2012 Volvo C30 T-5
Tool number: T9814075

Tool description: SPRAY GUN
Tool boards:
T9814076 SPRAY GUN

Tool description: SPRAY GUN
Tool boards:
Materials:
Cavity protection 1161682
Stone-chip protection 1161815
Underbody protection 116 1298
PREPARATION
Fig. 5: Cavity protection, 1161682

Rustproofing diagram for cavity protection
Attach the following items:
 see 9814075
 Use: Cavity protection, 1161682
Cavity protection is used for, e. g., weld seams and areas that have been reworked in other ways.
2012 Volvo C30 T-5
Insert the hose in the cavity and spray at the same time as the hose is pulled out slowly.
If repairs are made to the body, the areas marked in the illustrations are to rustproof extra thoroughly.
Fig. 6: Identifying Areas Rustproofing

Fig. 7: Identifying Areas Rustproofing

2012 Volvo C30 T-5
Fig. 8: Stone-chip protection, 1161815

Rustproofing schedule for stone-chip protection
Use: Stone-chip protection, 1161815
Apply stonechip protection to the areas of the vehicle marked in blue in the illustration.
see 9814076 .
Fig. 9: Underbody protection, 1161298

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
see 9814076
SHEET METAL, MATERIAL INFORMATION
STEEL, MATERIAL INFORMATION
Fig. 10: Identifying Sheet Metal, Material Information

2012 Volvo C30 T-5
Fig. 11: Identifying Steel, Material Information

Fig. 12: Identifying Zinc Area

2012 Volvo C30 T-5
Fig. 13: Identifying Zinc Area

HSS (High Strength Steel) is a general term for steel material within a specific strength range.
The vehicles are built of different steel material, partly to optimize the body (impact safety, rigidity, fuel
economy, etc.) and partly to make it as repair-friendly as possible. The steel material is classified into four
different groups based on tensile strength, which is the force required to plastically deform the material.
 Mild steel (MS). Trade steel with highest tensile strength of 180 MPa.
 High tensile strength steels (HS). Steel with a tensile 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.
CAUTION: HSS material must not be heated via gas welding or the like.
Mild Steel. This category of steel is used where use of a stronger steel is not necessary.
High Strength Steel There are three main types of steel in this category:
 Phosphorus-alloyed steel obtains is increase in strength with the help of the alloy matter phosphorus.
 HSLA steel (High Strength Low Alloy) is a low alloy steel in which the steel obtains its increase in
2012 Volvo C30 T-5
strength with the help of the alloy matter Vanadium, Niobium or Titanium.
 DP steel (Dual Phase) obtains its increase in strength through the thermal treatment that the steel
undergoes during manufacture. Then a two-phase structure of ferrite (iron) and martensite (carbon) is
formed. This steel loses its strength when exposed to temperatures above 300°C.
Extra High Strength Steel. This category contains both HSLA and DP steel, but the strength has been further
increased with greater additions of alloy substances.
Ultra High Strength Steel. There are two main types of steel in this category:
 DP-steel. Here, strength has been further increased with an advanced manufacturing 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 plasma cutting is recommended when replacing BORON steel components. BORON steel
welds well. It is not possible to galvanized BORON steel during the production process. It is therefore
very important to rustproof these components extra thoroughly.
CAUTION: BORON steel must not be straightened.
Fig. 14: Identifying Plastic, Material Information (Rear View)

2012 Volvo C30 T-5
Fig. 15: Identifying Plastic, Material Information (Front View)

WELDING, GENERAL (2007-2011)
GENERAL
Volvo bodies are manufactured to the highest quality. All bodywork repairs must therefore take place following
the same principles. Use light tools. Take care of the surface coating, electro dip (ED) and phosphating.
Always use welding primer between welded panel flanges.
PRIOR TO WELDING
CAUTION: Always remove the battery cables before welding in accordance with:
BATTERY DISCONNECTING AND CONNECTING .
CAUTION: Locate the welding ground connection as close as possible to the welding
point.
2012 Volvo C30 T-5
CAUTION: If the welding must be carried out in the immediate vicinity of an electronic
unit then this must be removed.
ASSEMBLY
Spot welding is mainly used when the bodies are manufactured, and use of this method should always be aimed
for with a repair.
CAUTION: Gas welding must not be used on Volvo bodywork.
WARNING: Use ventilation / extraction equipment.
Unless otherwise specified in the method, the distance between the welds must be the same as the original
design.
Fig. 16: Identifying Welding Symbols

There are a number of other assembly methods that are illustrated with the following symbols:
1. Spot weld/spot weld with the location of the weld and lens diameter specified with color (may be
replaced with 2)
2. 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
2012 Volvo C30 T-5
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.
NOTE: Always test weld in accordance with the method below. Always set the weld
according to panel quality
MAG WELDING
Punch replacement 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

Test weld several test pieces. Break the panels apart and measure the size of the welding lens diameter (A), see
illustration.
2012 Volvo C30 T-5
Fig. 18: Identifying Proper Spot Welds On Both Panels

NOTE: Use welding primer on all internal flanges.
Add filling primer if there is grinding damage.
CAUTION: Make sure that the spot welds take properly on both panels.
Fig. 19: Grinding Properly And Improperly

Grind down the plug weld.
CAUTION: Only grind welds, not the adjacent panel.

2012 Volvo C30 T-5
WELDING, GENERAL (2012)
GENERAL
Volvo bodies are manufactured to the highest quality. All bodywork repairs must therefore take place following
the same principles. Use light tools. Take care of the surface coating, electro dip (ED) and phosphating.
Always use welding primer between welded panel flanges.
PRIOR TO WELDING
CAUTION: Always remove the battery cables before welding in accordance with:
BATTERY DISCONNECTING AND CONNECTING .
CAUTION: Locate the welding ground connection as close as possible to the welding
point.
CAUTION: If the welding must be carried out in the immediate vicinity of an electronic
unit then this must be removed.
ASSEMBLY
Spot welding is mainly used when the bodies are manufactured, and use of this method should always be aimed
for with a repair.
CAUTION: Gas welding must not be used on Volvo bodywork.
WARNING: Use ventilation / extraction equipment.
Unless otherwise specified in the method, the distance between the welds must be the same as the original
design.
2012 Volvo C30 T-5
Fig. 20: Identifying Welding Symbols

There are a number of other assembly methods that are illustrated with the following symbols:
1. Spot weld/spot weld with the location of the weld and lens diameter specified with color (may be
replaced with 2)
2. 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
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.
NOTE: Always test weld in accordance with the method below. Always set the weld
according to panel quality
MAG WELDING
Punch replacement part for plug welding.
Select size of hole for plug welding according to the following panel thicknesses:
2012 Volvo C30 T-5
8 mm for thicknesses less than 2.5 mm
10 mm or more for thicknesses above 2.5 mm.
Fig. 21: Identifying Welding Lens Diameter

Test weld several test pieces. Break the panels apart and measure the size of the welding lens diameter (A), see
illustration.
Fig. 22: Identifying Proper Spot Welds On Both Panels

NOTE: Use welding primer on all internal flanges.
Add filling primer if there is grinding damage.
CAUTION: Make sure that the spot welds take properly on both panels.
2012 Volvo C30 T-5
Fig. 23: Grinding Properly And Improperly

Grind down the plug weld.
CAUTION: Only grind welds, not the adjacent panel.

2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB General - Removal, replacement and installation
General - Removal, replacement and installation
DISMANTLING WORK PRIOR TO BODY REPAIR

FRONT SECTION, EXPOSING
 Front fender. See FENDER

 Bottom sill. See BODY SILL REINFORCEMENT
 Bumper front. See COVER BUMPER FRONT (2007 - 2011 EARLY) or COVER BUMPER FRONT
(2011 LATE - 2012) .
 Fender widener. See FRONT FENDER WIDENER
 Wire hood lock. See WIRE LOCK ENGINE HOOD
 Hinge engine hood. See HOOD HINGE
 Radiator grille. See RADIATOR GRILLE (2007 - 2011 EARLY) or RADIATOR GRILLE (2011
LATE - 2012) .
 Headlights. See HEADLAMPS (2007-2009) , HEADLAMPS (2010 - 2011 EARLY) , or
HEADLAMPS (2011 LATE - 2012) .
 Fog lights front. See FRONT FOG 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 AND INSTALLATION
SIDE SECTION, EXPOSING
REMOVAL
 Body sill reinforcement, see BODY SILL REINFORCEMENT

 A-pillar trim panel, see A-PILLAR TRIM PANEL
 B-pillar trim panel, see B-PILLAR TRIM PANEL
C-pillar trim panel, see C-PILLAR TRIM PANEL
2012 Volvo C30 T-5
 side door, see SIDE DOOR

 Inflatable curtain, see INFLATABLE CURTAIN (2010-2012)
 Front fender widener, see FRONT FENDER WIDENER
 fender extension rear, see REAR FENDER WIDENER
 The front sill trim panel, see THE FRONT SILL TRIM PANEL
 The rear sill trim panel, see THE REAR SILL TRIM PANEL
 Sill panel, see SILL PANEL
 Front seat, see FRONT SEAT
 Side window fixed, rear, see FIXED SIDE WINDOW
 the dashboard, see DASHBOARD
ROOF SECTION, EXPOSING (2007-2009)
REMOVAL

 C-pillar trim panel, see C-PILLAR TRIM PANEL
 Headlining with sun roof, see HEADLINING WITH SUN ROOF
 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

 C-pillar trim panel, see C-PILLAR TRIM PANEL
 headlining
2012 Volvo C30 T-5
 Inflatable curtain, see INFLATABLE CURTAIN

 Glass sun roof, see GLASS SUN ROOF
 Wind deflector sunroof, see WIND DEFLECTOR SUNROOF
 Windshield, see WINDSHIELD
REAR SECTION, EXPOSING (2007-2009)
REMOVAL

 Side panel loadspace, see SIDE PANEL LOADSPACE
 Rear bumper rail, see REAR BUMPER RAIL
 tank hatch, see FUEL TANK FILLER COVER
 Door latch fuel filler door, see DOOR LATCH FUEL FILLER DOOR
 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

 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 BUMPER
REAR (2011 LATE - 2012)
 tank hatch, see FUEL TANK FILLER COVER
 Door latch fuel filler door, see DOOR LATCH FUEL FILLER DOOR
2012 Volvo C30 T-5
BRAKES Brake Control System - Removal, Replacement And Installation
BRAKES
Brake Control System - Removal, Replacement And Installation
ANTI-LOCK BRAKE (ANTI-SKID) (2007-12)

ANTI-LOCK BRAKE SYSTEM MODULE (ABS)
REMOVAL
Remove battery. See BATTERY
Fig. 1: Identifying Anti-Lock Brakes And Brake Pipe

1. Torque: Anti-lock brakes
14 Nm
2. Torque: Brake pipe M12 with wrench size 11mm
14 Nm
2012 Volvo C30 T-5

NOTE: Make sure that the mating faces are clean and free of foreign material.
Torque: M5
5 Nm
Remove hydraulic unit brake system. See HYDRAULIC UNIT BRAKE SYSTEM
INSTALLATION
Order and download software according to 30667171
Calibrate according to VIDA/DIAGNOSTICS/VEHICLE COMMUNICATION/Advanced/BCM/Calibration

(only vehicles with DSTC) using Volvo specific VIDA scan tool.
ANTI-LOCK BRAKE (ANTI-SKID) (2011-12)

HYDRAULIC UNIT BRAKE SYSTEM
REMOVAL
VEHICLES WITH STABILITY ASSIST
Perform anti-lock brake system module (ABS). See ANTI-LOCK BRAKE SYSTEM MODULE (ABS)
2012 Volvo C30 T-5
Fig. 3: Identifying Hydraulic Unit Brake System

NOTE: When installing this component, do not download any new software.
INSTALLATION

2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Installation Instructions, Accessories
BRAKES
Hydraulic-Vacuum-Hydraulic Brakes - Installation Instructions, Accessories
METAL PEDALS
METAL PEDALS
Fig. 1: Removing Original Covers (Manual Transmissions)

Graphic above applies to cars with manual transmissions. Graphic below applies to cars with automatic
transmissions
 Remove the rubber covers from the pedals by grasping the upper edge and pulling backwards.
 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
Fig. 3: Opening the Tabs

 Take the accelerator pedal's metal trimmed rubber cover from the kit.
 Hold as shown and fold out the three tabs.
Fig. 4: Fitting New Cover

 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
Fig. 5: Securing New Cover

 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.
APPLIES TO CARS WITH MANUAL TRANSMISSIONS
Fig. 6: Identifying Spacers

 Take the two spacer washers from the kit.

 Carefully separate the two covers from each other.
2012 Volvo C30 T-5
Fig. 7: Peeling Protective Film

 Remove the protective film from both covers. Ensure that the surfaces of the pedals are clean.
Fig. 8: Positioning Covers

 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

 Take one of the remaining covers from the kit.

Fig. 10: Fitting New Cover

 Hook the cover at the upper edge, at the same time hold the tabs and pull downwards.
2012 Volvo C30 T-5
Fig. 11: Securing New Cover

 Repeat steps 8-10 for the remaining pedal.
APPLIES TO CARS WITH AUTOMATIC TRANSMISSIONS
Fig. 12: Removing Protective Film

 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
Fig. 13: Positioning Spacers

 Position the longer cover, which has markings, in the recess on the brake pedal and press securely. The
thicker part of the cover must point downwards.

 Take the brake pedal's metal trimmed rubber cover from the kit.
2012 Volvo C30 T-5
Fig. 15: Fitting the Cover

 Hook the cover onto the right-hand shorter side of the pedal, at the same time hold the tabs and pull to the
left and downwards.
Fig. 16: Securing the Cover

BRAKE PEDALS
2012 Volvo C30 T-5
Fig. 17: Identifying The Pedals

Sport pedals
Equipment
Fig. 18: Weatherstrip Tool

Kit contents
2012 Volvo C30 T-5
Fig. 19: Identify the Kit Contents

2012 Volvo C30 T-5
Fig. 20: Kit for Manual Transmission

INSTALLATION
Fig. 21: Verify Clean Surfaces

2012 Volvo C30 T-5
Clean the surface.
Fig. 22: Removing Original Cover

Fig. 23: New Cover Fully in Place

2012 Volvo C30 T-5
Fig. 24: Use Mirror to Check

CAUTION: Using a mirror check that the pedal rubber covers the edges of the pedal.
CARS WITH AUTOMATIC TRANSMISSIONS
Fig. 25: Removing Brake Pedal Pad

The part(s) are not to be reused.

2012 Volvo C30 T-5
Fig. 26: Installing New Pad

Hook the pedal rubber onto the pedal at the lower edge and pull the pedal rubber upward.
Fig. 27: Use Tool As Needed

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
Fig. 28: Verify With Mirror

CARS WITH MANUAL TRANSMISSIONS
Fig. 29: Remove Original Pad

The part(s) are not to be reused.

2012 Volvo C30 T-5
Fig. 30: Installing New Pad

Hook the pedal rubber onto the pedal at the lower edge and pull the pedal rubber upward.
Fig. 31: Use Tool as Needed

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
Fig. 32: Verify with Mirror

LEFT HAND DRIVE VEHICLES
Repeat method steps for the clutch pedal.

2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Bumpers And Mudflaps - Installation Instructions, Accessories
ACCESSORIES AND EQUIPMENT
Bumpers And Mudflaps - Installation Instructions, Accessories
DECOR PANEL (2009-12)

DECOR PANEL
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.
APPLIES TO CARS WITHOUT ENGINE BLOCK HEATERS
Fig. 1: Prying Off Panel At Lower Edge

 Carefully pry off the panel at the lower edge and remove it.
APPLIES TO CARS WITH ELECTRIC ENGINE HEATERS

2012 Volvo C30 T-5
Fig. 2: Identifying Left Front Wheel

Cars with 4-cyl. engines
 Remove the left front wheel.
Cars with 5-cyl. engines
 Remove both the front wheels.
Fig. 3: Identifying Underside Panel

2012 Volvo C30 T-5
Fig. 4: Removing Wheel Arch Lining Screws

 Remove the screws and the plastic nut from the left-hand inner wing.
Fig. 5: Removing Wheel Arch Lining

APPLIES TO CARS WITH 4-CYL. ENGINES WHERE AN ELECTRIC ENGINE HEATER IS INSTALLED
2012 Volvo C30 T-5
Fig. 6: Pressing Locking Sleeve Over Cable Splice

 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.
Fig. 7: Identifying Cable Pressed Into Previously Installed Clips

 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
Fig. 8: Identifying Ground Lead With Screw And Toothed Washer

 Disconnect the ground lead from the outside of the side member.
Fig. 9: Identifying Tie Strap

 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
Fig. 10: Identifying Locking Sleeve

 Remove the lock sleeve over the joint to the engine heater's cable on the right side by the stay on the sub-
frame.
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

 Loosen the cable from the double clamp on the brake pipe on the right side in the engine compartment.
2012 Volvo C30 T-5

 Remove the cable tie that holds the cable to the cable harness at the top in the engine compartment.
Fig. 13: Loosening Cable From Clips Along Metal Edge In Engine Compartment
 Loosen the cable from the clips along the metal edge in the trailing edge of the engine compartment.
2012 Volvo C30 T-5

 Loosen the cable from the double clamp by the brake pipe in the top edge of the bulkhead on the left side.

underside.
2012 Volvo C30 T-5
 Disconnect the ground lead from the outside of the side member.

 Remove the cable tie at the left-hand lower bracket of the radiator.
2012 Volvo C30 T-5
Fig. 18: Prying Off Panel At Lower Edge

 Carefully pry off the panel at the lower edge and remove it.
Fig. 19: Identifying Panel And Cable From Bumper Cover

 Remove the panel and cable from the bumper cover.

 Remove the cable from the panel.
APPLIES TO ALL MODELS

2012 Volvo C30 T-5
Fig. 20: Cleaning Panel

Fig. 21: Enlarging Markings On Inside Of Panel

 Enlarge the markings on the inside of the panel.

2012 Volvo C30 T-5
Fig. 22: Drilling Out Holes

 Drill out the four holes according to the markings.
Fig. 23: Cleaning Outside Of Panel

 Clean the outside of the panel using isopropanol opposite where the securing tape on the new panel ends
up.
2012 Volvo C30 T-5
Fig. 24: Identifying Protective Panel

 Remove the protective tape from the new panel.
Fig. 25: Identifying Tape

2012 Volvo C30 T-5
Fig. 26: Identifying Spacer Washers

 Secure the spacer washers around the tree studs on the new panel.
Fig. 27: Inserting Studs Into Panel

 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
Fig. 28: Identifying Locking Washers

NOTE: Position the panel on a surface that will not damage it when pressing the
locking washers into place.
 Take the four locking washers and press them onto the four studs. Use a small nut socket with socket
extension to press the locking washers into place.
APPLIES TO CARS WITH ENGINE BLOCK HEATERS
Fig. 29: Identifying Panel

APPLIES TO CARS WITH ELECTRIC ENGINE HEATERS

2012 Volvo C30 T-5
Fig. 30: Inserting Cable Into New Panel

 Insert the cable through to the engine heater. Ensure the connector 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

2012 Volvo C30 T-5
Fig. 32: Installing Cable And Panel

 Insert the cable through the hole for the panel.
Fig. 33: Install Wheel To Wheel Hub

 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
PROTECTION, REAR BUMPER (2007-12)

PROTECTION, REAR BUMPER
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.
Fig. 34: Identifying Bumper Casing

 Open the boot lid.

 Wash the bumper casing and wipe dry.
Fig. 35: Marking Center Between Middle Ribs Using Tape

2012 Volvo C30 T-5
 Take the bumper cover from the kit. Mark the center between the middle ribs using a piece of tape.
Fig. 36: Applying Tape And Marking Center Of Bumper Casing

 Apply a piece of tape and mark the center of the bumper casing as shown.
Fig. 37: Identifying Bumper Cover Centering

 Center the bumper cover according to the pieces of tape and measure the dimensions as shown.
2012 Volvo C30 T-5
Fig. 38: Applying Pieces Of Tape To Mark Out Dimensions

 Apply pieces of tape to mark out the dimensions.
Fig. 39: Cleaning Marked Surface

 Remove the bumper cover.

 Clean the marked surface using isopropanol and wipe dry.
2012 Volvo C30 T-5
Fig. 40: Identifying Protective Tape

 Remove the protective tape from one side.
Fig. 41: Identifying Bumper Cover Center Marking

 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
Fig. 42: Identifying Bumper Cover

 Press the bumper cover towards the bumper casing over the entire surface.
NOTE: Do not use the vehicle for at least two hours after work has been carried out.
NOTE: Do not wash the vehicle for at least 48 hours after work has been carried out.
PROTECTIVE PLATE, BENEATH THE ENGINE (2010-12)

PROTECTIVE PLATE, BENEATH THE ENGINE
Fig. 43: Identifying Engine Splash Guard Screws

2012 Volvo C30 T-5
 Remove the screws for the engine splash guard and remove it.
 The two screws (1) will be reused, place the others to one side.
Fig. 44: View Of Subframe Clips

 Remove the five clips in the subframe and bracket for the radiator. They will not be reused.
APPLIES TO ALL CARS WITH 5 CYL. ENGINES
Fig. 45: Identifying Wood Positioned Inside Radiator Bracket

 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 drilling holes.
2012 Volvo C30 T-5
Fig. 46: View Of Covered Engine Bay

 Cover the underneath of the engine with cardboard or similar, so that drilling shavings does not blow up
into the engine compartment.
NOTE: Do not drill out the front hole to the left. A new hole will be drilled to the
side of it later.
 Carefully 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.
NOTE: Rustproof the hole edges thoroughly.
 Remove the cover from under the engine.

2012 Volvo C30 T-5
Fig. 47: Identifying Tool P/N 9512782

 Rivet the nuts in the drilled holes. Use tool part no. 9512782 .
Fig. 48: View Of New Protective Plate Screws

 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
Fig. 49: View Of Radiator Bracket Drill Hole

 Take a 8.5 mm (21/64") drill bit and drill through the hole in the engine's protective plate and through the
bracket for the radiator.
 Remove the engine splash guard.

 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.
2012 Volvo C30 T-5
NOTE: Rustproof the hole edge thoroughly.

 Rivet the nut in the drilled hole. Use tool part no. 9512782 .
 Remove the three pieces of wood, plastic or metal from the inside of the radiator bracket.

 Install the engine splash guard using two existing screws and the five screws with washers from the kit
according to the diagram.
2012 Volvo C30 T-5
NOTE: The two rear screws must have two spacer washers each between the mounting
lug and the subframe as shown.
Fig. 53: View Of Washers Between Mounting Lug And Subframe

Fig. 54: Identifying M8 Screws

 Torque tighten the M8 screws.
APPLIES TO CARS WITH 4 CYL. ENGINES

2012 Volvo C30 T-5
Fig. 55: Identifying Splash Guard Screws

 Remove the screws for the engine splash guard and remove it.
 The two screws (1) will be reused, place the others to one side.
Fig. 56: Identifying Subframe Clips

 Remove the five clips in the subframe and bracket for the radiator. They will not be reused.
2012 Volvo C30 T-5
Fig. 57: View Of Inner Wing Screws

 Remove the screws at the rear edge of the inner wings on both sides.
Fig. 58: Identifying Cover For Nozzles For Headlamp Washers

 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
Fig. 59: Identifying Catch Pressed Up

 Press the catch up. Remove the cover. Do not damage the painted surfaces or the washer nozzles.
Fig. 60: Prying Off Corner Of Bumper Cover Using Weatherstrip Tool
 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
Fig. 61: Identifying Locating Lugs

 Pull the bumper cover at the lower edge slightly to access the locating lugs 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

 shows cutting on the right-hand side.

2012 Volvo C30 T-5
Fig. 63: View Of Cutting The Left-Hand Side

 shows cutting on the left-hand side.
Fig. 64: View Of Cardboard Covering Rear Edge Engine Bay

 Cover the underneath 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 .
NOTE: Rustproof the hole edges thoroughly.

2012 Volvo C30 T-5

Fig. 66: View Of Splash Guard Center Line Marking

 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
Fig. 67: View Of Radiator Bracket Marking

 Make a longitudinal marking 8.5 mm (21/64") from the front edge and on the radiator bracket opposite
where the locating lug was cut off.
 Do the same on the other side where the other locating lug was cut off.
Fig. 68: Identifying Splash Guard Screws

 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 subframe for each mounting.
2012 Volvo C30 T-5
Do not tighten too hard as the engine splash guard must be adjusted at the front edge according to the
made markings.
Fig. 69: Identifying Splash Guard Screw And Washer Kit

Fig. 70: View Of Splash Guard Front Mounting Holes

 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
Fig. 71: View Of Left Front And The Center Mounting Hole
 Now take a loose drill bit with the same diameter as the holes in the front mounting holes and rotate to
create a marking on the longitudinal markings.
NOTE: take care when marking the two front hole. Drill the large holes on the
narrow panel edge.
 Remove the engine splash guard after marking.
Fig. 72: View Of Both Right-Hand Front Mounting Holes

 Previous graphic shows the left front and the center mounting hole.
 Graphic above shows both right-hand front mounting holes.
2012 Volvo C30 T-5
Fig. 73: View Of Left-Hand Hole Drill Mark

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.
 Make a clear punch mark in the center of the marking for both front holes.
 Cover part of the underneath of engine compartment to prevent shavings from being blown up.
 Pre-drill with a 4 mm (5/32") drill bit, then a 8 mm (5/16") drill bit and finally with drill bit part no.
9814112 . Use a drill stop to prevent drilling through parts above.
NOTE: Rustproof the hole edges thoroughly and as well any scriber markings.

2012 Volvo C30 T-5
Fig. 74: View Of Right-Hand Hole Drill Mark

 Previous graphic applies to the left-hand hole.

 Graphic above applies to the right-hand hole.

2012 Volvo C30 T-5
Fig. 76: View Of Protective Plate Screws

 Install the new protective plate for marking and drilling the three holes in the 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.
Fig. 77: View Of Splash Guard And Radiator Bracket Drill Holes
 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 T-5
Fig. 78: Identifying Drill Bit P/N 9814112

 Install the cover beneath the engine.

 Take drill bit part no. 9814112 and carefully drill out the three holes.
NOTE: Rustproof the hole edges thoroughly and as well any scriber markings.
Fig. 79: Identifying Rivet Nuts In Drill Holes

2012 Volvo C30 T-5

 Install the engine splash guard using two existing screws and the seven screws with washers from the kit
according to the diagram.
NOTE: The two rear screws must have two spacer washers each between the mounting
lug and the subframe as shown below.
Fig. 81: View Of Mounting Lug And Subframe Screws

2012 Volvo C30 T-5
Fig. 82: Tightening Splash Guard With Torque Specifications

 Torque tighten the M8 screws.
APPLIES TO THE C30
Fig. 83: Identifying Front Bumper Inner Wing


2012 Volvo C30 T-5
Fig. 84: Identifying Front Bumper Inner Wing Screws

Fig. 85: View Of Nozzle Cover

SIDE SCUFF PLATE (2009-12)

SIDE SCUFF PLATE
NOTE: Some steps in these installation instructions are presented with graphic only.

2012 Volvo C30 T-5
Fig. 86: Identifying Ignition Key In 0 Position

 Set the ignition key to position 0 .
NOTE: Wait at least one minute before unplugging the connectors or removing other
electrical equipment.
Fig. 87: Cleaning Door Sills

 Clean the door sills thoroughly on both sides, even underneath.

2012 Volvo C30 T-5
Fig. 88: Cleaning Door Sill Panels

 Clean the door sill panels where the 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

 Carefully drill out the rivets.

2012 Volvo C30 T-5
Fig. 90: Identifying Screws

Fig. 91: Identifying Panel

 Remove the panel.

 Remove the remains of the rivets.

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 Take the cradles for one side from the kit.
The cradles are marked out and only fit in one place.
Start with the front cradle on one side.
 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
 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
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.
 Press the middle of the pieces of mounting tape.
Fig. 94: Drilling Out Marked Out Holes In Cradle

 Drill out the six marked out holes in the cradle using a 6 mm (15/64") drill bit.
Fig. 95: Riveting Holder To Door Sill Panel

 Take pop rivets from the kit. Rivet the holder to the door sill panel.
2012 Volvo C30 T-5

 Remove the protective tape from the pieces of mounting tape on the rear cradle.
Fig. 97: Aligning Lugs At Front Edge In Rear Cradle In Holes At Front
 Align the lugs at the front edge in the rear cradle in the holes at the front.
NOTE: Ensure that the tape does not adhere yet.
 At the same time, hook the holder on top of the door sill panel using the hooks.
2012 Volvo C30 T-5
Fig. 98: Pressing Holder Onto Pieces Of Mounting Tape

 Press the holder onto the pieces of mounting tape.
Fig. 99: Drilling Out Marked Out Holes In Cradle

 Drill out the seven marked out holes in the cradle using a 6 mm (15/64") drill bit.
2012 Volvo C30 T-5
Fig. 100: Riveting Holder To Door Sill Panel

 Take pop rivets from the kit. Rivet the holder to the door sill panel.
Fig. 101: Twisting Off Hooks From Cradles

 Carefully twist off the hooks from the cradles.

2012 Volvo C30 T-5
Fig. 102: Hooking Sill Decore Onto Cradle

 Hook the sill decor onto the cradle. Align the holes in the panel with the hooks in the cradles.
 Press the decor strip into position securely so that all hooks engage.
Fig. 103: Drilling Out Hole

 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
Fig. 104: Riveting Mounting Lug To Car Body

 Rivet the mounting lug to the car body with a rivet. Now drill and rivet the holes alternately in front of
and behind the newly installed rivet.
NOTE: The front hole must be secured with plastic rivets and saved until last.
Fig. 105: Drilling Out Hole

 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: Drill through the middle of the oval hole.

2012 Volvo C30 T-5
Fig. 106: Identifying Central Pin

Fig. 107: Detaching Central Pin From Clip

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.
 Install the panel in the front hole using clips with a center pin.
APPLIES TO VEHICLES WITH DRIVE E

2012 Volvo C30 T-5
Fig. 108: Cutting Out Panel At Front Mounting

 Cut out the panel at the front mounting.
Fig. 109: Identifying Underside Panel

2012 Volvo C30 T-5

NOTE: Do not tighten the clips and screws fully yet.
Fig. 111: Identifying Screws And Clips

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Fig. 112: Tightening Screws And Clips

 Tighten screws and clips.

 Repeat steps for the other side.
SKID PLATE, FRONT BUMPER (2009-12)

SKID PLATE, FRONT BUMPER
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.
Fig. 113: Washing Surface Of Car

2012 Volvo C30 T-5
 Wash the surfaces of the car that are to be covered by the skid plate.
 Wipe dry.
Fig. 114: Identifying Air Baffle Center Screws

 Remove the two center screws from the air baffle. They will not be reused.
Fig. 115: Identifying Drilling Template And Skid Plate

 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.
2012 Volvo C30 T-5
Fig. 116: Identifying Backing Tape

 Remove the backing tape from both templates.
Fig. 117: Identifying Skid Plate And Screws

 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
Fig. 118: Identifying Skid Plate And Drilling Templates

 Now position the skid plate laterally (1). Ensure that the tape on the drilling templates does not adhere
yet.
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.
Fig. 119: Identifying Skid Plate

 Remove the skid plate from the grille.

2012 Volvo C30 T-5
Fig. 120: Drilling Out Holes

 Drill out the holes through the taped drilling templates.
Fig. 121: Identifying Drilling Templates

 Remove the drilling templates on both sides.

2012 Volvo C30 T-5
Fig. 122: Drilling Holes

 Drill the holes to 8 mm (5/16 ") .

 Remove the shavings and smooth off the hole edges.
Fig. 123: Inserting Spike On Clip Under Edge Of Hole In Skid Plate
 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.
2012 Volvo C30 T-5

 Now carefully pull off the protective tape 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

2012 Volvo C30 T-5
Fig. 126: Cleaning Marked Surfaces

 Clean the marked surfaces for the tape to the skid plate using isopropanol.
 Wipe dry.

 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
Fig. 128: Identifying Protection Tape

 Hold the skid plate with one hand at the same time as removing the protective tape.
 Press the center of the clips so that they engage.
Fig. 129: Pressing Skid Plate Into Place

 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
Fig. 130: Identifying Skid Plate And Screws

 Tighten the skid plate underneath using existing screws.
Fig. 131: Drilling Through Holes In Outer Ends Of Skid Plate And Through Air Baffle
 Drill through the existing holes in the outer ends of the skid plate and through the air baffle.
2012 Volvo C30 T-5
Fig. 132: Riveting Skid Plate In Outer Ends

 Take the rivets from the kit and rivet the skid plate in the outer ends.
SKID PLATE, FRONT BUMPER (2010-11)

SKID PLATE, FRONT BUMPER
Fig. 133: Identifying Spring Nuts

 Take the spring nuts from the kit and press them into the bumper cover.
2012 Volvo C30 T-5
Fig. 134: Tightening Skid Plate

 Tighten the skid plate at the outer ends.
SKID PLATE, REAR BUMPER (2009-12)

SKID PLATE, REAR BUMPER
Fig. 135: Cutting Out Skid Plate

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
 Tape the outside to prevent the saw foot from damaging the paint
NOTE: Take extra care not to damage the painted surface of the components.
 Smooth off the sawn edges with a fine toothed file.
Fig. 136: Sawing Out New Skid Plate

APPLIES TO CARS WITH PARKING ASSISTANCE
Fig. 137: Identifying Sensor

2012 Volvo C30 T-5
Fig. 138: Cleaning Area Using Isopropanol

 Clean using isopropanol .

 Allow to dry.
Fig. 139: Applying Layer Of Activator

 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
Fig. 140: Painting Sensor

 Paint the sensors with color code 426 . Only apply one layer.
CAUTION: Protect the connection's contact surfaces from paint. Too many
layers of paint can result in the function partially or totally
disappearing.
 When the paint has dried, reinstall the sealing rings.
Fig. 141: Identifying Markings On Inside Of Skid Plate

 Locate the 2 markings on the inside of the Skid plate.

 Mark the center with a scribe.
2012 Volvo C30 T-5
Fig. 142: Drilling Holes

 Drill holes in the centers of the markings using a 3 mm (7/64) diameter drill bit.
 Drill out the holes. Use a 10 mm (25/64") diameter drill bit.
Fig. 143: Enlarging Holes In Bumper Casing

 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
Fig. 144: Cleaning Surfaces Where Holders Are Located

 Clean the surfaces where the holders are to be located using isopropanol and wipe dry.
Fig. 145: Applying Activator To Cleaned Surfaces

 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
Fig. 146: Identifying Holder

 Take the 2 holders from the kit.

 Clean the surfaces as shown using a cleaning cloth P/N 9192678 .
 Allow to dry.
 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

 Carefully brush the hole edges with paint, color 426 .

2012 Volvo C30 T-5
Fig. 148: Identifying Left Side Wheel Arch

Fig. 149: Identifying Right Side Wheel Arch

2012 Volvo C30 T-5
Fig. 150: Identifying Bolts And Washers Under Rear Bumper

Fig. 151: Identifying Rear Sill Plates

2012 Volvo C30 T-5
Fig. 152: Identifying Piece Of Tape On Wind Extender's Rear Section

 Attach a piece of tape to the wing extender's rear section to protect it when removing the bumper cover at
the front edge. The tape must be positioned so as not to leave any marks when prying the bumper loose.
 Carry out the procedure on both sides of the car.
Fig. 153: Removing Bumper Cover

 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 the license plate lighting, on the left-hand side. If the car has rear parking
2012 Volvo C30 T-5
 Remove the pieces of tape.
Fig. 154: Identifying Connector For License Plate Lighting

Fig. 155: Disconnecting Connectors For Center Sensors

 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
Fig. 156: Prying Up Hooks On Each Sensor Holder

 Pry up the two hooks on each sensor holder and carefully pull out the sensors. They are to be reused.
Fig. 157: Identifying Clips Holding Cable Harness To Sensors

 Detach the four clips that hold the cable harness to the sensors in the holders in the existing Skid plate.

2012 Volvo C30 T-5
Fig. 158: Prying Off Hooks From Mountings In Bumper Cover

NOTE: Take extra care when working with the bumper cover and Skid plate.
 Carefully pry off the hooks from the mountings in the bumper cover and remove the existing Skid plate, it
will not be reused.
Fig. 159: Identifying Protective Film

 Remove the protective film from one side of the double-backed tape.
2012 Volvo C30 T-5
Fig. 160: Installing Tape On The Holders

 Attach the tape to the holders.
Fig. 161: Cutting Off Holders With Tape On Both Sides

 Cut off the holders with tape on both long sides so that a result is achieved shown below.
2012 Volvo C30 T-5
Fig. 162: Identifying Result Of Cutting Off Holders With Tape

Fig. 163: Identifying Centering Tool

 Install the centering tool in the holder as shown.

2012 Volvo C30 T-5
Fig. 164: Identifying Remaining Protective Film

 Remove the remaining protective film.
Fig. 165: Pressing Holders Into Place Using Centering Tool On Bumper Cover
 Press the holders into place using the centering tool on the bumper cover.
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

 Install the new Skid plate. Ensure that all the catches engage.
Fig. 167: Identifying Clips For Sensor's Cable Harness

 Press the clips for the sensor's cable harness in the holders in the new Skid plate.
2012 Volvo C30 T-5
Fig. 168: Identifying Sensors

 Install the two sensors.
Fig. 169: Connecting Connectors To Sensors

 Connect the connectors to the sensors.

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Fig. 170: Connecting Connector To Number Plate Lighting

 Connect the connector to the number plate lighting and to the parking assistance connector, if applicable.

2012 Volvo C30 T-5


2012 Volvo C30 T-5
Fig. 174: Identifying Left Side Wheel Arch

Fig. 175: Identifying Right Side Wheel Arch

2012 Volvo C30 T-5
Fig. 176: Identifying VIDA (Service Information) To Program Software

 Download software for the 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

2012 Volvo C30 T-5
Fig. 178: Identifying Left Wheel Arch Lining And Screws

Fig. 179: Identifying Bolts And Washers Under Rear Bumper

2012 Volvo C30 T-5


 Remove the bumper cover from the body 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
Fig. 182: Identifying Connector For License Plate Lighting

 Unplug the connector for the license plate lighting on the left side. If the car is equipped with reverse
warning, then unplug the connector for this on the right side.
WHEEL HOUSING EDGES
Fig. 183: Identifying Rear Fender's Panel

 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
Fig. 184: Identifying Fender Liner With Clips

 Loosen the fender liner with the three clips from the panel's clips by first pressing it in until 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

2012 Volvo C30 T-5

Fig. 187: Identifying Front Fender's Panel

 Carefully bend loose the front fender's 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.

2012 Volvo C30 T-5
Fig. 188: Identifying Fender Liner

 Loosen the fender liner with the three clips from the panel's clips by first pressing it in until 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.
 Repeat for the other side.
FRONT BUMPER COVER
Fig. 189: Identifying Panel To Left And Right Fog Light

 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 Volvo C30 T-5
APPLIES TO CARS WITH 4-CYLINDER ENGINE WHERE ELECTRIC ENGINE HEATER IS INSTALLED
Fig. 190: Identifying Engine Splash Guard

 Remove the seven screws from the engine splash guard.
Fig. 191: Identifying Screws Holding Bumper Cover At Left-Hand Wing Liner
 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
Fig. 192: Identifying Nut Holding Wing Liner At Left-Hand Front Member
 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.
Fig. 193: Pressing Locking Sleeve Over Cable Splice

 Remove the lock sleeve over the joint to the engine heater's cable on the left side by the stay on the sub-
frame.
2012 Volvo C30 T-5

underside.
 Loosen the ground cable from the leading edge of the side member's outside.
2012 Volvo C30 T-5

 Cut off the cable tie (1) that holds the cable to the left radiator bracket.
APPLIES TO CARS WITH 5-CYLINDER ENGINE WHERE ELECTRIC ENGINE HEATER IS INSTALLED

 Remove the seven screws from the engine splash guard.

2012 Volvo C30 T-5
Fig. 198: Identifying Screws Holding Bumper Cover At Left-Hand Wing Liner
 Remove the left and right-hand front wheels.

 Remove the five screws holding the bumper cover in the wing liner on the left and right-hand sides.
Fig. 199: Identifying Nut Holding Wing Liner At Left-Hand Front Member
 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
Fig. 200: Identifying Locking Sleeve

 Remove the lock sleeve over the joint to the engine heater's cable on the right side by the stay on the sub-
frame.
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.

 Loosen the cable from the double clamp on the brake pipe on the right side in the engine compartment.
2012 Volvo C30 T-5

 Remove the cable tie that holds the cable to the cable harness at the top in the engine compartment.
Fig. 203: Loosening Cable From Clips Along Metal Edge In Trailing Edge Of Engine Compartment
 Loosen the cable from the clips along the metal edge in the trailing edge of the engine compartment.
2012 Volvo C30 T-5

 Loosen the cable from the double clamp by the brake pipe in the top edge of the bulkhead on the left side.

underside.
2012 Volvo C30 T-5
Does not apply to cars for USA.
 Loosen the ground cable from the leading edge of the side member's outside.

 Cut off the cable tie (1) that holds the cable to the left radiator bracket.

2012 Volvo C30 T-5
Fig. 208: Identifying Clips And Screws

 Push in the center of the five clips (1). Remove the clips.
 Remove the two screws (2).
Fig. 209: Identifying Cover For Nozzles For Headlamp Washers

 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
Fig. 210: Identifying Catch Pressed Up

 Press the catch up and remove the cover. Do not damage the painted surfaces or the high-pressure washer
nozzles.
Fig. 211: Identifying Screws That Hold Bumper's Lower Part

 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
Fig. 212: Identifying Corner Of Bumper Cover

 Carefully pry off the corner of the bumper cover using a weatherstrip tool until the three hooks on the
inside release.
Fig. 213: Identifying Bumper Cover With Air Baffle

 Remove the bumper cover with air baffle by grasping the ends and pulling forwards until the remaining
hooks under the lamps release.
NOTE: Get help from a colleague for this procedure.
 Disconnect the connectors for the fog lamps or parking assistance if applicable.
DOOR SILL PANEL

2012 Volvo C30 T-5

Fig. 215: Identifying Bottom Sill's Panel

 Drive out the 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
Fig. 216: Identifying Bottom Sill's Panel

 Remove the bottom sill's panel by carefully bending it loose directly opposite the clips along its entire
length.
 Remove the rubber strip from the panel. Lay away the panel but the rubber strip is to be used again.
INSTALLATION
REAR SPOILER
Fig. 217: Identifying Clips For Cable Harness For Reverse Warning's Sensors
2012 Volvo C30 T-5
Applies to cars with reverse warning
 Loosen the clips for the cable harness for the reverse warning's sensors from the lower part's catches.
Fig. 218: Bending And Pulling Loose Bumper's Lower Part From Upper Part
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.
Fig. 219: Identifying Rear Spoiler

2012 Volvo C30 T-5
 Take the rear spoiler from the kit and press the upper part into it.
 Make sure that all catches engage.
Fig. 220: Pressing In Clips For Cable Harness For Reverse Warning In Spoiler's Catches
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

Press on the reflectors from the kit on the spoiler's ends.

2012 Volvo C30 T-5
Applies to cars for USA market
 Paint the covers from the kit.

 Press on the covers.
Fig. 222: Inserting Plastic String For Towing Eye's In Rectangular Hole In Lower Edge Of Opening
 Insert the plastic string for 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

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
Fig. 224: Connecting Connector To Number Plate Lighting


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FRONT SPOILER
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Fig. 228: Loosening Holder From Bumper Casing's Upper Part

 Loosen the holder from the bumper casing's upper part on both sides.
Fig. 229: Bending And Pulling Loose Bumper's Lower Part From Upper Part
 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.

2012 Volvo C30 T-5
Fig. 230: Cleaning Areas Underneath Spoiler

 Take the front spoiler from the kit.
NOTE: The unpainted spoiler must be painted first.
 Clean the marked areas underneath the spoiler where the anti-chafing protector is to be located. Use
isopropanol. Wipe dry.

 Remove the protective tape from the anti-chafing protector.

2012 Volvo C30 T-5
Fig. 232: Securing Anti-Chafing Protector Aling Edges Of Spoiler

 Position and secure the anti-chafing protector along the edges of the spoiler at the rear edge.
Fig. 233: Pressing Anti-Chafing Protector

 Press the anti-chafing protector at the rear edge forwards.

2012 Volvo C30 T-5

Fig. 235: Identifying Anti-Chafing Protector

 Press the anti-chafing protector into place.

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Fig. 237: Identifying Anti-Chafing Protector

 Press the anti-chafing protector into place.

 Repeat for the other side.
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Fig. 238: Identifying Front Spoiler

 Press the front spoiler into the upper section.

 Make sure that all catches engage.

 Reinstall the bumper cover. Make sure that the spoiler fits in the leading edge on the baffle.
2012 Volvo C30 T-5
Fig. 240: Identifying Clips And Screws

 Secure the bumper casing with the clips (1) and screws (2).
Fig. 241: Pulling Up High-Pressure Nozzle From Bumper Casing

 Pull up the high-pressure nozzle from the bumper casing and install the covers on both sides.
 Connect 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.
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 engine compartment.
 Remount the front wheel and tighten the wheel bolts to 90 Nm (66 lbf. ft.) .
2012 Volvo C30 T-5
Fig. 242: Identifying Spoiler's Brackets And Baffle's Outer Screw

 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)

2012 Volvo C30 T-5
Fig. 244: Identifying Fog Light Panel (2 Of 2)

DOOR SILL PANEL
Fig. 245: Identifying Bottom Sill Panel

 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
Fig. 246: Pressing In New Panel In Bottom Sill

 Press in the new panel in the bottom sill. Make sure all catches engage.
Fig. 247: Identifying Clips To Secure Panel In Lower Edge

 Get new clips from the kit and secure the panel in the lower edge.
WHEEL HOUSING EDGES

2012 Volvo C30 T-5
Fig. 248: Identifying Clips And Panel

 Get the new panel and new clips for the fender edge from the kit.
 Install new clips in the panel.
Fig. 249: Identifying Clips And Fender Edge

 Get new clips from the kit and install these around the fender edge.
2012 Volvo C30 T-5
Fig. 250: Identifying Fender Liner And Clips

 Reinstall the fender liner.

 Get new clips from the kit and press in to the fender liner.
 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

 Press in the new panel on the fender edge. Make sure all catches engage.
2012 Volvo C30 T-5
Fig. 252: Identifying Screws On Front Fender Front Edge

Fig. 253: Identifying Screws On Front Fender Rear Edge

2012 Volvo C30 T-5
Fig. 254: Identifying Screws On Rear Fender Front Edge

Fig. 255: Identifying Screws On Rear Fender Rear Edge

 Repeat for all wheel housing edges.
MUD GUARDS, FRONT (2007-09)

MUD GUARDS, FRONT
2012 Volvo C30 T-5
Fig. 256: Identifying Body Section

Fig. 257: Turning Wheel

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Fig. 258: Cleaning Area Where Mudflap Is To Be Positioned


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Fig. 260: Identifying Rivets And Panel

Fig. 261: Identifying Mud Guards, Front Drilling Location

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Fig. 263: Identifying Wheel

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Fig. 264: Cleaning Installation Area

Fig. 265: Removing Fender Clips

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Fig. 266: Installing Rear Clips

Fig. 267: Identifying Drilling Location

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Fig. 268: Install Wheel And Tighten To Specification

MUDFLAPS (2010-12)
MUDFLAPS

2012 Volvo C30 T-5
Fig. 270: Turning Wheel

 Turn the wheel.
Fig. 271: Cleaning Area Where Mudflap Is To Be Positioned

 Clean the area where the mudflap is to be positioned.

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Fig. 273: Identifying Rivets And Panel

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Fig. 274: Drilling Hole For Rivet


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Fig. 276: Identifying Wheel

Fig. 277: Identifying Rivets

NOTE: These will not be reused.

2012 Volvo C30 T-5
Fig. 278: Identifying Area That Is To Be Cleaned

 Clean the area where the mudflap is to be positioned.
Fig. 279: Identifying Wing Liner

 Fold the wing liner out of the way.

2012 Volvo C30 T-5
Fig. 280: Identifying Clip

 Install the clip.
Fig. 281: Identifying Mudflap

 Fold the inner wing back and install the mudflap.

2012 Volvo C30 T-5
Fig. 282: Identifying Rivets

Fig. 283: Drilling Hole For Rivet

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Fig. 284: Install And Tighten Wheel To Wheel Hub

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 BODY, CAB Bumpers And Mudflaps - Removal, replacement and installation
Bumpers And Mudflaps - Removal, replacement and installation
BUMPERS AND MUDFLAPS

COVER BUMPER FRONT (2007 - 2011 EARLY)
REMOVAL
VEHICLES EARLY VERSION
Fig. 1: Identifying Bumper Attachment Screws On Front Frame

Fig. 2: Identifying Bumper Screws On Inner Front Fender

VEHICLES WITH FRONT SIDE UNDERBODY AIR DEFLECTOR

2012 Volvo C30 T-5
Fig. 3: Identifying Rear Fender Splash Guard Attachment Screws

VEHICLES WITH FRONT UNDERBODY AIR DEFLECTOR
Fig. 4: Identifying Front Underbody Air Deflector Attachment Screws

VEHICLES WITHOUT UNDERBODY AIR DEFLECTORS

2012 Volvo C30 T-5
Fig. 5: Identifying Rear Bumper Attachment Screws

ALL VEHICLES
Fig. 6: Identifying Front Bumper Removal Points

WARNING: Be prepared to collect escaping fluid.
NOTE: This step requires the aid of another technician.

2012 Volvo C30 T-5
Fig. 7: Identifying Fog Light Connectors

Fig. 8: Identifying Underbody Air Deflector Attachment Screws

ALL VEHICLES
2012 Volvo C30 T-5
Fig. 9: Identifying Fog Light Removal Points

 headlight washers, see HEADLIGHT WASHERS

 Front fog lights, see FRONT FOG LIGHTS
 radiator grille, see RADIATOR GRILLE
Fig. 10: Identifying Lower Front Bumper Fasteners

VEHICLES LATE VERSION

2012 Volvo C30 T-5
Fig. 11: Identifying Mating Face

CAUTION: Take extra care not to damage the mating faces.
On both sides.

2012 Volvo C30 T-5
Fig. 13: Identifying Bumper Attachment Screws On Inner Front Fender

On both sides.


2012 Volvo C30 T-5

Fig. 16: Identifying Under Carriage Bumper Attachment Screws

ALL VEHICLES
2012 Volvo C30 T-5
Fig. 17: Identifying Complete Front Bumper Removal

On both sides.
Fig. 18: Identifying Fog Light Connector & Cable

On both sides.

2012 Volvo C30 T-5

ALL VEHICLES


INSTALLATION
ALL VEHICLES
COVER BUMPER FRONT (2011 LATE - 2012)

2012 Volvo C30 T-5
REMOVAL
Fig. 21: Identifying Mating Face

CAUTION: Take extra care not to damage the mating faces.
On both sides.

2012 Volvo C30 T-5
Fig. 23: Identifying Bumper Attachment Screws On Inner Front Fender

On both sides.


2012 Volvo C30 T-5

Fig. 26: Identifying Under Carriage Bumper Attachment Screws

ALL VEHICLES
2012 Volvo C30 T-5
Fig. 27: Identifying Complete Front Bumper Removal

On both sides.
Fig. 28: Identifying Fog Light Connector & Cable

On both sides.

2012 Volvo C30 T-5

ALL VEHICLES


INSTALLATION
COVER BUMPER REAR (2007 - 2011 EARLY)
REMOVAL
2012 Volvo C30 T-5
Fig. 31: Removing Rear Bumper Cover - All Versions (1 Of 9)


2012 Volvo C30 T-5

On both sides.

VEHICLES EARLY VERSION

2012 Volvo C30 T-5
Fig. 35: Early Version (1 Of 5)

On both sides.

2012 Volvo C30 T-5

On both sides.

2012 Volvo C30 T-5

VEHICLES LATE VERSION
Fig. 40: Late Version (1 Of 8)

On both sides.

2012 Volvo C30 T-5


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ALL VEHICLES

2012 Volvo C30 T-5


2012 Volvo C30 T-5


INSTALLATION
COVER BUMPER REAR (2011 LATE - 2012)
REMOVAL
2012 Volvo C30 T-5
Fig. 53: Removing Rear Bumper Cover (1 Of 17)



On both sides.
2012 Volvo C30 T-5


On both sides.
2012 Volvo C30 T-5


2012 Volvo C30 T-5



2012 Volvo C30 T-5


2012 Volvo C30 T-5



2012 Volvo C30 T-5


INSTALLATION
REAR BUMPER COVER LOWER SECTION (2007-2009)

2012 Volvo C30 T-5
Fig. 70: Removing Rear Bumper Cover Lower Section (1 Of 9)



2012 Volvo C30 T-5

NOTE: This step requires assistance from another technician.

2012 Volvo C30 T-5



2012 Volvo C30 T-5

REAR BUMPER COVER LOWER SECTION (2010 - 2011 EARLY)
REMOVAL
Fig. 79: Removing Rear Bumper Cover Lower Section - All Vehicles (1 Of 8)
2012 Volvo C30 T-5
VEHICLES WITH REAR UNDERBODY AIR DEFLECTOR
Fig. 81: Removing Rear Bumper Cover Lower Section - Vehicles With Rear Underbody Air Deflector

2012 Volvo C30 T-5
Fig. 82: Removing Rear Bumper Cover Lower Section - Vehicles Without Underbody Air Deflectors
ALL VEHICLES

2012 Volvo C30 T-5
2012 Volvo C30 T-5
INSTALLATION
REAR BUMPER COVER UPPER SECTION (2007 - 2011 EARLY

2012 Volvo C30 T-5
Fig. 89: Removing Rear Bumper Cover Upper Section (1 Of 4)



2012 Volvo C30 T-5


2012 Volvo C30 T-5
CABIN AIR FILTER Volvo - C30 & C70
CABIN AIR FILTER
Volvo - C30 & C70
REMOVAL & INSTALLATION
NOTE: Manufacturer's terminology for this filter is passenger compartment air cleaner
or particle filter.
CABIN AIR FILTER
Removal & Installation
REMOVAL

Remove the accelerator pedal (AP). See ACCELERATOR PEDAL .
Fold the floor carpet out of the way.
Remove:
2012 Volvo C30 T-5
 the 3 screws and raise the cover
Fig. 2: Identifying Passenger Compartment Air Cleaner (ACL)

 the filter by pulling it out behind the brake pedal.
INSTALLATION
2012 Volvo C30 T-5

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.
Install the air filter by compressing it slightly and inserting it behind the brake pedal.
Clamp the cover in place at the 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 .

2012 Volvo C30 T-5
ELECTRICAL Body Electrical
ELECTRICAL
Body Electrical
CAN NETWORK
FAULT TRACING ON CAN NETWORK
SIGNAL MISSING
GENERAL INFORMATION
NOTE: Illustrations shown are only examples.
HINT: For general information about CAN-troubleshooting:
 see GENERAL INFORMATION ABOUT FAULT-TRACING IN THE CAN NETWORK
General about CAN-related diagnostic trouble codes.
CEM-DF01 - DF17 can only be stored in Central electronic module (CEM). These diagnostic trouble
codes are stored when an electric fault is detected in CAN-lines. Start with these diagnostic trouble codes
first.
CEM-DEXX is only stored in Central electronic module (CEM). One diagnostic trouble code for every
control module on the CAN-net. These diagnostic trouble codes indicate that Central electronic module
(CEM) does not receive any reply from other control modules.
XXX-E000 (HS-CAN)/E001 (LS-CAN) can be stored in all CAN-connected control modules. These
diagnostic trouble codes indicate that the control module has detected interference on the 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.
Interference on the CAN-net can also store this diagnostic trouble code.
NOTE: In case of CAN-related faults, it is likely that a combination of above

diagnostic trouble codes occur.
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 have
stopped communicating, it may help to disconnect/reconnect the battery
to "restart" the control module/CAN-net.
2012 Volvo C30 T-5
If a communication diagnostic trouble code can be read from the control module, the malfunction is
probably intermittent. Intermittent fault in the voltage supply and ground to a control module on the CAN
network results in the Central electronic module (CEM) storing a diagnostic trouble code (DTC) for an
open-circuit in communication with the control module where the voltage supply does not work. There
will probably not be a diagnostic trouble code (DTC) in the control module 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.
NOTE: Central electronic module (CEM) should not be replaced in case of CAN-
fault, unless troubleshooting reveals that Central electronic module (CEM)
has an internal fault.
Fig. 1: View Of Control Module Block Diagram, Communications Network, And Trouble Codes
 Continue
Refer to CHECKING RESISTANCE IN CAN-NET
CHECKING RESISTANCE IN CAN-NET
Fig. 2: Ignition Off And Disconnecting Battery Negative Lead

 Ignition off
2012 Volvo C30 T-5
 Connect OBDII-Box (951 3015) to the diagnostics socket.
For general information about CAN-troubleshooting:
Measure resistance between the following connections on the OBDII-box/diagnostics socket.
 #3 and #11. The resistance should be approx. 55 - 65 ohms.

 If resistance is approx. 120 ohms, this indicates open circuit in the circuit so that only one
terminating resistor (120 ohms) has been measured.
 If resistance is above 1 kohms this indicates open circuit/high contact resistance somewhere in the
circuit.
 If resistance is below 55 ohms this indicates short-circuiting/contact resistance between the CAN-
lines somewhere in the circuit.
HINT: For LS-CAN , terminating resistors are located in Driver information module (DIM) and in
Supplemental restraint system module (SRS).
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.
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 terminating resistor
cannot be detected with this measurement. However, short-circuiting on a
branch can be detected. To measure resistance in the CAN-net to control
modules located in a branching of their own, the measurement shall be
done against the CAN-net at that control module. The values shall be as
above.
Remedy wiring as necessary.
Other information
 see BATTERY, DISCONNECTING

 see CHECKING WIRING AND TERMINALS
2012 Volvo C30 T-5
Fig. 3: Identifying Resistance Measurement In Low-Speed Net LS CAN

Was a fault detected?
 YES
Refer to VERIFICATION
 NO
Refer to CHECKING SHORT-CIRCUITING TO GROUND/VOLTAGE IN CAN-NET
CHECKING THE TRAFFIC LOAD ON THE CAN CABLES
Fig. 4: Checking Traffic Load On CAN Cables

 Connect the battery.

 Ignition on.

2012 Volvo C30 T-5
Faults in the CAN network may be due to a control module sending faulty messages that disrupt normal
communication. When messages are sent incorrectly, this results in a considerable increase in the amount
of traffic on the CAN network. The load can be checked by reading the average value of the voltage on
the CAN cables in relation to ground.
Measure voltage between the following connections on the OBDII-box/diagnostics socket.
 #3 and #4 (ground). The voltage should be approx:2, 8 - 3, 2 V.

 #11 and #4 (ground). The voltage should be approx:1, 8 - 2, 2 V.
 #3 and #11. The voltage shall be between approx. 0.55-1.4 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.
control modules may remain in Limp-Home even when the ignition has
been turned off and on a few times. For certain faults in the CAN-net where
control modules have stopped communicating, it may help to
disconnect/reconnect the battery to "restart" the control module/CAN-net.
HINT: DiCE can be used as fault detection tool if fault is suspected on the CAN-net that cannot be
detected with normal troubleshooting. Interference, intermittent faults, faulty messages on the
CAN-net etc., are examples of such faults. The tool registers fault messages used on the CAN-net.
Fault messages may be caused by short intermittent malfunctions on the CAN-net or by a control
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.
NOTE: Certain interference may occur without any real fault
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 modules may be difficult to find and troubleshooting may take time. Let the
vehicle stand with DiCE connected for an extended time period. Afterwards, activate functions to
provoke a malfunction. It may take up to several hours before the fault messages are sent. When the
indicator starts to flash, remove the fuse for one control module at a time until the indicator stops
flashing. When the indicator stops flashing, restore the fuse for the relevant control module and
check that the indicator starts to flash again. Then it is likely that the problem is identified.
2012 Volvo C30 T-5
Other information
 see BATTERY, DISCONNECTING

 see TROUBLESHOOTING USING DICE ERROR FRAME FINDER
Fig. 5: Identifying PCM Wiring Terminals

 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

2012 Volvo C30 T-5
HINT: DiCE can be used as fault detection tool if fault is suspected on the CAN-net that cannot be
detected with normal troubleshooting. Interference, intermittent faults, faulty messages on the CAN-net
(chattering control modules) etc., are examples of such faults. The tool registers fault messages used on
the CAN-net. Fault messages may be caused by short intermittent malfunctions on the CAN-net or by a
control module sending fault messages. See tools:951 3010 (memory card) as well as associated TJ 20402.
HINT: If the load on the CAN network is too high, this may be due to a control module transmitting
faulty messages on the CAN network. This is called a disruptive control module. The fault may also be
due to an intermittent short-circuit to supply voltage or ground in one of the CAN cables. This results in
the control modules on the CAN network starting to send faulty messages. The fault may occur without
any of the control modules storing a diagnostic trouble code (DTC). The voltage can be measured
between the CAN cables in order to check the load on the CAN network.
NOTE: It is not necessarily the control module that has set the diagnostic trouble code
that communicates incorrectly. Faulty messages can come from any control
module in the same section of the CAN network. However, faulty
communication in one network cannot affect the communication on the other
network. In other words, faulty communication on the LS-CAN cannot disrupt
communication on the HS-CAN and vice versa.
 Ignition on.
Check communication/load on CAN-net by measuring voltage between CAN-L and CAN-H. Measure voltage
between 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 which control module has faulty communication, cut the power supply to one control
module at a time. Check the voltage in the CAN cables again. The easiest way to cut the power supply is to
remove the fuse(s) for the relevant control module. Repeat until the voltage between the CAN wiring drops to
the normal level.
NOTE: When connecting and disconnecting certain control modules, diagnostic

trouble codes (DTCs) may be stored in other control modules.
HINT: When the suspected defective control module has been identified, connect and disconnect the
supply voltage to the control module a number of times to verify that the malfunction appears and
disappears. Switch off the ignition between each check.
2012 Volvo C30 T-5
NOTE: Do not cut the power to the central electronic module (CEM) unless it is the last
control module left to check.
A control module that is communicating incorrectly must be replaced.
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 have stopped
communicating, it may help to disconnect/reconnect the battery to "restart" the
control module/CAN-net.
Fig. 7: Identifying CCM Schematic

 Continue
VERIFICATION
HINT: Once a fault has been repaired, conduct a verification to check that the fault has been remedied.

2012 Volvo C30 T-5
Fig. 9: Identifying Belt Routing

 Reinstall the connectors, components etc.

 Ignition on
NOTE: For certain faults in the CAN-net where control modules have stopped
communicating, it may help to disconnect/reconnect the battery to
"restart" the control module/CAN-net.
 Erase diagnostic trouble codes (DTCs) in all control modules.

 Ignition off.
 Ignition on.
 Start the vehicle. Allow the vehicle to run for 10 minutes.
 Read out the diagnostic trouble codes in the vehicle via the DIAGNOSTICS tab.
Does the 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

 Ignition off.
 Disconnect the battery negative lead.
2012 Volvo C30 T-5
Checking for a short-circuit to ground
 #3 and #4 (ground). Measurement is shown in Fig. 11. The resistance should be above 1 kohms.
 #11 and #4 (ground). The resistance should be above 1 kohms.
If resistance is below 1 kohms this indicates short-circuiting between the CAN-line and ground.
Checking for a short-circuit to voltage
 #3 and #16 (voltage). Measurement is shown in Fig. 11. The resistance should be above 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-net at suitable points to decide where a short-circuit may be found.

2012 Volvo C30 T-5
Fig. 11: Identifying OWS Schematic

 YES
 NO
Refer to CHECKING THE TRAFFIC LOAD ON THE CAN CABLES
CHECKING VOLTAGE-DROP IN CABLE FOR CAN-H AND CAN-L, RESPECTIVELY

 Connect the battery.

 Ignition on.

2012 Volvo C30 T-5
In principle, the voltage measured in each cable in the CAN-net shall be the same at each control module
in the network. This means that the voltage-drop in the cable for CAN-H and CAN-L, respectively,
between the control modules should be very low. If there is a voltage-difference in the CAN-lines
between the diagnostics socket/Central electronic module (CEM) and a control module due to, e. g.,
contact resistance in a connector or branching, communication may be lost/interfered with. Check if there
is voltage-drop in the cable for CAN-H and CAN-L between the diagnostics socket/Central electronic
module (CEM) and the control module where there is problem with communication.
Carry out the following:
Measure voltage between the following connections on the OBDII-box/diagnostics 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 question for contact resistance and
oxidation.
Other information

2012 Volvo C30 T-5
Fig. 13: Identifying DIM Wiring Terminals

 Continue
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
ACCESSORIES AND BODY, CAB Interior - Installation Instructions, Accessories
Interior - Installation Instructions, Accessories
COSMETIC PANEL, DOORS (2007-2012)

COSMETIC PANEL, DOORS
REMOVE
 Turn the ignition key to position 0.
NOTE: Wait at least five minutes before disassembling the connectors or

removing other electrical equipment.
Fig. 1: Identifying Door Handle Internal Panel

Remove the door handle's interior panel
 Carefully pry loose 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

2012 Volvo C30 T-5
Fig. 2: Identifying Door Handle Clips

 Carefully pry around the door handle panel with door module so that the six clips release and the
cosmetic panel releases from the door panel.
Fig. 3: View Of Door Module Connector

 Pull up the panel with door module and unplug the connector on the bottom.
2012 Volvo C30 T-5
Fig. 4: Identifying Door Module Screws

Removing the door module
 Remove the four screws holding the door module at the panel.
 Remove the door module.
INSTALL
Installing a new cosmetic panel
 Take 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
Fig. 5: Attaching Sun Visor To Top Of Child Seat

 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)

2012 Volvo C30 T-5

 The sun visor can also be secured in the seat belt lead-ins in the seat backrest.

 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
Fig. 9: Identifying Luggage Compartment Windows

INSTALLING
Fig. 10: Identifying Sun Blind

2012 Volvo C30 T-5
Fig. 11: View Of Sun Blind Clips

Fig. 12: Identifying Sun Blind Clips Installation

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
Fig. 13: Folding Rear Window Sun Blind (1 of 4)


2012 Volvo C30 T-5


SUN BLIND, REAR SIDE WINDOW
INSTALLING
2012 Volvo C30 T-5
Fig. 17: Identifying Rear Side Window Sun Blind

Fig. 18: Installing Rear Side Window Sun Blind

2012 Volvo C30 T-5
Fig. 19: View Of Rear Side Window Sun Blind

ARMREST, REAR SEAT (2007-2008)

ARMREST, REAR SEAT
REMOVE
Fig. 20: Identifying Backrest Panel

 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
Fig. 21: Identifying Rear Seat Cushion

 Pull off the seat cushion, first at the rear edge where it is secured by one holder. 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

 Fold the backrest forward.

 Remove the panel for the backrest's left-hand mounting.
2012 Volvo C30 T-5
Fig. 23: Identifying Armrest Mounting

Fig. 24: Removing Backrest

 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
Fig. 25: View Of Control Arm Lug Components

Fig. 26: Identifying Control Arm Lug

 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
Fig. 27: Reinstall The Backrest

 Reinstall the backrest. Check that it is securely in its mountings.
Fig. 28: View Of Screw And Lock Pin

 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
Fig. 29: Installing Backrest Cover

Fig. 30: Repositioning Backseat

 Repeat points for the other backrest.

2012 Volvo C30 T-5
Fig. 31: Identifying Central Arm Rest

 Install the central armrest by grasping each end, moving it up towards the backrest lugs (1) and aligning
the holders (2) in the backrest's sides in 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

CHILD SEAT EYELETS (2007-2011)

CHILD SEAT EYELETS
REMOVE / INSTALL
2012 Volvo C30 T-5
Fig. 33: Identifying Passenger Seat Backrest Forward

 Fold the passenger seat backrest forward.
Fig. 34: View Of Seat Runners

 Slide the front seat as far forward as possible so that the seat wings are visible.
2012 Volvo C30 T-5
Fig. 35: View Of Seat Runner Screw

 Remove the seat wings on the left side by using a screwdriver to pry between the wings 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

 Fit the eyelet through the square hole on the left seat wing. Do the same on the right side.
2012 Volvo C30 T-5
Fig. 37: Tighten Nut Jacket On Eyelet

 Tighten the nut jacket on the eyelet on the left and right side.
NOTE: Store the removed seat wings in a suitable spot so that they can be
reinstalled if the child seat eyelets are removed.
CHILD SEAT, ISOFIX MOUNTING FRONT (2007-2012)

CHILD SEAT, ISOFIX MOUNTING FRONT
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.
REMOVE / INSTALL
2012 Volvo C30 T-5
Fig. 38: Folding Backrest Forward On Front Passenger Side

 Fold the backrest forward on the front passenger side.
INSTALL
Fig. 39: ISOFIX Attachment And Screws

 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
REMOVE / INSTALL
Fig. 40: Identifying RH Tunnel Console Floor Carpet

 Fold down the floor carpet on the right-hand side of the tunnel console.
Fig. 41: View Of Center Console Mounting Screw

 Remove the rear screw in the center console mounting.

2012 Volvo C30 T-5
Fig. 42: Identifying LH Mounting Screw

 Install the left-hand mounting with the existing screw. Torque tighten the screw to 24 Nm (18 lbf. ft.) .
Fig. 43: Identifying Floor Carpet Mounting Eyelet Marking

 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
Fig. 44: View Of Floor Carpet Mounting Eyelet

 Make a small cut in the floor carpet opposite the marking, equally as wide as the mounting eyelet.
Fig. 45: View Of Refit Carpet Over Mounting Eyelet

 Fold the carpet back over the mounting eyelet and refit it at the center console.
2012 Volvo C30 T-5
Fig. 46: Identifying Cover Panel

 Remove the cover panel over the front right-hand mounting by carefully prizing it off with a weatherstrip
tool.
 Remove the screw in the mounting.
Fig. 47: Identifying Mounting Screw

 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
Fig. 48: Identifying T-Shape Cut In Carpet

Fig. 49: View Of Mounting Eyelet

 Insert the 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
Fig. 50: View Of Mounting Eyelet

CHILD SEAT, PROTECTIVE CUSHION (2007-2012)

CHILD SEAT, PROTECTIVE CUSHION (2007-2009)
REMOVE / INSTALL
Fig. 51: View Of Protective Cushion In Position

 Take 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
Fig. 52: Washing Back Of Child Seat

 Wash the back of the child seat for affixing the Velcro strap using a mixture of 30% washer fluid and
70% water as indicated by the marking.
 Wipe dry.
Fig. 53: Identifying Protective Cushion Velcro Strap

 Pull off one Velcro strap from the protective cushion.
NOTE: Do not pull only on the white protective tape.

2012 Volvo C30 T-5
Fig. 54: View Of Velcro Strap On The Centre Of Backrest

 Pull off the protective tape from the detached Velcro strap.
 Press the Velcro strap into the center of the backrest 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

2012 Volvo C30 T-5
 Fold the backrest forward on the front passenger side.
Fig. 56: ISOFIX Attachment And Screws

 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.
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
Illustration applies to the rear seat and car models
Fig. 58: Identifying Isofix Guide

Installing the Isofix guide:
 Press 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
HVAC Climate Units - Component Location
HVAC
Climate Units - Component Location
CLIMATE CONTROL SYSTEM (B5254T7)
LOCATION OF COMPONENTS
LOCATING THE CLIMATE CONTROL SYSTEM COMPONENTS IN THE PASSENGER

COMPARTMENT/DOOR MIRROR
Fig. 1: Identifying Climate Control System Components

1. Climate control unit (ECC or MCC)

2. Outside temperature sensor (left-hand side)
3. Passenger compartment temperature sensor (ECC)
4. Sun sensor (ECC)
2012 Volvo C30 T-5
5. Climate control unit

6. Air quality sensor (AQS).
LOCATION OF THE CLIMATE CONTROL UNIT COMPONENTS
Fig. 2: Identifying Climate Control Unit Components

1. Heat exchanger
2. Evaporator
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
Fig. 3: Identifying Engine Compartment Components

1. Compressor
2. The pipe/hose between the compressor and the condenser
3. Condenser
4. Service valve HT, draining/vacuum pumping
5. 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)

2012 Volvo C30 T-5
Fig. 4: Identifying Passenger Compartment Components

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

Overview, climate control unit

2. Damper motor module (DMM) temperature right. Only applies to vehicles equipped with ECC
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
Fig. 6: Identifying Passenger Compartment Components

Overview, passenger compartment
1. Climate control module (CCM)

2. Switch tunnel console front
3. Switch tunnel console rear
4. Passenger compartment temperature sensor with blower fan
5. Seat heating module (SHM) left
6. Seat heating module (SHM) right.
2012 Volvo C30 T-5

Overview, climate control unit

2. Damper motor module (DMM) temperature right
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
2012 Volvo C30 T-5
LOCATION OF ENGINE COOLANT HEATER COMPONENTS
The information applies to the D5WZ/D5WS and B5WS engine coolant heaters.
The engine coolant heater is located in the rear right-hand part of the engine compartment.
Fig. 8: Identifying Engine Coolant Heater Components

Main components:
1. Engine coolant 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, parallel with other
fuel hoses/pipes, up to the heater unit.
COMPONENTS ENGINE COOLANT HEATER

2012 Volvo C30 T-5
Fig. 9: Identifying Booster Heater

2012 Volvo C30 T-5
Fig. 10: Exploded View Of Booster Heater Components

1. Combustion preheater module (CPM)

2. Fan 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)

2012 Volvo C30 T-5
Fig. 11: Identifying Water Pump (Parking Heater), Combustion Preheater Module (CPM) And Fuel
Pump (FP)
Overview
1. Water pump (parking heater)

2. Combustion preheater module (CPM)
3. Fuel pump (FP).
2012 Volvo C30 T-5
HVAC Climate Units - Removal, Replacement And Installation
HVAC
Climate Units - Removal, Replacement And Installation
CONTROL
CLIMATE CONTROL MODULE (CCM)
and/or models. Some variation may occur. However, the essential information is
always correct.
PREPARATORY WORK
IMPORTANT INFORMATION
Fig. 1: Identifying Climate Control Module Components

The unit is a complete control module that has many different functions in addition to controlling the climate
functions.
REMOVAL
2012 Volvo C30 T-5
REMOVING CENTER CONSOLE
Ignition off.
Fig. 2: Identifying 4 Hidden Clips

Remove the panel inside the center console. It is secured with 4 hidden clips.
2012 Volvo C30 T-5
Fig. 3: Identifying Radio Panel

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
Fig. 4: Identifying Infotainment Control Module

Remove the infotainment control module (ICM). It is secured with 2 hidden clips.
HINT: Grip the infotainment control module (ICM) with both hands. Push the control module straight
out of the center console.
Remove:
 the 2 connectors from the infotainment control module (ICM)

 the connector from the center console.
2012 Volvo C30 T-5
Fig. 5: Identifying 4 Screws

Remove:
 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

Remove:
 the 8 screws.
2012 Volvo C30 T-5
Fig. 7: Identifying Climate Control Module (CCM) Screws

 the 4 screws
 the climate control module (CCM).
INSTALLATION
INSTALLING THE CLIMATE CONTROL MODULE (CCM)
CAUTION: Tighten the screws carefully. There is a risk of cracks forming.
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

2012 Volvo C30 T-5
Install:
 the gear selector lever boot

 the center console
 the 4 screws. Tighten
 the panel. See: POWER SOCKET 12V (2007) or POWER SOCKET 12V (2008-2012)
 the connector for the center console
 the 2 connectors for the infotainment control module (ICM)
 the infotainment control module (ICM). It is secured with 2 hidden clips
 the radio panel
 the panel inside the center console. It is secured with 4 hidden clips.
FINISHING
ORDERING SOFTWARE
Order software. See:
C30 30782266
PROGRAMMING CUSTOMER PARAMETERS AND ADJUSTING DAMPER MOTORS
Reprogram the customer programmed data
Carry out self-adjustment of the damper motor end positions. This is carried out in VIDA (Volvo scan tool)
Vehicle communication.
Test drive the vehicle. Check that the engine and climate control system are functioning.
AIR DISTRIBUTION
DRIVER SIDE REGISTER (2010-2012)
CENTER VENTILATION VENT, REPLACING
REMOVING THE CENTER VENTILATION VENT

2012 Volvo C30 T-5
Fig. 8: Identifying Ventilation Grilles And Vent Housing

Remove:
 the ventilation grilles. Pry off the grilles from inside

 the vent housing by prying up the hooks. See the illustration
 the connector for the switch.
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
REMOVING OUTER VENTILATION VENTS
Fig. 9: Identifying Ventilation Grilles And Vent Housing

Remove:
 the ventilation grilles. Pry off the grilles from outside

 the vent housing by prying up the hooks. See the illustration.
INSTALLING OUTER VENTILATION VENTS
Install 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
2012 Volvo C30 T-5
REMOVING THE ACCELERATOR PEDAL (AP)
Remove the accelerator pedal (AP). See ACCELERATOR PEDAL .
REMOVAL
REMOVING THE PASSENGER COMPARTMENT AIR CLEANER (ACL)

Fold the floor carpet out of the way.
Remove:
 the 3 screws and raise the cover

2012 Volvo C30 T-5

 the filter by pulling it out behind the brake pedal.
INSTALLATION
INSTALLING THE PASSENGER COMPARTMENT AIR CLEANER (ACL)

2012 Volvo C30 T-5

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.
Install the air filter by compressing it slightly and inserting it behind the brake pedal.
Clamp the cover in place at the 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 .
POLLEN FILTER CLIMATE CONTROL SYSTEM (2008-2012)
REMOVAL / INSTALLATION

2012 Volvo C30 T-5

Torque: M6
10 Nm
Fig. 14: Identifying Screw

2012 Volvo C30 T-5
Fig. 15: Identifying Pollen Filter

Fig. 16: Identifying Air Flow

VENTILATION DUCT FOOT SPACE REAR
REMOVE / INSTALL
2012 Volvo C30 T-5
Fig. 17: Identifying Air Ducts

AIR DISTRIBUTION UNIT DASHBOARD LOUDSPEAKER, REPLACING
REMOVING THE AIR DISTRIBUTION UNIT FROM THE DASHBOARD

2012 Volvo C30 T-5
Fig. 18: Identifying Air Distribution Unit

Remove the dashboard. See: DASHBOARD .
Turn the dashboard upside down.
Remove the 3 screws and the 2 tie straps. Lift up the cable duct.
Disconnect the 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
Fig. 19: Identifying Air Duct Outer Vent

Remove the dashboard. See: DASHBOARD
Turn the dashboard 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
AIR DUCT FRONT FLOOR, REPLACING
REMOVING AIR DUCT FRONT FLOOR
Remove:
2012 Volvo C30 T-5
 the soundproofing panel on the driver's side. See: INSTRUMENT PANEL LOWER
 the air duct on the driver's side. Slacken off the screw a few turns and pry off the air duct
 the lower soundproofing panel on the passenger side. This is secured with 2 clips
 the glove compartment. See GLOVE COMPARTMENT
 the air duct on the passenger side. Slacken off the screw a few turns and pry off the air duct.
INSTALLING AIR DUCT FRONT FLOOR
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 CENTER TO PASSENGER COMPARTMENT REAR, REPLACING
REMOVING CENTER AIR DUCT TO FLOOR REAR PASSENGER COMPARTMENT
Fig. 20: Identifying Center Air Duct

2012 Volvo C30 T-5
Remove:
 the front seat as described in, see FRONT SEAT

 the tunnel compartment. See: FLOOR CONSOLE
 the front sill trim panel. See: SILL EDGE
Fold the front floor carpet to one side.
Remove the rear air vent.
Pull / pry off the duct at the center console. Detach the duct at the upper mounting.
Press down the upper section of the duct in front of the cross member.
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 FLOOR FRONT TO PASSENGER COMPARTMENT REAR, REPLACING
REMOVING FRONT AIR DUCT TO FLOOR REAR PASSENGER COMPARTMENT

2012 Volvo C30 T-5
Fig. 21: Identifying Air Duct

Remove center console. See: REMOVING CENTER CONSOLE.
Pull down the top of the air duct. Angle the duct out from the dashboard. Remove the duct.
INSTALLING FRONT AIR DUCT TO FLOOR REAR PASSENGER COMPARTMENT
Install:
 air duct. Start at the bottom 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
2012 Volvo C30 T-5
Fig. 22: Identifying Front Side Door Sill Trim Panel

Pull the rear edge straight up.
Ease out the front mount against the dashboard.
INSTALLING THE SILL TRIM PANEL FOR THE FRONT SIDE DOOR
Secure the front mount against the dashboard.
Press the sill trim panel into place.
CAUTION: Ensure that the sill trim panel goes into the groove at the B-pillar panel.
REAR DOOR SILL TRIM PANEL, REPLACING
REMOVING THE SILL TRIM PANEL FROM THE REAR SIDE DOOR
2012 Volvo C30 T-5
Fig. 23: Identifying Removal Of Sill Trim Panel From Rear Side Door
Pull the front edge straight up.
Ease out the rear mount against the C-post panel.
INSTALLING THE SILL TRIM PANEL FOR THE REAR SIDE DOOR
Secure the rear mount against the C-post panel.
CAUTION: Ensure that the sill trim panel goes into the groove at the B-pillar panel.
SILL TRIM PANEL TRUNK LID, REPLACING
REMOVING THE SILL TRIM PANEL TRUNK LID

2012 Volvo C30 T-5
Fig. 24: Identifying Removal Of Sill Trim Panel Trunk Lid

Lift up the cargo compartment floor.
Remove the 2 screw clips.
Pull the sill trim panel straight up.
INSTALLING THE SILL TRIM PANEL TRUNK LID
Install the 2 screw clips.
Fold the cargo compartment floor down.
CLIMATE UNIT
ACTUATOR DAMPER CLIMATE CONTROL SYSTEM DRIVER'S SIDE
2012 Volvo C30 T-5
PREPARATORY WORK
The are 2 damper motor modules (DMM) for temperature, one on the right and one on the left-hand side.
REMOVING THE DASHBOARD
REMOVAL
REMOVING THE DAMPER MOTOR MODULE (DMM) FOR TEMPERATURE
Fig. 25: Identifying Screws And Control Module

Disconnect the connector.
HINT: Using a small electrician's screwdriver, pry up the connector at the lock. Pull the connector off.
2012 Volvo C30 T-5
Remove:
 the 3 screws
 the control module.
INSTALLATION
INSTALLING THE DAMPER MOTOR MODULE (DMM) FOR TEMPERATURE
Install:
 the control module in position. Adjust the shaft journal so that it goes in
 the 3 screws. Tighten crosswise
 the switch
NOTE: Identify the damper motor module (DMM) temperature. See VIDA (Volvo scan
tool) Vehicle communication.
FINISHING
TESTING THE CLIMATE CONTROL SYSTEM
Carry out a performance test on the climate control unit. See: CLIMATE CONTROL SYSTEM, CHECK .
ACTUATOR, MIXER DAMPER
PREPARATORY WORK
The damper motor module (DMM) for air distribution is only on the left-hand side.
REMOVAL
REMOVING THE DAMPER MOTOR MODULE (DMM) FOR AIR DISTRIBUTION

2012 Volvo C30 T-5

Remove:
 the 3 screws
INSTALLATION
INSTALLING THE DAMPER MOTOR MODULE (DMM) FOR AIR DISTRIBUTION
Install:
 the switch
 the dashboard. See: DASHBOARD .
2012 Volvo C30 T-5
NOTE: Identify the damper motor module (DMM) air distribution. See VIDA (Volvo scan
FINISHING
ACTUATOR RECIRCULATION
PREPARATORY WORK
REMOVING THE GLOVE COMPARTMENT
Remove the glove compartment. See: GLOVE COMPARTMENT .
REMOVAL
REMOVING THE DAMPER MOTOR MODULE (DMM) FOR RECIRCULATION

2012 Volvo C30 T-5

Remove:
 the 4 screws
INSTALLATION
INSTALLING THE DAMPER MOTOR MODULE (DMM) FOR RECIRCULATION
Install:
 the switch
 the glove compartment. See GLOVE COMPARTMENT .
2012 Volvo C30 T-5
NOTE: Identify the damper motor module (DMM) recirculation. See VIDA (Volvo scan
FINISHING
ACTUATOR REGISTER DUCT FOOTWELL
PREPARATORY WORK
The damper motor module (DMM) for the defroster is only on the right-hand side.
REMOVAL
REMOVING THE DAMPER MOTOR MODULE (DMM) FOR THE DEFROSTER

2012 Volvo C30 T-5

Remove:
 the 3 screws
INSTALLATION
INSTALLING THE DAMPER MOTOR MODULE (DMM) FOR THE DEFROSTER
Install:
 the switch
2012 Volvo C30 T-5
NOTE: Identify the damper motor module (DMM) defroster. See VIDA (Volvo scan tool)
Vehicle communication.
FINISHING
AIR QUALITY SENSOR (2007)
PREPARATORY WORK
IGNITION OFF AND REMOVING THE GLOVE COMPARTMENT

Ignition off.
2012 Volvo C30 T-5
Remove the glove compartment. See: GLOVE COMPARTMENT .
REMOVAL
REMOVING THE AIR QUALITY SENSOR (AQS)
Fig. 30: Air Quality Sensor

The air quality sensor (AQS) is located in front of the damper motor module (DMM) recirculation.
Turn the air quality sensor (AQS) approximately 60 degrees counter-clockwise.
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 QUALITY SENSOR (AQS)

2012 Volvo C30 T-5
Carry out a performance test on the air quality sensor (AQS). See: AIR QUALITY SENSOR, CHECKING.
AIR QUALITY SENSOR, CHECKING
PREPARATORY WORK
PREPARATORY WORK
Remove the cowl. See PLENUM CHAMBER .
CHECK
CHECKING AIR QUALITY SENSOR (AQS)
Fig. 31: Identifying Air Quality Sensor (AQS)

Start the car with the climate control system automatic button in the ON position.
2012 Volvo C30 T-5
Spray a little rust solvent or windshield washer fluid from a spray bottle in the area around the air quality
sensor.
NOTE: Only spray a little.
If the air quality sensor and the other electronics are fault free, the damper for the air intake should close within
a short period of time.
If the air quality 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)
Remove glove compartment, see GLOVE COMPARTMENT
Fig. 32: Identifying Air Quality Sensor

2012 Volvo C30 T-5
Fig. 33: Identifying Sensor Rotating 60 Degrees

BLOWER MOTOR PASSENGER COMPARTMENT
Special tools:
see 9997115
PREPARATORY WORK
IMPORTANT INFORMATION AND REMOVING COMPONENTS
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.
Remove:
 the instrument panel, according to DASHBOARD

2012 Volvo C30 T-5
Fig. 34: Identifying Air Distribution Damper Cover Screws

 the air quality sensor (AQS)

 the connector 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
Fig. 35: Identifying Catch On Connector For Fan Motor

Press in the catch on the connector for the fan motor and pull straight out.
2012 Volvo C30 T-5
Fig. 36: Identifying Lock Button And Limit Position

Press the lock button (1).
Turn the fan motor counter-clockwise to the limit position (2).

2012 Volvo C30 T-5
Fig. 37: Identifying Blower Fan Motor

Remove the fan motor from the passenger side. Use: see 9997115 .
INSTALLATION
INSTALLING THE BLOWER FAN MOTOR

2012 Volvo C30 T-5
Fig. 38: Identifying Blower Fan Motor

Place the fan motor in the correct position for installation. Use: see 9997115 .
NOTE: Turn the fan motor to the position for installation.
Insert the fan motor from the driver's side. Turn clockwise to the limit position.
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

2012 Volvo C30 T-5
Test the operation of the fan motor.
Install the dashboard. See: DASHBOARD
CLIMATE UNITS
PREPARATORY WORK
DRAINING THE AIR CONDITIONING (A/C) SYSTEM
WARNING: Follow the safety instructions for work on air conditioning systems. See:
REFRIGERANT .
Read the instructions for slow and fast leaks acc. to: AC-SYSTEM, OIL, REFILLING .
CAUTION: Always use new O-rings lubricated with compressor oil.
NOTE: Plug the pipes and connections when working on the climate control system.
Drain the refrigerant from the AC-system acc. to: REFRIGERANT, DRAINING .
DRAINING COOLANT AND REMOVING COMPONENTS

2012 Volvo C30 T-5
Fig. 39: Identifying Shield And Clips

Remove the expansion 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
Fig. 40: Identifying Dashboard

REMOVAL
REMOVING THE CLIMATE CONTROL UNIT

2012 Volvo C30 T-5
Fig. 41: Identifying Spacer And Right-Hand Half Of Lead-In

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
Fig. 42: Identifying Screw Securing Air Conditioning (A/C) Pipes

Lift up both air conditioning (A/C) hoses from their mountings below the right-hand spring strut turret.
Remove the 1 screw securing the air conditioning (A/C) pipes to the evaporator. See the illustration.
Pull the pipes off from the evaporator connection.
Separate the pipes to the heat exchanger. see HEAT EXCHANGER

2012 Volvo C30 T-5
Fig. 43: Identifying Drainage Hose From Lower Connection On Right-Hand Side Under Heat Exchanger
Housing
Remove:
 the drainage hose from the lower connection on 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

2012 Volvo C30 T-5
 the 1 M8 screw securing the air conditioning (A/C) pipes to the evaporator in the engine compartment.
Tighten
 both the air conditioning (A/C) hoses in their mountings below the right-hand spring strut turret
 the spacer that holds the heat exchanger and evaporator pipes apart
 the 2 screws and the right-hand half of the lead-in. Tighten
 the dashboard. Do not install the glove compartment. See: DASHBOARD
 the drain nipple on the radiator.
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. See: LEAK DETECTION, TRACER AGENT , LEAK
TRACING, ELECTRONIC LEAK TRACER (2007, 2010-11) or LEAK TRACING, ELECTRONIC
LEAK TRACER (2008-09) .
2012 Volvo C30 T-5

Install:
 the glove compartment. See GLOVE COMPARTMENT

 the shield under the vehicle using the 7 clips
ACCUMULATOR
PREPARATORY WORK
DRAINING THE AIR CONDITIONING (A/C) SYSTEM AND REMOVING COMPONENTS
REFRIGERANT .
2012 Volvo C30 T-5
Drain the refrigerant from the air conditioning (A/C) system. See: REFRIGERANT, DRAINING .
Remove:
 right-hand front headlamp. See: HEADLAMP BULB (2007) or HEADLAMP BULB (2008-2012)
 the bumper shell. See COVER BUMPER FRONT (2007 - 2011 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
2012 Volvo C30 T-5
Fig. 45: Identifying Nut Under Front Fender Liner On Right-Hand Side
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
Fig. 46: Identifying Pipe/Hose Connector

Disconnect the pipe / hose connection to the receiver. See the illustration.
2012 Volvo C30 T-5
Fig. 47: Identifying Pipe Coupling

Remove:
 the screw (A) for the pipe coupling

 the 3 screws (B) for mounting the receiver.
Remove the receiver.
INSTALLATION
INSTALLING RECEIVER
Fill the recommended volume of compressor oil. See: AC-SYSTEM, OIL, REFILLING .
NOTE: Install the receiver within 5-10 minutes of the plugs having been removed. This
prevents the absorbent material absorbing moisture from the air.
Install:
2012 Volvo C30 T-5
 the receiver together with 3 M8 screws. Tighten.

 the pipe couplings, 2 x M8. Make sure the O-rings are securely located. Tighten the screws.
 the M8 nut below the fender liner. Tighten.
 the fender liner together with the plastic nut and the retaining clip.
FINISHING
CHECKING THE FUNCTION AND LEAK TRACING
Fill the air conditioning (A/C) system with refrigerant. See: REFRIGERANT, FILLING .
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) .
ELECTRIC BOOSTER HEATER (2007)
PREPARATORY WORK
REMOVING COMPONENTS
REMOVAL
REMOVING THE ELECTRICAL PREHEATER

2012 Volvo C30 T-5
Fig. 48: Identifying Screws For Right-Hand Mounting Bracket, Clamps For Cable Harness And
Connectors
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
Fig. 49: Identifying Preheater Screws

WARNING: Do not perform any work on the electrical preheater until the heating coil
has cooled to ambient temperature.
Remove the 2 screws.
Pull out the preheater.
INSTALLATION
INSTALLING THE ELECTRICAL PREHEATER
Install the preheater. Ensure that it is situated horizontally and engages in the guide pins on the opposite side.
Install:

2012 Volvo C30 T-5
 the 3 connectors
 the cable harness on the mounting bracket using the 2 clips
 the right-hand mounting bracket using the 4 screws (of which 3 M8). Tighten.
FINISHING
Install the center console. See: INSTALLING CENTER CONSOLE.
FUNCTION TESTING THE ELECTRICAL PREHEATER
Test the function of the electrical preheater. First read the information below and ensure that the conditions for
the function test are correct.
The electrical preheater comprises 3 separate heater elements assembled in a housing. The preheater 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 of the generator (GEN).
ELECTRIC BOOSTER HEATER (2008-2012)
PREPARATORY WORK
REMOVING COMPONENTS
REMOVAL
REMOVING THE ELECTRICAL PREHEATER

2012 Volvo C30 T-5
Fig. 50: Identifying Screws For Right-Hand Mounting Bracket, Clamps For Cable Harness And
Connectors
Remove:
 the cable harness from the mounting bracket. This is secured with 2 clips
 the 4 screws. Remove the right-hand mounting bracket
2012 Volvo C30 T-5
Fig. 51: Identifying Preheater Screws

WARNING: Do not perform any work on the electrical preheater until the heating coil
has cooled to ambient temperature.
Pull out the preheater.
INSTALLATION
INSTALLING THE ELECTRICAL PREHEATER
Install the preheater. Ensure that it is situated horizontally and engages in the guide pins on the opposite side.
Install:

2012 Volvo C30 T-5
 the cable harness on the mounting bracket using the 2 clips
 the right-hand mounting bracket using the 4 screws (of which 3 M8). Tighten.
FINISHING
Install the center console. See: INSTALLING CENTER CONSOLE
FUNCTION TESTING THE ELECTRICAL PREHEATER
Test the function of the electrical preheater. First read the information below and ensure that the conditions for
the function test are correct.
The electrical preheater comprises 3 separate heater elements assembled in a housing. The preheater 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 of the generator (GEN).
HEAT EXCHANGER
PREPARATORY WORK
2012 Volvo C30 T-5

Draining coolant and removing the engine splash guard.
Remove:
 the cover for the expansion tank and raise the vehicle
 the engine splash guard.
Attach a hose on the nipple at the radiator and lower the hose to a container.
Open the nipple and drain off the coolant.
Fig. 53: Identifying Radiator Hoses

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 it to hang from the wiring. See CONTROL
MODULE RELAY BOX PASSENGER COMPARTMENT
2012 Volvo C30 T-5
Fig. 54: Identifying Climate Control Unit Brackets, Air Duct And Screws
Remove:
 the brackets on both sides of the climate control unit and the screws, 3 per bracket
 the air duct
 the 8 x screws for the cover.
Pull the cover at angle downwards/backwards.
Heat exchanger. See HEAT EXCHANGER.
Fig. 55: Identifying Heat Exchanger Pipes

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
Place some paper below the pipe couplings to collect any spilled coolant.
Cut or saw off the pipes.
Press the pipes towards the firewall so that they protrude into the engine compartment.
HINT: To facilitate, also route the pipes from the engine compartment.
Fig. 56: Identifying Screws And Lead-In's Right Half

Remove:
 the 2 x screws and the lead-in's right half.

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.
NOTE: Note how the seal is located on the heat exchanger.
INSTALLATION
NOTE: Install a new seal carefully using the removed evaporator as a template.
Install:
 the heat exchanger

2012 Volvo C30 T-5
 the heat exchanger pipes through the seal.
HINT: To facilitate assembling the pipes, lubricate the ends with a little oil.
NOTE: Use new O-rings for the pipe ends.
Install the pipes at the connection to the heat exchanger pipes.
Fig. 57: Identifying Clips

Install the clips so that they lock securely. A click must be heard.
NOTE: The clips only fit one way in the pipe connection.
Fig. 58: Identifying Screws For Cover, Air Duct And Brackets On Both Sides Of Climate Control Units
2012 Volvo C30 T-5
Install:
 the 8 x screws for the cover. Tighten

 the air duct
 the brackets on both sides of the climate control unit and the screws, 3 per bracket. Tighten.
FINISHING
Install:
 the central electrical unit in its bracket. See CONTROL MODULE RELAY BOX PASSENGER
COMPARTMENT
 the center console. See INSTALLING CENTER CONSOLE.
Install the radiator hoses in the connections by 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.
Install the glove compartment. See GLOVE COMPARTMENT .
TEMPERATURE SENSOR PASSENGER COMPARTMENT
PREPARATORY WORK
COMPONENT OVERVIEW
2012 Volvo C30 T-5
Fig. 59: Identifying Passenger Compartment Temperature Sensor (ECC Only)

REMOVING COMPONENTS
Fig. 60: Identifying 4 Hidden Clips

Use a weatherstrip tool and remove the panel inside the center console. It is secured with 4 hidden clips.
2012 Volvo C30 T-5
Fig. 61: Identifying Driver's Side Soundproofing Panel

Remove the end cover on the left-hand side. Use a weatherstrip tool and start at the rear edge.
Remove the 3 screws and the clip for the driver's side soundproofing panel. Leave the soundproofing panel
hanging from the cable harness.
REMOVAL
REMOVING THE BLOWER FAN MOTOR PASSENGER COMPARTMENT TEMPERATURE SENSOR

2012 Volvo C30 T-5
Fig. 62: Identifying Catches

Press in the catches. Lift straight up.
INSTALLATION
INSTALLING THE BLOWER 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
PREPARATORY WORK
DRAINING THE AIR CONDITIONING (A/C) SYSTEM AND REMOVING THE COVER
REFRIGERANT .
NOTE: Plug the pipes and connections when working on the climate control system
(air conditioning).
Raise the vehicle.
Remove the drive belts. See: ACCESSORY DRIVE BELT TENSIONER

2012 Volvo C30 T-5

Remove the cover under the vehicle. It is secured with 7 clips.
REMOVAL
REMOVING COMPRESSOR
2012 Volvo C30 T-5
Fig. 64: Identifying Lower/Front Pipe/Hose Connector

Remove:
 the connector to the magnetic clutch

 the pipe connections for the compressor (1) and (2).
2012 Volvo C30 T-5
Fig. 65: Identifying Compressor Mounting Screws

 the 3 mounting screws for the compressor.
Remove the compressor.
INSTALLATION
INSTALLING THE COMPRESSOR

2012 Volvo C30 T-5

Position the compressor.
 Fasten the compressor with screws, 3 pcs. M8

 Install the longest screw in the rear mounting
 Insert the screws
 Begin by tightening the longest M8
 Tighten the remaining 2 pcs. M8.
It is important to follow 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.
Install the pipe connections, 2 M8 (1) and (2). Ensure that the O-rings are securely located between the
compressor and the pipes.
Tighten the screws.

2012 Volvo C30 T-5
Install the drive belts. See: ACCESSORY DRIVE BELT TENSIONER .
FINISHING
Vacuum pump the air conditioning (A/C) system. See: VACUUM PUMPING
Fill the AC-system with refrigerant acc. to: REFRIGERANT, FILLING
CHECKING THE PERFORMANCE

Install the shield under the vehicle using the 7 clips.
2012 Volvo C30 T-5
PREPARATORY WORK
DRAINING THE AIR CONDITIONING (A/C) SYSTEM AND REMOVING COMPONENTS
REFRIGERANT .
Remove:
 right-hand front headlamp. See: HEADLAMP BULB (2007) or HEADLAMP BULB (2008-2012)
 the bumper shell. See COVER BUMPER FRONT (2007 - 2011 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
2012 Volvo C30 T-5
Fig. 68: Identifying Nut Under Front Fender Liner On Right-Hand Side
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

Disconnect the pipe / hose connection to the receiver. See the illustration.
2012 Volvo C30 T-5

Remove:
 the screw (A) for the pipe coupling

 the 3 screws (B) for mounting the receiver.
Remove the receiver.
INSTALLATION
INSTALLING RECEIVER
Fill the recommended volume of compressor oil. See: AC-SYSTEM, OIL, REFILLING .
NOTE: Install the receiver within 5-10 minutes of the plugs having been removed. This
prevents the absorbent material absorbing moisture from the air.
Install:
2012 Volvo C30 T-5
 the receiver together with 3 M8 screws. Tighten

 the pipe couplings, 2 x M8. Make sure the O-rings are securely located. Tighten the screws
 the M8 nut below the fender liner. Tighten
 the fender liner together with the plastic nut and the retaining clip.
FINISHING
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) .
CONDENSER (B5244S4, B5254T3)
PREPARATORY WORK
SAFETY INFORMATION COOLING SYSTEM .

2012 Volvo C30 T-5
REMOVING COMPONENTS
Fig. 71: Identifying Rear Connector

Remove:
 the bumper shell. See COVER BUMPER FRONT (2010, 2011 EARLY) or COVER 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

2012 Volvo C30 T-5
Fig. 72: Removing The Condenser

Press in the catch. Carefully pry off both sides using a screwdriver.
Remove the condenser from the air conditioning unit.
INSTALLATION
INSTALLING THE CONDENSER

2012 Volvo C30 T-5
Fig. 73: Installing The Condenser

Fill the condenser with oil. See AC-SYSTEM, OIL, REFILLING .
Press the condenser into the mounting points.
NOTE: Ensure that both retaining clips secure the condenser.
FINISHING

2012 Volvo C30 T-5

Install:
 the air conditioning unit. See: RADIATOR (B5254T3, B5254T7) or RADIATOR (B5244S4)
 the 2 M8 screws (1) and (2) at the condenser connection (see the illustration). Tighten.
TRACING, ELECTRONIC LEAK TRACER (2008-2009) or LEAK TRACING, ELECTRONIC LEAK
TRACER (2007, 2010-11) .
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 COVER BUMPER
FRONT (2010, 2011) .
2012 Volvo C30 T-5
CONDENSER (B5254T7)
PREPARATORY WORK
DRAINING THE A/C SYSTEM
SAFETY INFORMATION COOLING SYSTEM .
REMOVAL
REMOVING THE AIR CONDITIONING AGGREGATE
Remove the air conditioning aggregate. See: RADIATOR (B5244S4) or RADIATOR (B5254T3, B5254T7) .
REMOVING THE CONDENSER

2012 Volvo C30 T-5
Fig. 75: Identifying Screws And Cover From Frame

Remove:
 the 4 screws
 the cover from the frame.
2012 Volvo C30 T-5
Fig. 76: Identifying Condenser

Lift the condenser straight up.
INSTALLATION
INSTALLING THE CONDENSER

2012 Volvo C30 T-5
Fig. 77: Identifying Screws And Cover From Frame

Fill the condenser with oil. See AC-SYSTEM, OIL, REFILLING .
Install:
 the condenser
 the cover 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
Fill the system. See: REFRIGERANT, FILLING .

2012 Volvo C30 T-5
Leak trace the system. See: LEAK DETECTION, TRACER AGENT , LEAK TRACING, ELECTRONIC
LEAK TRACER (2008-2009) or LEAK TRACING, ELECTRONIC LEAK TRACER (2007, 2010-11) .
ELECTROMAGNETIC CLUTCH
Special tools:
see 9995596
see 9995598
see 9995599
see 9995600
see 9995597
see 9995602
PREPARATORY WORK
REMOVING COMPONENTS
2012 Volvo C30 T-5

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
Fig. 79: Identifying Right-Hand Screw Securing Air Baffle

 the 5 screws and the plastic nut. Detach 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
Fig. 80: Identifying Clutch Plate And Counterhold

Remove:
 the screw for the flex plate. Use: see 9995596

2012 Volvo C30 T-5
Fig. 81: Identifying Shims

 the flex plate. Use: see 9995596

2012 Volvo C30 T-5
Fig. 82: Identifying Snap Ring

 the snap ring.

2012 Volvo C30 T-5
Fig. 83: Identifying Puller And Socket

Pull off the pulley. Use: see 9995598 and: see 9995599 .
2012 Volvo C30 T-5
Fig. 84: Identifying Solenoid Coil's Cable And Compressor Housing

NOTE: Note the position of the solenoid coils cable in relation to the compressor
housing. It should be located under cover panel.
Cut off the cable from the solenoid coil. Cut close 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

2012 Volvo C30 T-5
Fig. 85: Identifying Cable And Retaining Clip

Lower the compressor a little by slackening off the 3 mounting screws.
Remove 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.

2012 Volvo C30 T-5
Fig. 86: Identifying Magnet Coil

 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
Fig. 87: Identifying Puller And Socket

Install a new belt pulley. Use: see 9995598 and: see 9995600 .
NOTE: Place the tools behind the compressor mountings.

2012 Volvo C30 T-5
Fig. 88: Identifying Shims

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
Fig. 89: Identifying Feeler Gauge Between Clutch Plate And Pulley
Check the clearance between the clutch plate and pulley. Use a feeler gauge.
The clearance should ideally be 0.3 mm all the way around, although a play up to max. 0.5 mm is allowed.
Replace the shims if the clearance is not within the stated values.
FINISHING
2012 Volvo C30 T-5

Install:
 the auxiliaries belts. See: ACCESSORY DRIVE BELT TENSIONER

 the right-hand screw securing the air baffle
 the right-hand fender liner using the 5 screws and the plastic nut
 the right-hand front wheel.
 the shield under the vehicle using the 7 clips. See the illustration.
EVAPORATOR
PREPARATORY WORK
Drain refrigerant from the A/C system. See: REFRIGERANT, DRAINING .

2012 Volvo C30 T-5
DRAINING COOLANT AND REMOVING THE COVER

Raise the vehicle.
Remove the shield under the vehicle. It is secured with 7 clips. See the illustration.
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
 the center console. See: REMOVING CENTER CONSOLE

 the multimedia module (MMM) (if applicable). See: CONTROL MODULE INFORMATION AND
ENTERTAINMENT
Fig. 92: Identifying Central Electrical Unit Bracket Nuts

 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

Lift up both air conditioning (A/C) pipes from their mountings below the right-hand spring strut turret.
Remove the 1 screw securing the air conditioning (A/C) pipes to the evaporator. See the illustration.
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

Remove:
 the 2 screws and remove the right-hand half of the lead-in. See the illustration
2012 Volvo C30 T-5
Fig. 95: Identifying Evaporator Pipes

Cut off the evaporator pipes.
Pull and press out the pipes through the seal. See the illustration.
2012 Volvo C30 T-5
Fig. 96: Identifying Evaporator Screws

Remove the 3 screws. Remove the cover.
Pull out the evaporator. Pull alternately at the top and bottom edges. It may be hard to remove.
NOTE: Note how the seal is located on the evaporator.
INSTALLATION
INSTALLING THE EVAPORATOR
Install a new seal, using the removed evaporator as a template.

2012 Volvo C30 T-5

Install the evaporator far enough that the cover can be installed (approximately 3-4 mm inside the opening).
Position the front edge of the cover between the evaporator and the heater unit.
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

NOTE: Pull the insulation for the pipes as far in towards the evaporator as possible
before installing the spacer and the right-hand half of the lead-in.
Install:
 the spacer that holds the heat exchanger and evaporator pipes apart
 the right-hand half of the lead-in using the 2 screws.
Install:
 the M8 screw securing the air conditioning (A/C) pipes in the engine 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
2012 Volvo C30 T-5
FINISHING
Fill with coolant and warm up the engine until the thermostat opens. Top up if necessary.
TRACER (2007, 2010-11) .

Install:
2012 Volvo C30 T-5

 the multimedia module (MMM) (if applicable). See: CONTROL MODULE INFORMATION AND
ENTERTAINMENT
 the shield under the vehicle using the 7 clips.
EXPANSION VALVE
PREPARATORY WORK
REFRIGERANT .
REMOVING THE EXPANSION VALVE (ORIFICE)

2012 Volvo C30 T-5
Fig. 100: Identifying Cap Nut For Expansion Valve

Clean the join thoroughly.
Slacken off the cap nut.
NOTE: Make a note of the position of the expansion valve in the pipe.
Pull or work out the expansion valve. See the illustration. It is not screwed in place.
HINT: The expansion valve can be removed using round-nosed pliers.
CAUTION: Make sure that the expansion valve does not come off.
INSPECTING THE FILTER SECTION OF THE EXPANSION VALVE

2012 Volvo C30 T-5
Fig. 101: Identifying Filter Sections Of Expansion Valve

(A) shows an approved expansion valve.
If 4 or 5 filter sections in the expansion valve are clogged (B) , the compressor oil must be inspected.
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
INSTALLING THE EXPANSION VALVE (ORIFICE)
Install a new expansion valve.
NOTE: Make sure that the expansion valve is properly pressed into the pipe section at
the evaporator.
Install the cap nut. Tighten. See: TIGHTENING TORQUE .
FINISHING
TRACER (2007, 2010-11) .
LOW PRESSURE SWITCH CLIMATE CONTROL
REMOVE / INSTALL
Fig. 102: Identifying Low Pressure Switch Climate Control

2012 Volvo C30 T-5
NEEDLE VALVE
Special tools:
see 9511204
see 9811994
PREPARATORY WORK
DRAINING REFRIGERANT
Drain the refrigerant from the system. See REFRIGERANT, DRAINING .
REMOVAL
REMOVING THE NEEDLE VALVE / SERVICE VALVE

2012 Volvo C30 T-5
Fig. 103: Identifying Needle Valve/Service Valve

Remove the needle valve in the service valve. Use: see 9511204 .
INSTALLATION
INSTALLING THE NEEDLE VALVE / SERVICE VALVE
Install the needle valve. Use: see 9511204 .
Use: see 9811994 and tighten, see: TIGHTENING TORQUE .
NOTE: Use only your finger and thumb when tightening the needle valve to avoid
damage to the valve seal.
FINISHING
2012 Volvo C30 T-5
TRACER (2007, 2010-11) .
REFRIGERANT PIPE ACCUMULATOR TO COMPRESSOR
PREPARATORY WORK
REFRIGERANT .
REMOVING THE SHIELD

2012 Volvo C30 T-5

Raise the vehicle.
PIPE/HOSE BETWEEN COMPRESSOR AND CONDENSER (PRESSURE SIDE), REPLACING
REMOVING THE PIPE/HOSE BETWEEN THE COMPRESSOR AND THE CONDENSER

2012 Volvo C30 T-5

Remove:
 the rear/upper 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

Lower the vehicle.
Remove the upper charge air cooler (CAC) hose.
Remove the dip stick.
Disconnect the rear connector (1) to the condenser, to the left of the right-hand headlamp. See the illustration.
Route 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
2012 Volvo C30 T-5
 the pipe coupling by the compressor, 1 M8. Make sure the O-rings are securely located. Tighten the screw
 the charge air pipe upper and lower connectors.
Carry out finishing work. See: FINISHING.
PIPE/HOSE BETWEEN COMPRESSOR AND RECEIVER (SUCTION SIDE), REPLACING
REMOVING THE PIPE/HOSE BETWEEN THE COMPRESSOR AND THE RECEIVER

Remove the lower/front pipe/hose connector (2) on the compressor.

2012 Volvo C30 T-5

Lower the vehicle.
Remove the upper connector of the charge air hose to the charge air cooler (CAC).
Disconnect the pipe/hose connector to the receiver adjacent to the power steering fluid reservoir. See the
illustration.
Route the pipe/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
2012 Volvo C30 T-5
 the pipe coupling by the compressor, 1 M8. Make sure the O-rings are securely located. Tighten the
screw.
Carry out finishing work. See: FINISHING.
FINISHING
FUNCTION TESTING TOGETHER WITH LEAK TRACING
TRACER (2007, 2010-11) .
INSTALLING SHIELD AND BUMPER COVER

Install the shield under the vehicle with 7 clips. See the illustration.
2012 Volvo C30 T-5
Install the front bumper cover. See: COVER BUMPER FRONT (2010, 2011 EARLY) , COVER BUMPER
FRONT (2011 LATE - 2012)
REFRIGERANT PIPE CONDENSER TO EXPANSION VALVE
PREPARATORY WORK (THE SAME FOR ALL METHODS)
REFRIGERANT .
PIPE/HOSE BETWEEN EVAPORATOR AND RECEIVER, REPLACING
REMOVING COMPONENTS
2012 Volvo C30 T-5
Fig. 110: Identifying Coolant Reservoir, Power Steering Fluid Reservoir And Hoses
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 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

2012 Volvo C30 T-5

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

Remove:
 the right-hand headlamp. See: HEADLAMP BULB (2007) or HEADLAMP BULB (2008-2012) .
 the nut. Disconnect the pipe coupling (A) at the receiver.
NOTE: Plug the intake pipe for the receiver immediately after disconnection.
INSTALLING THE PIPE/HOSE BETWEEN THE 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:
2012 Volvo C30 T-5
 the mounting block in the grooves on the pipe

 the M8 screw securing the air conditioning (A/C) pipes to the evaporator.
Press in the hose into the mounting below the right-hand suspension turret.
PIPE/HOSE BETWEEN CONDENSER AND EXPANSION VALVE, REPLACING
REMOVING COMPONENTS
Fig. 113: Identifying Coolant Reservoir, Power Steering Fluid Reservoir And Hoses
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 conditioning (A/C) system pressure sensor from the air conditioning (A/C)
2012 Volvo C30 T-5
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 CONDENSER AND THE EXPANSION VALVE

Remove the cap nut for the expansion valve. See the illustration.
2012 Volvo C30 T-5

Unscrew the cover from the service valve.
Remove:
 the service valve using an extended 24 mm sleeve

 the screw (2) at the 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.
2012 Volvo C30 T-5
Carry out finishing work.
PIPE BETWEEN EXPANSION VALVE AND EVAPORATOR, REPLACING
REMOVING THE PIPE BETWEEN THE EXPANSION VALVE AND THE EVAPORATOR

Remove:
 the screw securing the air conditioning (A/C) pipes to the evaporator. See the illustration
 the mounting block from the pipes.
2012 Volvo C30 T-5

Remove the cap nut for the expansion valve. See the illustration.
INSTALLING THE PIPE BETWEEN THE EXPANSION VALVE AND THE EVAPORATOR
Install:
 the mounting block in the grooves on the pipe

 the M8 screw securing the air conditioning (A/C) pipes to the evaporator
 the cap nut for the expansion valve.
FINISHING WORK (THE SAME FOR ALL METHODS)

2012 Volvo C30 T-5
Install:
 the coolant reservoir

 the power steering fluid reservoir
 the ground strip on the connection at the right-hand suspension turret
 the 2 switches for the air conditioning (A/C) system pressure sensor on the air conditioning (A/C) pipes /
hoses
 the front bumper cover. See: COVER BUMPER FRONT (2011 LATE - 2012) or COVER BUMPER
FRONT (2010, 2011 EARLY)
TRACER (2007, 2010-11) .
SWITCH HIGH PRESSURE (2007-2011)
REMOVE / INSTALL
Fig. 118: Identifying High Pressure Switch


2012 Volvo C30 T-5
SWITCH HIGH PRESSURE (2012)
REMOVAL
Fig. 119: Identifying High Pressure Switch

Follow the instruction for tightening torques, see TIGHTENING TORQUE
INSTALLATION
Perform climate unit, checking, see CLIMATE CONTROL SYSTEM, CHECK
TEMPERATURE SENSOR EVAPORATOR
PREPARATORY WORK
IGNITION OFF
2012 Volvo C30 T-5

Ignition off.
REMOVAL
REMOVING THE TEMPERATURE SENSOR FOR THE EVAPORATOR

2012 Volvo C30 T-5
Fig. 121: Identifying Temperature Sensor For Evaporator

Fold down the carpet in the driver's side footwell towards the heater unit.
Turn the temperature sensor together with the cable harness a 1/4 turn clockwise.
Pull the temperature sensor straight out. Remove the temperature sensor.
Remove the connector.
INSTALLATION
INSTALLING THE TEMPERATURE SENSOR FOR THE EVAPORATOR
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 Volvo C30 T-5
AUXILIARY HEATER, FUEL OPERATED

COOLANT PIPE FUEL-POWERED PREHEATER (B5244S4)
PREPARATORY WORK
REPLACING PIPE COUPLINGS
Remove:
 the engine coolant heater. See: FUEL FIRED BOOSTER HEATER (B5244S4)
 the engine 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

2012 Volvo C30 T-5
Fig. 122: Identifying Heat Exchanger Cover Screws

Remove cover over heat exchanger. It is secured using 4 screws.
Lift up the cover a little until the snap rings for the pipe couplings release.
Ease out and pull the pipe couplings upwards, one at a time.
REMOVING PIPE COUPLING AND SNAP RING

2012 Volvo C30 T-5
Fig. 123: Identifying Pipe Coupling And Snap Rings

There are snap rings on the underneath of the cover that also hold the pipe couplings in place. The snap rings
are located in a groove on the pipe coupling.
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
Fig. 124: Clamping Snap Ring By Compressing Groove

Install the pipe.
Clamp the snap ring by compressing the groove. See the illustration.
Press in the pipes. Adjust the pipes so that they are positioned according to previous markings.
Press down the cover fully. 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

2012 Volvo C30 T-5
COOLANT PIPE FUEL-POWERED PREHEATER (B5254T3, B5254T7)
PREPARATORY WORK
REPLACING PIPE COUPLINGS
Remove:
 the engine coolant heater. See: FUEL FIRED BOOSTER HEATER (B5254T3, B5254T7)
 the engine 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

2012 Volvo C30 T-5
Fig. 125: Identifying Heat Exchanger Cover Screws

Remove cover over heat exchanger. It is secured using 4 screws.
Lift up the cover a little until the snap rings for the pipe couplings release.
Ease out and pull the pipe couplings upwards, one at a time.
REMOVING PIPE COUPLING AND SNAP RING

2012 Volvo C30 T-5
Fig. 126: Identifying Pipe Coupling And Snap Rings

There are snap rings on the underneath of the cover that also hold the pipe couplings in place. The snap rings
are located in a groove on the pipe coupling.
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
Fig. 127: Clamping Snap Ring By Compressing Groove

Install the pipe.
Clamp the snap ring by compressing the groove. See the illustration.
Press in the pipes. Adjust the pipes so that they are positioned according to previous markings.
Press down the cover fully. 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
FINISHING

2012 Volvo C30 T-5
FAN MOTOR FUEL-POWERED PREHEATER (B5244S4)
PREPARATORY WORK
REMOVING COMPONENTS
Remove:
 the engine coolant heater. See FUEL FIRED BOOSTER HEATER (B5244S4)
 the combustion preheater module (CPM). See: FUEL FIRED BOOSTER HEATER CONTROL UNIT
(B5244S4).
REMOVAL
REMOVING THE FAN MOTOR FOR THE ENGINE COOLANT HEATER

2012 Volvo C30 T-5
cover. See: COOLANT PIPE FUEL-POWERED PREHEATER (B5244S4).

illustration.
2012 Volvo C30 T-5

Disconnect the cable terminals and wiring for the fan motor at positions 13 and 14 (black and brown).
2012 Volvo C30 T-5

Lift the fan motor away from the heat exchanger.
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
Fig. 132: Identifying Gasket, Combustion Chamber And Molded Gasket

Replace both gaskets supplied with the fan motor.
Install:
 the gasket (1) between the heat exchanger housing and the combustion chamber
 the combustion chamber (2)
 the molded gasket (3). Ensure that the hole for the glow plug is above the hole in the combustion chamber
 the fan motor. Ensure that the molded gasket is positioned correctly in the recess.
NOTE: The molded gasket (3) has a small tab that must fit in the corresponding mating
faces on the heat exchanger housing and the fan.
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
2012 Volvo C30 T-5
 the cover over the fan motor using 4 screws.

If necessary adjust the pipe coupling. See: COOLANT PIPE FUEL-POWERED PREHEATER (B5244S4).
Install:
 the control module. See: FUEL FIRED BOOSTER HEATER CONTROL UNIT (B5244S4)
 the auxiliary heater acc. to: FUEL FIRED BOOSTER HEATER (B5244S4).
FINISHING
Carry out a performance test of the engine coolant heater. See: FUEL-POWERED PREHEATER,
CHECKING .
FAN MOTOR FUEL-POWERED PREHEATER (B5254T3, B5254T7)
2012 Volvo C30 T-5
PREPARATORY WORK
REMOVING COMPONENTS
Remove:
(B5254T3, B5254T7).
REMOVAL
REMOVING THE FAN MOTOR FOR THE ENGINE COOLANT HEATER

cover. See: COOLANT PIPE FUEL-POWERED PREHEATER (B5254T3, B5254T7).
2012 Volvo C30 T-5

illustration.
2012 Volvo C30 T-5

Disconnect the cable terminals and wiring for the fan motor at positions 13 and 14 (black and brown).
2012 Volvo C30 T-5

Lift the fan motor away from the heat exchanger.
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
Fig. 138: Identifying Gasket, Combustion Chamber And Molded Gasket

Replace both gaskets supplied with the fan motor.
Install:
 the gasket (1) between the heat exchanger housing and the combustion chamber
 the combustion chamber (2)
 the molded gasket (3). Ensure that the hole for the glow plug is above the hole in the combustion chamber
 the fan motor. Ensure that the molded gasket is positioned correctly in the recess.
NOTE: The molded gasket (3) has a small tab that must fit in the corresponding mating
faces on the heat exchanger housing and the fan.
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
2012 Volvo C30 T-5
 the cover over the fan motor using 4 screws.

If necessary adjust the pipe coupling. See: COOLANT PIPE FUEL-POWERED PREHEATER (B5254T3,
B5254T7).
Install:
 the control module. See: FUEL FIRED BOOSTER HEATER CONTROL UNIT (B5254T3,
B5254T7)
 the auxiliary heater acc. to: FUEL FIRED BOOSTER HEATER (B5254T3, B5254T7).
FINISHING
CHECKING .
FLAME SENSOR FUEL-POWERED PREHEATER (B5244S4)

2012 Volvo C30 T-5
PREPARATORY WORK
Remove the control module. See: FUEL FIRED BOOSTER HEATER CONTROL UNIT (B5244S4).
REMOVAL
REMOVING THE FLAME SENSOR

cover. See: COOLANT PIPE FUEL-POWERED PREHEATER (B5244S4).
2012 Volvo C30 T-5

illustration.
2012 Volvo C30 T-5

Disconnect the cable terminal and cable for the flame sensor at positions 1 and 2 (blue and brown).
2012 Volvo C30 T-5

Remove the flame sensor (1).
INSTALLATION
INSTALLING THE FLAME SENSOR
Install the flame sensor. Tighten. See TIGHTENING TORQUE .
Install the cable terminals and cables in the connectors. See:
Ensure:

that the cable seal on the water pump is correctly positioned and that the cable runs behind the fan motor
2012 Volvo C30 T-5
like the others.
If necessary adjust the pipe coupling. See: COOLANT PIPE FUEL-POWERED PREHEATER (B5244S4).
Install the control module. See: FUEL FIRED BOOSTER HEATER CONTROL UNIT (B5244S4).
FINISHING
CHECKING .
FLAME SENSOR FUEL-POWERED PREHEATER (B5254T3, B5254T7)
PREPARATORY WORK
Remove the control module. See: FUEL FIRED BOOSTER HEATER CONTROL UNIT (B5254T3,
B5254T7).
REMOVAL
REMOVING THE FLAME SENSOR

2012 Volvo C30 T-5

cover. See: COOLANT PIPE FUEL-POWERED PREHEATER (B5254T3, B5254T7).
2012 Volvo C30 T-5

illustration.
2012 Volvo C30 T-5

Disconnect the cable terminal and cable for the flame sensor at positions 1 and 2 (blue and brown).
2012 Volvo C30 T-5

Remove the flame sensor (1).
INSTALLATION
INSTALLING THE FLAME SENSOR
Install the flame sensor. Tighten. See TIGHTENING TORQUE .
Install the cable terminals and cables in the connectors. See:
Ensure:

that the cable seal on the water pump is correctly positioned and that the cable runs behind the fan motor
2012 Volvo C30 T-5
like the others.
If necessary adjust the pipe coupling. See: COOLANT PIPE FUEL-POWERED PREHEATER (B5254T3,
B5254T7).
Install the control module. See: FUEL FIRED BOOSTER HEATER CONTROL UNIT (B5254T3,
B5254T7).
FINISHING
CHECKING .
FUEL FIRED BOOSTER HEATER (B5244S4)
Special tools:
see 9512619
PREPARATORY WORK
REMOVING COMPONENTS AND DRAINING THE ENGINE COOLANT

2012 Volvo C30 T-5

Raise the vehicle.
REMOVAL
REMOVING THE ENGINE COOLANT HEATER

2012 Volvo C30 T-5
Fig. 149: Identifying Engine Coolant Hose, Connector, Fuel Line And Holder
Disconnect the engine coolant hose (1). Plug the opening to prevent the remaining coolant in the heater running
out in an uncontrolled way.
Place paper under 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 (B5244S4).
2012 Volvo C30 T-5
Fig. 150: Identifying Connector For Water Pump

Disconnect the connector 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
Fig. 151: Identifying Mounting Screw For Engine Coolant Heater

Remove:
 the mounting screw for the engine coolant heater. See the illustration
 the bracket for the connector.
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 ENGINE COOLANT HOSES
Transfer the engine coolant hoses.

2012 Volvo C30 T-5
NOTE: Mark the internal position of the hoses in relation to each other before removal.
This ensures that the hoses are correctly positioned and not under stress
during installation.
INSTALLATION
INSTALLING THE ENGINE COOLANT HEATER
Position the engine coolant heater in its lower mounting.
Install the fuel line over the engine coolant heater using a new clamp.
HINT: Use: 9512619 to secure the clamp.
Press the top edge of the heater into place.
Install the mounting screw and the bracket for the connector. Tighten. See: TIGHTENING TORQUE .
Install:
 the lower coolant hose on the water pump. See the marking made earlier
 the connector on the water pump
 the exhaust pipe for the engine coolant heater. 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.
Fill with coolant and warm up the engine until the thermostat opens.
Top up if necessary.
FINISHING
TESTING THE ENGINE COOLANT HEATER AND INSTALLING THE COVER

2012 Volvo C30 T-5

CHECKING .
FUEL FIRED BOOSTER HEATER (B5254T3, B5254T7)
Special tools:
see 9512619
PREPARATORY WORK
REMOVING COMPONENTS AND DRAINING THE ENGINE COOLANT

2012 Volvo C30 T-5
Fig. 153: Identifying EVAP Canister Pipe And Upper Charge Air Pipe
Remove:
 the EVAP canister 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

Raise the vehicle.
REMOVAL

2012 Volvo C30 T-5
Fig. 155: Identifying Engine Coolant Hose, Connector, Fuel Line And Holder
Disconnect the engine coolant hose (1). Plug the opening to prevent the remaining coolant in the heater running
out in an uncontrolled way.
Place paper under 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 C30 T-5
Fig. 156: Identifying Connector For Water Pump

Disconnect the connector 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
Fig. 157: Identifying Mounting Screw For Engine Coolant Heater

Remove:
 the mounting screw for the engine coolant heater. See the illustration
 the bracket for the connector.
Angle out the top edge of the engine coolant heater.
HINT: Use: see 9512619 to detach and secure the clamps.
Lift up the engine coolant heater.
TRANSFERRING ENGINE COOLANT HOSES
Transfer the engine coolant hoses.

2012 Volvo C30 T-5
NOTE: Mark the internal position of the hoses in relation to each other before removal.
This ensures that the hoses are correctly positioned and not under stress
during installation.
INSTALLATION
INSTALLING THE ENGINE COOLANT HEATER
Position the engine coolant heater in its lower mounting.
Install the fuel line over the engine coolant heater using a new clamp.
HINT: Use: see 9512619 to secure the clamp.
Press the top edge of the heater into place.
Install the mounting screw and the bracket for the connector. Tighten. See: TIGHTENING TORQUE .
Install:
 the lower coolant hose on the water pump. See the marking made earlier
 the connector on the water pump
 the exhaust pipe for the engine coolant heater. See: FUEL FIRED BOOSTER HEATER EXHAUST
PIPE
 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.
Install:
 the screws for the intake manifold in the cylinder head

 the intake manifold between the air cleaner (ACL) and the turbocharger (TC)
 the hose for the EVAP canister from the intake manifold.
Fill with coolant and warm up the engine until the thermostat opens.
Top up if necessary.
FINISHING
2012 Volvo C30 T-5
TESTING THE ENGINE COOLANT HEATER AND INSTALLING THE COVER

CHECKING .
FUEL FIRED BOOSTER HEATER CONTROL UNIT (B5244S4)
PREPARATORY WORK
Remove the Combustion Preheater Module. See: FUEL FIRED BOOSTER HEATER (B5244S4)
2012 Volvo C30 T-5
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 control module connectors are not bent or damaged. This might be
the cause of the fault.
REMOVAL
Fig. 159: Identifying Combustion Preheater Module (CPM) Screws

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 release the catches.
Pull off the control module.
INSTALLATION
2012 Volvo C30 T-5
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.
Install the engine coolant heater. See: FUEL FIRED BOOSTER HEATER (B5244S4)
FINISHING
FINAL CHECK OF THE ENGINE COOLANT HEATER
Test run the engine coolant heater and check its function. See: FUEL-POWERED PREHEATER,
CHECKING
Check that no diagnostic trouble codes (DTCs) have been stored while the repair was carried out.
FUEL FIRED BOOSTER HEATER CONTROL UNIT (B5254T3, B5254T7)
PREPARATORY WORK
Remove the engine coolant heater. See: FUEL FIRED BOOSTER HEATER (B5254T3, B5254T7)
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 control module connectors are not bent or damaged. This might be
the cause of the fault.
REMOVAL

2012 Volvo C30 T-5
Fig. 160: Identifying Combustion Preheater Module (CPM) Screws

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 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 C30 T-5
Install the engine coolant heater. See: FUEL FIRED BOOSTER HEATER (B5254T3, B5254T7)
FINISHING
FINAL CHECK OF THE ENGINE COOLANT HEATER
CHECKING
Check that no diagnostic trouble codes (DTCs) have been stored 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

2012 Volvo C30 T-5
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.

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
Fig. 163: Identifying Lower Mounting For Fuel Pipe

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
Fig. 164: Identifying Long Extension Rod

Disconnect the lower mounting under the engine. Use a long extension rod. See the illustration.
Pull the exhaust pipe down through the right-hand wheel arch.
INSTALLATION
INSTALLING 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

Install:

 the lower mounting on the nut for the exhaust system. Tighten. See: TIGHTENING TORQUE
CHECKING .
FUEL FIRED BOOSTER HEATER EXHAUST PIPE (B5254T3, B5254T7)
PREPARATORY WORK
REMOVING COMPONENTS
2012 Volvo C30 T-5
Remove:
 the EVAP canister hose (1) from the intake manifold

 the intake manifold (2) between the air cleaner (ACL) and the turbocharger (TC).
Remove:

 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
Fig. 167: Identifying Upper Mounting

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

Raise the vehicle.
Remove:

 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

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
Fig. 170: Identifying Long Extension Rod

Disconnect the lower mounting under the engine. Use a long extension rod. See the illustration.
Pull the exhaust pipe down through the right-hand wheel arch.
INSTALLATION
INSTALLING 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
 the screws for the intake manifold in the cylinder head

 the intake manifold between the air cleaner (ACL) and the turbocharger (TC)
 the hose for the EVAP canister from the intake manifold.
FINISHING
INSTALLING COMPONENTS AND TESTING THE ENGINE COOLANT HEATER

Install:

 the lower mounting on the nut for the exhaust system. Tighten. See: TIGHTENING TORQUE
CHECKING .
2012 Volvo C30 T-5
FUEL FIRED BOOSTER HEATER WATER-IN-FUEL SENSOR (B5244S4)
PREPARATORY WORK
REMOVING COMPONENTS

Remove:
 the engine coolant heater. See: FUEL FIRED BOOSTER HEATER (B5254T3, B5254T7) or FUEL
FIRED BOOSTER HEATER (B5244S4)
(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
2012 Volvo C30 T-5
 the housing around the fan motor.
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 connector.
REMOVAL
REMOVING THE OVERHEAT PROTECTION THERMOSTAT/ENGINE COOLANT TEMPERATURE SENSOR
Fig. 173: Identifying Overheat Protection Thermostat/Engine Coolant Temperature Sensor

Remove the 1 screw for the holder.
Remove the sensors from the recesses.
Disconnect all the remaining cable terminals and cables apart from:
- those for the overheat protection thermostat at positions 5 and 6 (red cables)
- those for the engine coolant temperature sensor at positions 3 and 4 (blue cables)
2012 Volvo C30 T-5
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 cover.
Install the holders for the sensors using 1 screw. Tighten.

Install the removed cables together with cable terminals.
- Water pump in positions 10 and 11 (brown and violet).
- Fan motor in positions 13 and 14 (black and brown).

2012 Volvo C30 T-5
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: see FUEL FIRED BOOSTER HEATER (B5244S4) or FUEL FIRED
BOOSTER HEATER (B5254T3, B5254T7).
FINISHING
CHECKING .
FUEL FIRED BOOSTER HEATER WATER-IN-FUEL SENSOR (B5254T3, B5254T7)
PREPARATORY WORK
REMOVING COMPONENTS
2012 Volvo C30 T-5

Remove:
(B5254T3, B5254T7) or FUEL FIRED BOOSTER HEATER CONTROL UNIT (B5244S4)
(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.
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 connector.
REMOVAL
REMOVING THE OVERHEAT PROTECTION THERMOSTAT/ENGINE COOLANT TEMPERATURE SENSOR

2012 Volvo C30 T-5
Fig. 176: Identifying Overheat Protection Thermostat/Engine Coolant Temperature Sensor

Remove the 1 screw for the holder.
Remove the sensors from the recesses.
Disconnect all the remaining cable terminals and cables apart from:
- those for the overheat protection thermostat at positions 5 and 6 (red cables)
- those for the engine coolant temperature sensor at positions 3 and 4 (blue cables).
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 cover.
Install the holders for the sensors using 1 screw. Tighten.

2012 Volvo C30 T-5

Install the removed cables together with cable terminals.
- Water pump in positions 10 and 11 (brown and violet).
- Fan motor in positions 13 and 14 (black and brown).
Install:
 the housing around the fan motor

 the cover for the fan motor using 4 screws. Tighten
(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: see FUEL FIRED BOOSTER HEATER (B5254T3, B5254T7).
2012 Volvo C30 T-5
FINISHING
CHECKING .
FUEL LINE FUEL-POWERED PREHEATER (B5244S4)
Special tools:
see 9512619
PREPARATORY WORK
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.
FUEL PIPE, FRONT, REPLACING
REMOVING THE FRONT FUEL LINE

2012 Volvo C30 T-5

Remove the lower mounting for the fuel pipe.
Disconnect the quick-release connector.
NOTE: Wipe up any fuel spills.

2012 Volvo C30 T-5
Fig. 179: Identifying Intake Hose, Exhaust System, Fuel Pipe And Mounting Screw
Disconnect the intake hose (1).
Disconnect the exhaust system (2) but do not remove it. See FUEL FIRED BOOSTER HEATER EXHAUST
PIPE (B5244S4).
Remove:
 the fuel pipe (3) from the clip mounting

 the mounting screw (4). Angle the engine coolant heater out slightly.
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
Position the fuel line.
Install the upper fuel connection using a new clamp.
Secure the engine coolant heater in the bracket. Tighten. See: TIGHTENING TORQUE .
Install:
 the fuel pipe in the clip mounting

 the exhaust system. See: FUEL FIRED BOOSTER HEATER EXHAUST PIPE (B5244S4)
 the intake hose
 the lower quick-release connector for the fuel pipe. Secure the fuel pipe in the lower mounting.
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 rear quick-release connectors for the fuel line.
SUCTION PIPE, FUEL TANK, REPLACING
REMOVING THE SUCTION PIPE

2012 Volvo C30 T-5
Fig. 180: Identifying Fuel Pump Connector

Remove the fuel tank. See: FUEL TANK .

2012 Volvo C30 T-5
Fig. 181: Identifying Quick-Release Connector To Suction Pipe

Place paper around the suction pipe connection to the fuel tank unit.
Release the quick-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 .
FINISHING
2012 Volvo C30 T-5
CHECKING .
FUEL LINE FUEL-POWERED PREHEATER (B5254T3, B5254T7)
Special tools:
see 9512619
PREPARATORY WORK
FUEL PIPE, FRONT, REPLACING
REMOVING THE FRONT FUEL LINE

2012 Volvo C30 T-5
Remove:
 the EVAP canister pipe (1)

 the upper charge air pipe (2).
2012 Volvo C30 T-5

Remove the lower mounting for the fuel pipe.
Disconnect the quick-release connector.

2012 Volvo C30 T-5
Fig. 184: Identifying Intake Hose, Exhaust System, Fuel Pipe And Mounting Screw
Disconnect the intake hose (1).
Disconnect the exhaust system (2) but do not remove it. See: FUEL FIRED BOOSTER HEATER
EXHAUST PIPE.
Remove:
 the fuel pipe (3) from the clip mounting

 the mounting screw (4). Angle the engine coolant heater out slightly.
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
Position the fuel line.
Install the upper fuel connection using a new clamp.
Secure the engine coolant heater in the bracket. Tighten. See: TIGHTENING TORQUE .
Install:
 the fuel pipe in the clip mounting

 the exhaust system. See: FUEL FIRED BOOSTER HEATER EXHAUST PIPE
 the intake hose
 the lower quick-release connector for the fuel pipe. Secure the fuel pipe in the lower mounting.
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 rear quick-release connectors for the fuel line.
SUCTION PIPE, FUEL TANK, REPLACING
REMOVING THE SUCTION PIPE

2012 Volvo C30 T-5

Remove the fuel tank. See: FUEL TANK .

2012 Volvo C30 T-5
Fig. 186: Identifying Quick-Release Connector To Suction Pipe

Place paper around the suction pipe connection to the fuel tank unit.
Release the quick-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
FINISHING
2012 Volvo C30 T-5
CHECKING .
FUEL PUMP, FUEL-DRIVEN AUXILIARY HEATER (B5244S4)
PREPARATORY WORK
Fig. 187: Identifying Fuel Pump (FP)

NOTE: There must be no dirt present when handling the fuel lines' connections.
2012 Volvo C30 T-5
The fuel pump (FP) is a complete unit together with fuel hoses.
REMOVING COMPONENTS
Remove:
 the right rear wheel

 the connector for the fuel pump (FP)
 the fuel pump (FP) together with the bracket from the rear sub-frame.

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
Fig. 189: Identifying Fuel Lines, Fuel Pump (FP) And Hoses
Remove the quick-release connector on the fuel hose routed to the fuel pump (FP) for the engine coolant heater
at the suction hose on the fuel tank unit.
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:
2012 Volvo C30 T-5
 the fuel pump and its bracket in the rear sub-frame. Do not tighten the mounting screw yet
 the fuel lines on top of the fuel tank
 the fuel connection on the suction side at the fuel tank unit
 the fuel tank. See: FUEL TANK
 the fuel connection in front of the fuel tank.
Tighten the 1 M6 screw for the fuel pump (FP) bracket.
FINISHING
CHECKING .
FUEL PUMP, FUEL-DRIVEN AUXILIARY HEATER (B5254T3, B5254T7)
PREPARATORY WORK
2012 Volvo C30 T-5
Fig. 190: Identifying Fuel Pump (FP)

the risk of fuel spill.
The fuel pump (FP) is a complete unit together with fuel hoses.
REMOVING COMPONENTS
Remove:
 the right rear wheel

 the connector for the fuel pump (FP)
 the fuel pump (FP) together with the bracket from the rear sub-frame.
2012 Volvo C30 T-5

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
Fig. 192: Identifying Fuel Lines, Fuel Pump (FP) And Hoses
Remove the quick-release connector on the fuel hose routed to the fuel pump (FP) for the engine coolant heater
at the suction hose on the fuel tank unit.
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:
2012 Volvo C30 T-5
 the fuel pump and its bracket in the rear sub-frame. Do not tighten the mounting screw yet
 the fuel lines on top of the fuel tank
 the fuel connection on the suction side at the fuel tank unit
 the fuel tank. See: FUEL TANK
 the fuel connection in front of the fuel tank.
Tighten the 1 M6 screw for the fuel pump (FP) bracket.
FINISHING
CHECKING .
WATER PUMP, FUEL-DRIVEN AUXILIARY HEATER (B5244S4)
PREPARATORY WORK
DRAINING THE ENGINE COOLANT

2012 Volvo C30 T-5

Open the holder for the radiator hoses behind the engine to expose the lower radiator hose to the water pump.
Raise the vehicle.
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
Fig. 194: Identifying Water Pump

Remove:
 the screw holding the water pump and rubber mounting.

 the connector.
Pull the water pump forward a little.
HINT: 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

2012 Volvo C30 T-5

The water pump for the engine coolant heater has a rubber-mounted mounting. The lower section is hooked
onto the mounting bracket on the vehicle.
Install:
 the hoses using new hose clamps according 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
CHECKING .
Check for leakage from the coolant hoses.
Top up the coolant if necessary.
INSTALLING THE COVER

Install the cover. It is secured with 7 clips.
Lower the vehicle.
WATER PUMP, FUEL-DRIVEN AUXILIARY HEATER (B5254T3, B5254T7)
PREPARATORY WORK
2012 Volvo C30 T-5
DRAINING THE ENGINE COOLANT

Open the holder for the radiator hoses behind the engine to expose the lower radiator hose to the water pump.
Raise the vehicle.
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

Remove:
 the screw holding the water pump and rubber mounting.

 the connector.
Pull the water pump forward a little.
HINT: 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

2012 Volvo C30 T-5

The water pump for the engine coolant heater has a rubber-mounted mounting. The lower section is hooked
onto the mounting bracket on the vehicle.
Install:
 the hoses using new hose clamps according 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
CHECKING .
Check for leakage from the coolant hoses.
Top up the coolant if necessary.
INSTALLING THE COVER

Install the cover. It is secured with 7 clips.
Lower the vehicle.

2012 Volvo C30 T-5
TRANSMISSION Clutch - Cleaning, Inspection And Adjustment
TRANSMISSION
Clutch - Cleaning, Inspection And Adjustment
CLUTCH CONTROL
BLEEDING THE CLUTCH SYSTEM
Special tools
999 7446 Bleeding tool

Tool description: Bleeding tool
Tool boards: 40
Materials
Brake fluid 9437430
REMOVAL
Fig. 1: 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
Use: Brake fluid, 9437430
Fig. 2: Identifying Bleeding Tool

see 9997446
2012 Volvo C30 T-5
Fig. 3: Clutch Bleeding Procedure (1 Of 11)


2012 Volvo C30 T-5



2012 Volvo C30 T-5


2012 Volvo C30 T-5


2012 Volvo C30 T-5


2012 Volvo C30 T-5

INSTALLATION

2012 Volvo C30 T-5
TRANSMISSION Clutch - Removal, replacement and installation
TRANSMISSION
Clutch - Removal, replacement and installation
MECHANICAL CLUTCH
CLUTCH DISC AND PRESSURE PLATE (B5244S4)
Special tools
999 7068 Counterhold

Tool description: Counterhold
Tool boards: 43
999 7120 Gear sector

Tool description: Gear sector
Tool boards: 21
999 5662 Compression tool (clutch) P200-V40

Tool description: Compression tool (clutch) P200-
V40
Tool boards: 40
999 5663 Centering tool (clutch plate) P200-V40

Tool description: Centering tool (clutch plate)
P200-V40
Tool boards: 40
999 5675 Socket (centering clutch plate) used
with 9995663
Tool description: Socket (centering clutch plate)
used with 9995663
Tool boards: 40
Materials
Isopropanol 1161721
REMOVAL
Perform transmission, removal

2012 Volvo C30 T-5
Fig. 1: Identifying Counterhold Tool 9997068 And Gear Sector Tool 9997120
NOTE: Note the position of the component before removal.
see 9997068 see 9997120
Fig. 2: Locating Counterhold Tool Stop Pin

2012 Volvo C30 T-5
Fig. 3: Identifying Compression Tool 9995662 And Pressure Plate Bolts

see 9995662
Fig. 4: Identifying Centering Tool 999 5663 And Socket Tool 999 5675 Attached To Clutch Disc
CAUTION: The cone on the special tool must only be tightened finger tight to prevent
damage to the clutch disc.
see 9995663 see 9995675

2012 Volvo C30 T-5
Fig. 5: Identifying Cleaning Agent, 1161721

Use: Cleaning agent, 1161721
Fig. 6: Identifying Compression Tool 9995662 Attached To Pressure Plate

WARNING: Take care not to trap any fingers when removing the special tool.
Torque: M8
24 Nm
2012 Volvo C30 T-5
Fig. 7: Identifying Removal Of Centering Tool Assembly

INSTALLATION
Perform transmission installation
CLUTCH DISC AND PRESSURE PLATE (B5254T3, B5254T7)
Special tools
999 7068 Counterhold

Tool description: Counterhold
Tool boards: 43
999 7120 Gear sector

Tool description: Gear sector
Tool boards: 21
999 5662 Compression tool (clutch) P200-V40

Tool description: Compression tool (clutch) P200-
V40
Tool boards: 40
999 5663 Centering tool (clutch plate) P200-V40

Tool description: Centering tool (clutch plate)
P200-V40
Tool boards: 40
2012 Volvo C30 T-5
999 5675 Socket (centering clutch plate) used

with 9995663
Tool description: Socket (centering clutch plate)
used with 9995663
Tool boards: 40
Materials
Cleaning agent 1161721
REMOVAL
Remove transmission, see TRANSMISSION
Fig. 8: Identifying Counterhold Tool 9997068 And Gear Sector Tool 9997120
see 9997068 see 9997120

2012 Volvo C30 T-5
Fig. 9: Identifying Compression Tool 9995662 And Pressure Plate Bolts

see 9995662
INSTALLATION
Fig. 10: Identifying Centering Tool 999 5663 And Socket Tool 999 5675 Attached To Clutch Disc
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
see 9995663 see 9995675
Fig. 11: Identifying Cleaning Agent, 1161721

Use: Cleaning agent, 1161721
Fig. 12: Identifying Compression Tool 9995662 Attached To Pressure Plate

WARNING: Take care not to trap any fingers when removing the special tool.
Torque: M8
24 Nm
2012 Volvo C30 T-5
Fig. 13: Identifying Removal Of Centering Tool Assembly

Install the transmission, see TRANSMISSION
CLUTCH CONTROL (B5244S4)

CLUTCH SLAVE CYLINDER
REMOVAL
Remove the transaxle. See TRANSMISSION, REMOVING.
Fig. 14: Identifying Removal Of Retaining Pin To Link Arm

2012 Volvo C30 T-5
Fig. 15: Locating Bolt For Clutch Slave Cylinder

Torque: M6
10 Nm
INSTALLATION
Install the transaxle. See TRANSMISSION, 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
REMOVING THE LEFT-HAND ENGINE PAD
Remove the left-hand engine pad. See ENGINE SUPPORT INSULATOR LEFT .
REMOVING DRIVE SHAFTS
Remove:
 the right drive shaft. See DRIVE SHAFT RIGHT

 the left drive shaft. See DRIVE SHAFT LEFT .
REMOVING THE FENDER LINER
Remove the front left-hand fender liner. Slacken off the front 6 screws and the plastic nut in the frame member.
Fold back the fender liner.
REMOVING THE AIR CLEANER (ACL)
Remove:
 the hose clamps for the fresh air intake

 the evaporator 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
NOTE: Unscrew the bleed screw until drops start to form. Versions using a rubber
gasket instead of a cone.
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.
NOTE: The clutch cylinder does not leak fluid if the pedal is pressed during work.
REMOVAL
REMOVING THE GROUND LEAD

2012 Volvo C30 T-5
Fig. 16: Locating Ground

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
Fig. 17: Locating Bracket Bolts

Remove the bracket from the transmission.
REMOVING THE GEAR SELECTOR CABLES

2012 Volvo C30 T-5
Fig. 18: Identifying Gear Selector Cable Ball Joints

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
Fig. 19: Identifying Clutch Line

Pull up the striker plate. Pull the clutch line including the bleed nipple from the terminal.
Remove the rubber bushing from its bracket on the transmission.
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
Fig. 20: Locating Bellhousing Bolts

Remove:
 the starter motor. See STARTER MOTOR (TURBO) or STARTER MOTOR (NON-TURBO)
 the 4 screws between the engine and transmission.
NOTE: One screw is located against the heat shield for the three-way catalytic
converter (TWC).
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

2012 Volvo C30 T-5
Fig. 21: Locating Bracket Bolts

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
Fig. 22: Securing Transmission

Install a tensioner strap between the rear engine mounting and the front cross member. Pull the engine and
transmission as far forwards as possible without touching the radiator.
REMOVING THE LOWER SCREWS

2012 Volvo C30 T-5
Fig. 23: Locating Bellhousing Bolts

There are 7 screws between the engine and transmission. Remove 5 screws, leaving 2 screws in position.
2012 Volvo C30 T-5
Fig. 24: Locating Bellhousing Bolt

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.
INSTALLING THE FIXTURE ON THE MOBILE JACK AND TRANSMISSION

2012 Volvo C30 T-5
Fig. 25: Identifying Mobile Jack And Transmission Fixture

Install: see 9995463 to: see 9995972 . Use the fixture and plate together with: see 9985972 .
NOTE: Tighten all the screws to the fixtures.
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
2012 Volvo C30 T-5
Fig. 26: Locating Bolts

Remove the remaining 2 screws between the engine and transmission.
REMOVING THE TRANSMISSION
NOTE: Ensure that the transmission is taken straight out in relation to the engine.
NOTE: Lower the transmission slightly when removing so that it will pass the side
member.
Remove the transmission.
TRANSMISSION, INSTALLING
Special tools:
see 9997089
2012 Volvo C30 T-5
is always correct.
PREPARATORY WORK
Fig. 27: Applying Thread Lock To Bolt Threads

Move the ball catch to the new gear box.
Apply the thread lock 1161056 to the threads.
Tighten to 32 Nm.
When replacing the transmission, the transmission cable bracket must be transferred to the new transmission.
INSTALLATION
NOTE: For tightening torques, See TIGHTENING TORQUE .
CLEANING 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 little grease.
2012 Volvo C30 T-5
INSTALLING THE TRANSMISSION
Fig. 28: Identifying Installation Of Transmission

Adjust height and angle with the mobile jack and the transmission fixture. Locate the transmission on the
engine. Ensure that the transmission goes straight in, in relation to the engine, and that no deviation occurs in
the clutch driven plate center.
INSTALLING ENGINE MOUNTING

2012 Volvo C30 T-5
Fig. 29: Identifying Mounting For Transmission And Screws

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
Fig. 30: Identifying Lifting Tools

Lift the engine/transmission. Align the mounting against 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
Install:
 the 4 x M10 screws for the transmission and engine. Tighten

 the starter motor.
INSTALLING THE CLUTCH LINE
Fig. 32: Identifying Clutch Line

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
Fig. 33: Identifying Bracket Holder, Bracket And Coolant Hose

Install:
 the bracket holder

 the bracket and the coolant hose.
INSTALLING THE GEAR SELECTOR CABLE

2012 Volvo C30 T-5
Fig. 34: Identifying Back-Up Lamp Switch Connector And Transmission Cables To Bracket And Levers
NOTE: Ensure that the cable and sleeve do not crack or break.
Install:
 the connector for the back-up lamp switch

 the transmission cables to the bracket and 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
Install the air cleaner (ACL) module. See.
2012 Volvo C30 T-5
Fig. 36: Identifying Oil Line And Ground Lead

Install:
 the ground lead on the transmission

 the torque rod mounting to the transmission, 3 x M10. Tighten.
INSTALLING THE SUB-FRAME
Fig. 37: Identifying Bolt To Sub-Frame And Fixture Plate

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 ANTI-ROLL BAR

2012 Volvo C30 T-5
Fig. 38: Identifying Anti-Roll Bar Screws

Install the anti-roll bar. Use 4 new M10 screws. Tighten. See TIGHTENING TORQUE .
SECURING THE SUB-FRAME

2012 Volvo C30 T-5
Fig. 39: Identifying Adjustment Tool 9997089

Install see 9997089 on both sides. Carefully raise the sub-frame so that the adjustment tools are lined up with
the holes in the side members.
INSTALLING THE SCREWS
Fig. 40: Identifying Screws For Rear Mounting Of Sub-Frame

2012 Volvo C30 T-5
Install the screws for the rear mounting of the sub-frame. Loosely install new M16 screws, together with the
brackets and their 4 M8 screws.
Tighten the M16 screws. See TIGHTENING TORQUE .
Tighten the 4 M8 screws for the brackets. Tighten.
Install the rubber mountings for the exhaust pipe mounting.
INSTALLING THE SCREWS, CONTINUED
Fig. 41: Identifying Screws For Steering Gear/Sub-Frame

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 THE TRANSMISSION FLUID LEVEL
Top up the transmission with fluid if necessary. See TRANSAXLE OIL .

2012 Volvo C30 T-5
INSTALLING WHEELS
Install the front wheels. See WHEELS .
INSTALLING COMPONENTS IN ENGINE COMPARTMENT
Fig. 42: Identifying Steering Gear Screws

Tighten the two M12 screws for the steering gear.
INSTALLING THE BATTERY LEAD
Fig. 43: Identifying Battery Box

Install:
 the box for the battery

 the battery negative lead. See BATTERY DISCONNECTING AND CONNECTING .
2012 Volvo C30 T-5
CHECK THE BRAKE FLUID
Check the brake fluid level. Use only Volvo Genuine parts brake fluid (Volvo DOT 4+) when topping up.
CLUTCH PEDAL (2011)
Remove clutch pedal, see MASTER CYLINDER, CLUTCH
MASTER CYLINDER, CLUTCH
Special tools
999 5511 PRESS TOOL (BALL SEAT GEAR
CABLE) 800
Tool description: PRESS TOOL (BALL SEAT
GEAR CABLE) 800
Tool boards: 43
999 7172 Wrench

Tool description: Wrench
Tool boards: 43
999 7119 Mounting

Tool description: Mounting
Tool boards: 21
Materials
Anti-squeak tape 1161842
Silicone grease 1161687
REMOVAL

2012 Volvo C30 T-5
Fig. 44: Identifying Clutch Pedal

Fig. 45: Removing Clutch Pedal Spring

2012 Volvo C30 T-5
Fig. 46: Centering Steering Wheel

WARNING: The steering column may contain pyrotechnic components.
NOTE: Make sure that the road wheels are in the straight ahead position.
Remove position sensor clutch pedal engine compartment, see POSITION SENSOR CLUTCH PEDAL
ENGINE COMPARTMENT
Fig. 47: Identifying Connector Removal


2012 Volvo C30 T-5
Fig. 48: Removing Clutch Hose

Fig. 49: Positioning Hose Above Fluid Level In Reservoir

CAUTION: Make sure the open end of the hose is secured above the fluid level in the
reservoir.
 Lighting switch, see LIGHTING SWITCH

 Panel steering column, see PANEL STEERING COLUMN
 Stoplamp switch, see STOPLAMP SWITCH
2012 Volvo C30 T-5
Fig. 50: Removing/Installing Steering Shaft Joint

NOTE: Make sure that a new component is installed.
Torque: steering column to steering gear (steering shaft joint)
25 Nm
Fig. 51: Locating Connectors

2012 Volvo C30 T-5
Fig. 52: Identifying Clutch Line Removal

Fig. 53: Identifying Steering Column To Dashboard Bolts

Torque: Steering column to dashboard
24 Nm
2012 Volvo C30 T-5
Fig. 54: Identifying Steering Column Assembly

Fig. 55: Locating Switch Cover

Torque: M6
10 Nm
Remove Start Inhibitor Switch clutch pedal passenger compartment, see START INHIBIT SWITCH
2012 Volvo C30 T-5
Fig. 56: Identifying Start Inhibit Switch

VEHICLES MANUFACTURED FROM CHASSIS NUMBER: 22095
Remove the collision warning control module, see COLLISION WARNING CONTROL MODULE
ALL VEHICLES
Fig. 57: Identifying Bracket

2012 Volvo C30 T-5
Fig. 58: Identifying Special Tool 9995511

see 9995511
Fig. 59: Locating Clutch Pedal Mounting Bracket Bolts

Torque: M8
24 Nm
2012 Volvo C30 T-5
Fig. 60: Identifying Wrench 9997172 To Adjust Clutch Tension

see 9997172
Fig. 61: Identifying Seal

NOTE: Note the position of each component before removal.

2012 Volvo C30 T-5
Fig. 62: Locating Seal For Disposal

NOTE: Use a new seal.
INSTALLATION
Fig. 63: Identifying Bracket

NOTE: This step is not necessary when installing a new component.

2012 Volvo C30 T-5
Fig. 64: Identifying Where to Cut

Fig. 65: Visually Inspecting That Bracket Is At 90Degrees

see 9997119
2012 Volvo C30 T-5
Fig. 66: Anti-squeak tape, 1161842

Use: Anti-squeak tape, 1161842
Fig. 67: Identifying Silicone grease, 1161687

2012 Volvo C30 T-5
Use: Silicone grease, 1161687
Perform clutch system venting, see BLEEDING THE CLUTCH SYSTEM
Special tools
999 7172 Wrench

Tool description: Wrench
Tool boards: 43
REMOVAL
Remove battery, see BATTERY
Fig. 68: Identifying Removal Of M6 Screws

Torque: M6
2012 Volvo C30 T-5
Fig. 69: Identifying Removal Of Connector

Fig. 70: Identifying Connector Removal


2012 Volvo C30 T-5
Fig. 71: Identifying Method To Detach Line

Fig. 72: Identifying Removal Of Clutch Line

CAUTION: Make sure the open end of the hose is secured above the fluid level in the
reservoir.
 Panel steering column, see PANEL STEERING COLUMN

 Combined instrument panel, see COMBINED INSTRUMENT PANEL
 Start Inhibit Switch, see START INHIBIT SWITCH
2012 Volvo C30 T-5
Fig. 73: Centering Steering Wheel

WARNING: The steering column may contain pyrotechnic components.
NOTE: Make sure that the road wheels are in the straight ahead position.
Fig. 74: Identifying Bolt On Steering Shaft Joint

NOTE: Make sure that a new component is installed.
Torque: steering column to steering gear (steering shaft joint)
25 Nm
2012 Volvo C30 T-5
Fig. 75: Locating Clutch Line Attachment Point

Fig. 76: Locating Clutch Line Steering Wheel Connectors

Fig. 77: Identifying Connector

2012 Volvo C30 T-5
Fig. 78: Identifying Clutch Line Removal

Fig. 79: Identifying Steering Column To Dashboard Bolts

Torque: Steering column to dashboard
24 Nm
2012 Volvo C30 T-5
Fig. 80: Locating Clutch Line Fasteners

Fig. 81: Identifying Clutch Piston Attachment Clips

2012 Volvo C30 T-5
Fig. 82: Identifying Clutch And M8 Bolts

Torque: M8
24 Nm
Fig. 83: Identifying Wrench 9997172 To Adjust Clutch Tension

see 9997172
2012 Volvo C30 T-5
Fig. 84: Locating Seal For Disposal

NOTE: Use a new seal.
INSTALLATION
Perform clutch system venting, see BLEEDING THE CLUTCH SYSTEM
START INHIBIT SWITCH
REMOVAL
2012 Volvo C30 T-5
Fig. 85: Identifying Clutch Pedal Arm

Fig. 86: Removing Connector


INSTALLATION
2012 Volvo C30 T-5

POSITION SENSOR CLUTCH PEDAL ENGINE COMPARTMENT
Special tools
999 7402 Installer

Tool description: Installer
Tool boards: 40
REMOVAL
Remove battery, see BATTERY

2012 Volvo C30 T-5
Fig. 89: Identifying Removal Of M6 Screws

Torque: M6
10 Nm
Fig. 90: Identifying Removal Of Connector

2012 Volvo C30 T-5
Fig. 91: Identifying Installer Tool 999 7402 And Clutch Pedal Position Sensor
see 9997402
INSTALLATION
CLUTCH CONTROL (B5254T3)

REMOVAL
Remove transmission, see TRANSMISSION

2012 Volvo C30 T-5
Fig. 92: Identifying Removal Of Retaining Pin To Link Arm

Fig. 93: Locating Bolt For Clutch Slave Cylinder

Torque: M6
10 Nm
INSTALLATION
see MASTER CYLINDER, CLUTCH
CLUTCH CONTROL (B5254T7)

2012 Volvo C30 T-5
see CLUTCH SLAVE CYLINDER
CLUTCH PEDAL (2011)
see CLUTCH PEDAL (2011)
see MASTER CYLINDER, CLUTCH
POSITION SENSOR CLUTCH PEDAL ENGINE COMPARTMENT
see POSITION SENSOR CLUTCH PEDAL ENGINE COMPARTMENT (2011)
CLUTCH CONTROL
START INHIBIT SWITCH
REMOVAL
Fig. 94: Identifying Clutch Pedal Arm

Remove instrument panel lower, see INSTRUMENT PANEL LOWER

2012 Volvo C30 T-5
Fig. 95: Identifying Removal Start Inhibit Switch

INSTALLATION


2012 Volvo C30 T-5
ACCESSORIES & EQUIPMENT Collision Avoidance
ACCESSORIES & EQUIPMENT
Collision Avoidance
COLLISION AVOIDANCE
COLLISION WARNING CONTROL MODULE
REMOVAL
Remove the combined instrument panel, see COMBINED INSTRUMENT PANEL
Fig. 1: View of Collision Warning Control Module

Torque: M6
10 Nm
2012 Volvo C30 T-5
ACCESSORIES & EQUIPMENT Collision Avoidance
Fig. 2: Removing Collision Warning Control Module

CAUTION: Take extra care not to damage the clips.
NOTE: Make sure that the component terminals are not bent or damaged.
Torque: M6
10 Nm
INSTALLATION

2012 Volvo C30 T-5
COMMON SPECS & PROCEDURES C30
COMMON SPECS & PROCEDURES
C30
SPECIFICATIONS INDEX
SPECIFICATIONS INDEX - C30
System Specification/Procedure
Air Conditioning
Service Procedures see CLIMATE UNITS -
CLEANING, INSPECTION AND
ADJUSTMENT
Service Specifications see AC COMPRESSOR
Torque see SUMMARY OF TIGHTENING
TORQUES FOR SPECIFIC
COMPONENTS
Axle Nut/Hub Nut
Torque Tighten the screws for the hub
alternately. See HUB AND
BEARING
First Step: tighten to 20 Nm
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 the illustrations under
ACCESSORY DRIVE BELT
Engine Cooling
General Service Specifications see COOLING SYSTEM -
WATER QUALITY
2012 Volvo C30 T-5
Thermostat R & I see THERMOSTAT (B5254T7)

Water Pump R & I see COOLANT PUMP
Engine Mechanical
Compression NA
Oil Pressure @100 °C see appropriate engine under
ENGINE - SPECIFICATIONS,
MECHANICAL
Overhaul see appropriate engine under ENGINE
- SPECIFICATIONS,
MECHANICAL
COMPONENTS
Fluid Specifications See FLUIDS under
MAINTENANCE/FLUIDS tab. From
within Manager or Service Writer, click
the "30/60/90 Interval" or "Maint."
button.
Flywheel/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 & Cylinder Identification see FIRING ORDER & CYLINDER
IDENTIFICATION
Spark Plug
Bosch P/N: FR7MPP10
Gap .028-.032 In. (.70-.80 mm)
Torque 18 ft. lb (25 N. m)
Starter
Torque Starter mounting bolts: 50 Nm
Battery positive cable to solenoid: 11
2012 Volvo C30 T-5
Start impulse lead: 8.5 Nm
Wheel Alignment
Adjustment Specifications see WHEEL ALIGNMENT
COMPONENTS
Wheel & Tire
Wheel To Wheel Hub Stage 1: 20 Nm
Stage 2: 140 Nm
2012 Volvo C30 T-5
ELECTRICAL Cables And Fuses - Removal, Replacement And Installation
ELECTRICAL
Cables And Fuses - Removal, Replacement And Installation
CONNECTORS
CONNECTOR ANTI-LOCK BRAKING SYSTEM MODULE (ABS)
Special tools:
see 9512630
see 9512631
DISASSEMBLY
DISASSEMBLING SECONDARY LOCK
Fig. 1: Identifying Secondary Lock Released Using Electrician's Screwdriver

2012 Volvo C30 T-5
Disconnect the secondary lock. Use an electrician's screwdriver, as shown.
CAUTION: Disconnect and work with only one cable at a time to minimize the risk of
mixing them up.
DISASSEMBLING PRIMARY LOCK
Fig. 2: Identifying Tools 951 2636 And 951 2639 To Remove Primary Lock
Use tool see 9512630 and tool see 9512631 to remove the primary lock as shown.
At the same time pull the cable carefully backwards.
ASSEMBLY
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 approximately
3 times per 100 mm.
2012 Volvo C30 T-5
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.
CONNECTOR CONTROL MODULE EXTRA SAFETY SYSTEM
Special tools:
see 9512812
see 9512637
DISASSEMBLY
DISASSEMBLING SECONDARY LOCK

2012 Volvo C30 T-5
Fig. 3: Identifying Receptacle Housings Removal

Press in the active catches on both sides of the socket housing and slide out the receptacle housings.
CAUTION: Disconnect and work with only one cable at a time to minimize the risk of
mixing them up.
DISASSEMBLING PRIMARY LOCK

2012 Volvo C30 T-5
Fig. 4: Identifying Locking Tab Pressed In On Cable Terminal Using Special Tool 9512812
Press in the locking tab on the cable terminal and carefully pull out the cable and the cable terminal. Use tool:
see 9512812 or tool: see 9512637 , as shown.
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
REMOVAL

Fig. 6: Identifying Accessory Control Module (AEM) Removal Procedure (1 Of 8)

Remove side panel cargo compartment. See SIDE PANEL LOADSPACE

2012 Volvo C30 T-5



2012 Volvo C30 T-5


2012 Volvo C30 T-5


INSTALLATION
CABLE, BATTERY TO GENERATOR (B5244S4; 2007-11)
REMOVAL
always correct.
2012 Volvo C30 T-5
Fig. 14: Locating Connection To Battery, Nut On Starter And Air Cleaner
 battery negative lead. See BATTERY DISCONNECTING AND CONNECTING

 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
CABLE, BATTERY TO GENERATOR (B5254T3; 2007, B5254T7; 2008-12)
REMOVAL
2012 Volvo C30 T-5
always correct.
Fig. 15: Locating Connection To Battery, Nut On Starter And Air Cleaner
 Battery negative lead. See BATTERY DISCONNECTING AND CONNECTING

 the air cleaner (ACL).
 connection to battery.
14 Nm
 nut on starter motor.
Torque: Starter motor B+ terminal
15 Nm
 the clamp, x1
 1 clip
 the lead.
INSTALLATION
CONTROL MODULE RELAY BOX PASSENGER COMPARTMENT

2012 Volvo C30 T-5
REMOVAL
Perform, see BATTERY DISCONNECTING AND CONNECTING
CAUTION: The control module must be removed, reinstalled and downloaded with
software before the control module is replaced.
NOTE: This module contains customer parameters.
Fig. 16: Identifying Control Module Relay Box & Clip

2012 Volvo C30 T-5
Fig. 17: Identifying Zip Ties

Fig. 18: Identifying Control Module Relay Box Tilted Down

Fig. 19: Identifying Control Module Relay Box Pulled Forward And Down
2012 Volvo C30 T-5
Fig. 20: Identifying Control Module Relays And Cables

Fig. 21: Identifying Removal Of Control Module Relay Box

INSTALLATION
Set the clock.
LEAD BATTERY TO CENTRAL ELECTRICAL UNIT ENGINE COMPARTMENT
Special Tool
2012 Volvo C30 T-5
T9512636 TERMINAL REMOVAL TOOL (COLOR

CODE: BLUE)
Tool description: TERMINAL REMOVAL TOOL (COLOR
CODE: BLUE)
Tool boards:
T9512852 TERMINAL REMOVAL TOOL

Tool description: REMOVAL TOOL
Tool boards:
REMOVAL
Disconnect the negative battery lead. See BATTERY DISCONNECTING AND CONNECTING
2012 Volvo C30 T-5
Fig. 22: Identifying Direction To Remove Central Electrical Unit Cover

Fig. 23: Identifying Battery Lead To Battery Lead Terminal, 14 Nm

14 Nm
2012 Volvo C30 T-5
Fig. 24: Identifying Relay/Fuse Holder's Screw(s)

Remove the relay/fuse holder's screws, 2 pcs. Lift the relay/fuse holder straight up at the trailing edge. Remove
the lower casing.
Fig. 25: Identifying Position Of Relays

NOTE: Note the position of the relays. Remove relays and fuses from the relay/fuse
holder as needed.
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.

2012 Volvo C30 T-5
Fig. 26: Identifying Removal Of Front Secondary Catch With Terminal Removal Tool 9512636
Remove the thin cable. see 9512636
Fig. 27: Identifying Terminal Removal Tool 9512852 For Removal Of Front Secondary Catch
Alternatively. see 9512852
INSTALLATION
Install in reverse order.

2012 Volvo C30 T-5
ENGINE Cooling System - Removal, Replacement And Installation
ENGINE
Cooling System - Removal, Replacement And Installation
RADIATOR AND CONNECTIONS

RADIATOR (B5244S4; 2007-10)
REMOVAL
REMOVING THE ENGINE COOLING FAN (FC)
Remove the cooling fan. See ENGINE COOLING FAN (FC)
Fig. 1: Re-installing Radiator Bracket with Fan Removed

 bracket
 screws, lightly, 4 pcs.
2012 Volvo C30 T-5
Fig. 2: Identifying Panel And Screws

 screw
 engine compartment panel.
Fig. 3: Locating Mounting Screws

 screw
 radiator mounting.
2012 Volvo C30 T-5
Fig. 4: Supporting Condenser Assembly

Slightly raise the condenser and suspend from a suitable place, so that the condenser is not put under any strain.

 the screws for the upper radiator mounting, 2 pcs on both sides
 bracket under air conditioning aggregate
 radiator downwards.
INSTALLATION
NOTE: Tighten. See TIGHTENING TORQUE
INSTALLING THE ENGINE COOLING FAN (FC)

2012 Volvo C30 T-5

 the radiator
 Bracket
 screws, 4 pcs, lightly.

Install the screws for the upper radiator mounting, 2 pcs on both sides.
2012 Volvo C30 T-5

 engine compartment panel.

 screws, M6.
Fig. 9: Identifying Mobile Jack

Install a mobile jack under the radiator.

2012 Volvo C30 T-5
Fig. 10: Identifying Radiator Bracket

Remove the bracket.
Install the engine cooling fan. See ENGINE COOLING FAN (FC)
RADIATOR (B5254T3; 2007-08, B5254T7; 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

2012 Volvo C30 T-5
Install:
 the bracket
 the 4 x screws, lightly.
Remove the charge air cooler (CAC). See CHARGE AIR COOLER (B5244S4; 2007-09, B5254T3; 2007,
B5254T7; 2008-11) or CHARGE AIR COOLER (B5254T7; 2011 LATE - 2012)
REMOVING THE ENGINE COMPARTMENT PANEL

Remove:
 screws
 the engine compartment panel.
REMOVING THE UPPER RADIATOR MOUNTING

2012 Volvo C30 T-5

Remove the following on both sides:
 the screw
 the radiator mounting.
SUSPENDING THE CONDENSER
Fig. 14: Supporting Condenser Assembly

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

Remove:
 the screws for the upper radiator mounting, 2 on both sides.

 the bracket under the air conditioning aggregate
 the radiator downwards.
INSTALLATION
INSTALLING THE RADIATOR

2012 Volvo C30 T-5
Install:
 Radiator
 the bracket
 the 4x screws, lightly.

 the screws for the upper radiator mounting, 2 on both sides.

 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
INSTALLING ENGINE COOLANT FAN (FC)


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
REMOVAL
Perform cooling system draining, charging and bleeding. See COOLING SYSTEM - DRAINING,
CHARGING AND BLEEDING
Remove timing belt. See TIMING BELT
Fig. 21: Identifying Water Pump and Bolts

Torque: M7
17 Nm
INSTALLATION
THERMOSTAT (B5244S4; 2007-10)
REMOVAL
Drain cooling system, draining, filling, and bleeding. See COOLING SYSTEM - DRAINING, CHARGING
AND BLEEDING
2012 Volvo C30 T-5
Fig. 22: Identifying Water Outlet

Torque: M6
10 Nm
Fig. 23: Identifying Thermostat

INSTALLATION

2012 Volvo C30 T-5
THERMOSTAT (B5254T3; 2007-08, B5254T7; 2008-12)
REMOVAL
Drain cooling system, draining, filling, and bleeding, see COOLING SYSTEM - DRAINING, CHARGING
AND BLEEDING
Fig. 24: Identifying Water Outlet

Torque: M6
10 Nm
2012 Volvo C30 T-5
Fig. 25: Identifying Thermostat

INSTALLATION
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
Fig. 26: Identifying Cover

Remove:
 the cover for the brake control module (BCM)
Fig. 27: Identifying Expansion Tank Cap

 the expansion tank cap

2012 Volvo C30 T-5
Fig. 28: Identifying Connector And Clips

 the connector for the engine cooling fan (FC)

 the hoses from the clips, x 2.
Only applies 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

Only applies to vehicles with premair sensors
Remove the connector for the premair sensor.

2012 Volvo C30 T-5
Fig. 30: Identifying Splash Panel

Remove:
 the 7x screws
 the splash guard under the engine.

REMOVING THE ENGINE COOLING FAN

2012 Volvo C30 T-5

Remove:
 the 4 screws
 the bracket for the air conditioning aggregate.
Fig. 33: Locating Coolant Hoses

Remove the 2x coolant hoses.

2012 Volvo C30 T-5
Fig. 34: Identifying Clips and Catches

NOTE: When removing the engine cooling fan (FC), ensure that no cables are
damaged.
Press in both clips on the upper section and lift the engine cooling fan (FC) from the catches.
Remove the fan downwards.
INSTALLATION
INSTALLING THE ENGINE COOLING FAN
Install:
 the engine cooling fan (FC) from underneath. 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
2012 Volvo C30 T-5

Install the connector to the premair sensor
Install:
 the oil cooler to the transmission

 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
REMOVING THE BUMPER
Remove the bumper cover. See COVER BUMPER FRONT (2011 LATE - 2012) or COVER BUMPER
FRONT (2010-11)
Drain coolant. See COOLING SYSTEM - DRAINING, CHARGING AND BLEEDING
REMOVING COMPONENTS
Fig. 36: Identifying Cover

Remove:
 the cover for the brake control module (BCM)
Fig. 37: Identifying Expansion Tank Cap

2012 Volvo C30 T-5
 the expansion tank cap
Fig. 38: Identifying Connector And Clips

 the connector for the engine cooling fan (FC)

 the hoses from the clips, x 2.
Remove the screws for the transmission's oil cooler. Place the oil cooler to one side.

Remove the connector for the premair sensor.

2012 Volvo C30 T-5
Fig. 40: Identifying Splash Panel

Remove:
 the 7x screws
 the splash guard under the engine.

REMOVING THE ENGINE COOLING FAN

2012 Volvo C30 T-5

Remove:
 the 4 screws
 the bracket for the air conditioning aggregate.
Fig. 43: Locating Coolant Hoses

Remove the 2x coolant hoses.

2012 Volvo C30 T-5
Fig. 44: Identifying Clips and Catches

NOTE: When removing the engine cooling fan (FC), ensure that no cables are
damaged.
Press in both clips on the upper section and lift the engine cooling fan (FC) from the catches.
Remove the fan downwards.
INSTALLATION
INSTALLING THE ENGINE COOLING FAN
Install:
 the engine cooling fan (FC) from underneath. 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
2012 Volvo C30 T-5

Install the connector to the premair sensor
Install:
 the oil cooler to the transmission

 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. See COVER BUMPER FRONT (2010-11 EARLY) or COVER BUMPER
FRONT (2011 LATE - 2012)
CHARGE AIR COOLER WITH CONNECTION

2012 Volvo C30 T-5
CHARGE AIR COOLER (B5244S4; 2007-09, B5254T3; 2007-08, B5254T7; 2008-11 EARLY)
PREPARATORY WORK
Remove the bumper cover. See COVER BUMPER FRONT (2010-11 EARLY) .
REMOVAL
REMOVING THE CHARGE AIR COOLER (CAC)
Fig. 46: Identifying Screw Locations

Remove:
 the switch
 the hoses
 the 2 screws.
2012 Volvo C30 T-5
Fold the air baffle up.
Remove the charge air cooler (CAC).
INSTALLATION
INSTALLING THE CHARGE AIR COOLER (CAC)
NOTE: For tightening torques, see TIGHTENING TORQUE .
Fold the air baffle up.
Install:
 the charge air cooler (CAC)

 the 2 M6 screws
 the hoses.
FINISHING
Install the bumper cover. See COVER BUMPER FRONT (2010-11 EARLY) .
CHARGE 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

2012 Volvo C30 T-5
Fig. 47: Locating Screws

Remove the screws on both sides.
REMOVING THE CHARGE AIR COOLER (CAC)

2012 Volvo C30 T-5
Fig. 48: Identifying Fasteners

Remove:
 the hoses (1)

 the 2 screws (2).
Lift the charge air cooler (CAC). Remove 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.
2012 Volvo C30 T-5
INSTALLING THE UPPER SCREWS FOR THE LOWER AIR BAFFLE
Fig. 49: Locating Screws

Install the M5 screws on both sides.
FINISHING
The bumper shell. See COVER BUMPER FRONT .

2012 Volvo C30 T-5
ELECTRICAL
Body Electrical
BODY ELECTRICAL
DATA LINK CONNECTOR (OBD-II)
Special tools
951 2636 Terminal removal tool (Color code:
Blue)
Tool description: Terminal removal tool (Color
code: Blue)
Tool boards: 39
REMOVAL
Fig. 1: Locating Data Link Connector (OBD-II)

2012 Volvo C30 T-5

Fig. 3: Identifying Data Link Connector (OBD-II) Release Tab

Fig. 4: Removing Data Link Connector

2012 Volvo C30 T-5
Fig. 5: Releasing Tab with Tool 9512636

see 9512636
NOTE: Only work on 1 cable at a time.
INSTALLATION

2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Doors And Lids - Removal, replacement and installation
Doors And Lids - Removal, replacement and installation
FUEL TANK FILLER DOOR

DOOR LATCH, FUEL FILLER DOOR
Fig. 1: Door Latch Fuel Filler Door Remove/Install Components (1 Of 3)

2012 Volvo C30 T-5


FUEL TANK FILLER DOOR
2012 Volvo C30 T-5
REMOVAL
REMOVING THE FUEL TANK FILLER COVER
Open the fuel tank filler cover.
Fig. 4: Removing Fuel Filler Door

Remove:
 the 2 screws
 the holder for the fuel tank filler cap (1).
INSTALLATION
INSTALLING THE FUEL TANK FILLER COVER
Install:
2012 Volvo C30 T-5

 the holder for the fuel tank filler cap.
LOCK, HANDLE
DOOR LATCH, FRONT DOOR
Remove the Front Door Interior Handle Cable, see FRONT DOOR INTERIOR HANDLE CABLE
Fig. 5: Removing Front Door Latch (1 Of 4)


2012 Volvo C30 T-5


DOOR LATCH, GLOVE COMPARTMENT

2012 Volvo C30 T-5
Remove glove compartment, see GLOVE COMPARTMENT
Fig. 9: Removing Pins

Fig. 10: Identifying Handle

2012 Volvo C30 T-5
Fig. 11: Identifying Mounting Points

FRONT DOOR INTERIOR HANDLE CABLE
REMOVAL
 Window, front door. See WINDOW, FRONT DOOR.

 Handle outer door front, see HANDLE OUTER DOOR FRONT
2012 Volvo C30 T-5
Fig. 12: Removing Front Door Interior Handle Cable (1 Of 7)



1. Torque: Door latch to door
8 Nm
2. Torque: M6
10 Nm
2012 Volvo C30 T-5



2012 Volvo C30 T-5

INSTALLATION
FRONT DOOR OUTER HANDLE
Disconnect the battery ground cable. See BATTERY DISCONNECTING AND CONNECTING .
Fig. 19: Removing Front Door Outer Handle (1 Of 3)

2012 Volvo C30 T-5

NOTE: Slacken off the screw by 4 turns only.
Torque: Door lock cylinder to external handle (vehicles without keyless vehicle module (KVM))
3 Nm
Torque: Door lock cylinder to external handle (vehicles with keyless vehicle module (KVM))
4 Nm

Only vehicles with KVM (keyless vehicle module).

2012 Volvo C30 T-5
NOTE: Make sure that the connector fastens in the park position during dismantling.
LOCK CYLINDER, DOOR
Fig. 22: View Of Removing Door Lock Cylinder

NOTE: Do not loosen the bolt more than 4 turns.
Fig. 23: Identifying Door Lock Cylinder

OUTER TAILGATE/TRUNK LID HANDLE

2012 Volvo C30 T-5
Remove the liftgate trim panel, see TAILGATE/TRUNK LID PANEL
Fig. 24: Removing Outer Tailgate/Trunk Lid Handle (1 Of 2)

Torque: Exterior handle to tailgate/luggage compartment lid
3 Nm
Fig. 25: Removing Outer Tailgate/Trunk Lid Handle (2 Of 2)

TRUNK LID/TAILGATE LOCK MECHANISM
REMOVAL
2012 Volvo C30 T-5
Fig. 26: Removing Trunk Lid/Tailgate Lock Mechanism (1 Of 2)

Fig. 27: Removing Trunk Lid/Tailgate Lock Mechanism (2 Of 2)

Torque: Door latch to luggage compartment lid
20 Nm
INSTALLATION
ROOF HATCH
2012 Volvo C30 T-5
APRON MOLDING SUNROOF
REMOVAL
REMOVING THE APRON MOLDING FOR THE SUN ROOF
Fig. 28: Identifying Apron Molding Pulled Into Car

The sun roof must be in the half open position.
Pull the apron molding backwards.
Release the top edge and unhook the bottom edge of the apron molding.
Remove the apron molding.
INSTALLATION
2012 Volvo C30 T-5
INSTALLING APRON MOLDING FOR THE SUN ROOF
Hook the apron molding into place at the top and bottom edges.
DRAIN DUCT SUNROOF
PREPARATORY WORK
REMOVING THE SUNROOF GLASS
Remove the sunroof glass. See: GLASS SUN ROOF.
REMOVAL
REMOVING THE GUTTER
Fig. 29: Pressing Out The Front Mounting

Press out the front mounting for the gutter on both sides.
2012 Volvo C30 T-5
Fig. 30: Pressing Out Gutter

Carefully press out the center of the gutter and then press the corner outwards to release the gutter clips from the
sunroof frame. Repeat the procedure on the other side.
INSTALLATION
INSTALLING THE GUTTER
Fig. 31: Identifying Clips

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
Fig. 32: Ensuring Clips Are In Correct Position

First align one corner with the gutter and then the other.
CAUTION: Ensure that the clips are in the correct position.
NOTE: Do not damage or loosen the clips.
Fig. 33: Installing The Gutter

Press both front mountings for the gutter into place.
FINISHING
2012 Volvo C30 T-5
Install the sunroof glass. See: GLASS SUN ROOF.
GLASS SUN ROOF
REMOVAL
REMOVING THE SUN ROOF GLASS
Fig. 34: Identifying 4 Screws For The Glass Cover

Close the sun roof.
Slide the inner cover back as far as possible.
Remove:
 the inner cover. See: APRON MOLDING SUNROOF

 the 4 screws for the glass cover
2012 Volvo C30 T-5
 the glass sun roof.
REPLACING COMPONENTS
REMOVING THE WEATHERSTRIP SUN ROOF
Remove the weatherstrip from the sun roof. It is not bonded.
INSTALLING WEATHERSTRIP SUN ROOF
Fig. 35: Identifying Weatherstripping

Press the weatherstrip into place in the T-groove.
NOTE: The join for the weatherstrip must be in the middle of the rear edge of the
sunroof (1).
INSTALLATION
INSTALLING THE GLASS SUN ROOF
Install:
2012 Volvo C30 T-5
 the glass sun roof

 the 4 M5 screws. Tighten. See: TIGHTENING TORQUE .
Adjust the glass cover. See: SUN ROOF .
Install the apron molding. See: APRON MOLDING SUNROOF.
SUN ROOF
PREPARATORY WORK
IGNITION OFF
Fig. 36: Disconnecting Battery Lead

Ignition off.
Remove the key from the ignition switch.
Wait 1 minute before starting work.
REMOVAL
REMOVING THE SUN ROOF

2012 Volvo C30 T-5
Fig. 37: Locating Connector

Remove the headlining 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
Fig. 38: Identifying 10 Screws For The Sun Roof Frame

 the 10 screws for the sun roof frame.
NOTE: Note the position and dimensions of all spacers and screws.
Lower the sun roof. Remove the sun roof from the vehicle.
NOTE: 2 people are required for this task.
REMOVING SUN ROOF 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

2012 Volvo C30 T-5
NOTE: 2 people are required for this task.
Fig. 39: Identifying Screw Locations

HINT: Position the screws, spacers and nylon washers on the frame before installing the sun roof.
Install the 10 M6 screws as follows:
1. 1 M6x16, with nylon washer

5. 1 M6x25, with nylon washer and spacer, 20x6.5x6
10. 1 M6x35, with nylon washer and spacer, 20x6.5x20.
2012 Volvo C30 T-5
Guide in the sun roof in relation to the guide holes.
Tighten the screws in numerical order as illustrated. Tighten. See: TIGHTENING TORQUE .
INSTALLING SUN ROOF COMPONENTS
Install:
 the electric motor / control module. See: THE ELECTRIC MOTOR / SUN ROOF MODULE (SRM).
 the connector.
Connect the 4 drain hoses.
Install:
 the sun visor / inner sun roof. See: SUN VISOR/INNER COVER SUN ROOF
 the wind deflector. See: WIND DEFLECTOR SUNROOF
 the sun roof glass. See: GLASS SUN ROOF.
FINISHING
ADJUSTING AND CHECKING THE SUN ROOF
Adjust the sun roof glass. See: SUN ROOF .
Check for leakage. See: LEAK TESTING THE SUN 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:
RECALIBRATION OF THE ELECTRIC MOTOR/SUN ROOF MODULE (SRM) .
SUN VISOR/INNER COVER SUN ROOF
REMOVAL
2012 Volvo C30 T-5
REMOVING THE SUN VISOR / INNER COVER SUN ROOF
Fig. 40: Identifying Screws And Mounting

Remove the lens. 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
INSTALLING THE SUN VISOR / INNER COVER SUN ROOF
Install:
 the 2 rear slides

 the 2 screws at the rear mounting. Tighten.
Slide in the sun visor / inner cover half way.
Install:
 the 2 front slides

 the 2 screws at the front mounting. Tighten.
Check the operation of the sun visor / inner cover.
Install the lens. See: GLASS SUN 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
2012 Volvo C30 T-5

Ignition 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
Fig. 42: Locating Connector

 the connector.
Slacken off the 3 screws for the interior lighting frame.

2012 Volvo C30 T-5
Fig. 43: Locating Electric Motor / Control Module Screws

Carefully lower the electric motor / control module.
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
Fold back the sun visors.
FINISHING
CALIBRATION OF NEW ELECTRIC MOTOR / SUN ROOF MODULE (SRM)
When installing a new electric motor / control module, perform new calibration. See: NEW CALIBRATION
OF ELECTRIC MOTOR / SUN ROOF MODULE (SRM) .
RECALIBRATION OF PREVIOUSLY USED ELECTRIC MOTOR / SUN ROOF MODULE (SRM)
When 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

2012 Volvo C30 T-5
Fig. 44: Removing Wind Deflector

Open the sun roof completely.
Press the end of the wind deflector (1) using a screwdriver.
CAUTION: Do not damage the painted surfaces.
At the same time pull the wind deflector carefully backwards (2) until the locking tab at the front edge releases.
Carry out the same operation on the other side.
Lift up and remove the wind deflector.
INSTALLATION
INSTALLING THE WIND DEFLECTOR FOR THE SUN ROOF
Insert the ends of the wind deflector into the 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.
CAUTION: Do not damage the painted surfaces.
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 OPERATION

DOOR HALF HINGE
Remove the side section. See SIDE SECTION, EXPOSING

2012 Volvo C30 T-5
Fig. 45: Identifying Door Half Hinge

Torque: M8
24 Nm
DOOR PANEL
Materials:
Bodywork adhesive 1161524
PUR adhesive 1161821
Body putty 1161767
Remove the side door. See SIDE DOOR

2012 Volvo C30 T-5
Fig. 46: Bodywork adhesive, 1161524

Attach the following items:
1. Use: Bodywork adhesive, 1161524

2. Use: PUR adhesive, 1161821
Fig. 47: Body putty, 1161767

Use: Body putty, 1161767
Install the side door. See SIDE DOOR
DOOR STOP FRONT SIDE DOOR

2012 Volvo C30 T-5
Remove door panel. See PANEL FRONT DOOR .
Fig. 48: Removing Door Stop From Front Side Door (1 Of 2)

Fig. 49: Removing Door Stop From Front Side Door (2 Of 2)

1. Torque: M6
10 Nm
2. Torque: M8
24 Nm
2012 Volvo C30 T-5
SIDE DOOR
REPLACEMENT
 lift mechanism side door front. See LIFT MECHANISM, FRONT DOOR
 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)


2012 Volvo C30 T-5


TRUNK LID, TAILGATE WITH HINGE AND SUPPORT

TAILGATE AND TRUNK LID HINGES

2012 Volvo C30 T-5
 roof sill panel. See CANT RAIL PANEL

 panel C/D-pillar. See C/D-PILLAR TRIM PANEL
Fig. 54: Removing Tailgate And Trunk Lid Hinges (1 Of 2)

Torque: M8
24 Nm
Fig. 55: Removing Tailgate And Trunk Lid Hinges (2 Of 2)

Torque: M6
10 Nm
Install in the reverse order.
TAILGATE
2012 Volvo C30 T-5
 wiper motor rear, see REAR WIPER MOTOR

 handle outer tailgate. See OUTER TAILGATE/TRUNK LID HANDLE
 panel roof sill. See CANT RAIL PANEL
 panel C/D-pillar. See C/D-PILLAR TRIM PANEL
 spoiler rear. See SPOILER REAR
 spoiler rear (T5). See SPOILER REAR
Fig. 56: Removing Tailgate (1 Of 5)

Torque: M8
24 Nm

2012 Volvo C30 T-5


2012 Volvo C30 T-5

Torque: M6
10 Nm
Adjust tailgate. See DOORS AND HATCHES.
DOORS AND HATCHES
ADJUSTMENT MEASUREMENTS
Below you will find the measurements for the body gaps measured when manufacturing the vehicle. The
measurements are an average value of the measurements on the new values.
Measuring takes place on a painted body. The gap increases by 0.2 mm for an unpainted body.
NOTE: The measurements vary from one vehicle to another. This list is only a base
from which to start.
No max. or min. measurements are given since there must be harmony between the gaps on the visual surface.
NOTE: The final check/adjustment shall be performed when the vehicle is painted in
the correct color.
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)

2012 Volvo C30 T-5
Fig. 61: Identifying Level Adjustment

The front part must be positioned above the part behind it (see illustration), partly to overlap in case of a
collision, partly to reduce wind noise.
Measurement M1 = 0.5 mm.
MEASUREMENTS, ENGINE HOOD

2012 Volvo C30 T-5
Fig. 62: Identifying Hood Measurements

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
Fig. 63: Identifying Door Measurements

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
Fig. 64: Identifying Door Measurements

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
Fig. 65: Identifying Trunk Lid Measurements

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
Fig. 66: Identifying Trunk Lid Measurements

S40 (04-)
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

2012 Volvo C30 T-5
Fig. 67: Removing Front Door Window Lift Mechanism Electric Motor (1 Of 2)
Remove panel side door front, see PANEL FRONT DOOR
Fig. 68: Removing Front Door Window Lift Mechanism Electric Motor (2 Of 2)
Torque: M6
10 Nm
INSTALLATION
Order and download software according to: 30669920
Perform power window motor, initiation, see DOOR WINDOW MOTOR INITIALIZATION
2012 Volvo C30 T-5
LIFT MECHANISM, FRONT DOOR
REMOVAL
 Window, front door. See WINDOW, FRONT DOOR.

 Handle outer door front, see HANDLE OUTER DOOR FRONT
Fig. 69: Removing Front Door Window Lift Mechanism (1 Of 9)


2012 Volvo C30 T-5

Torque: M6
10 Nm

2012 Volvo C30 T-5



2012 Volvo C30 T-5
Torque: M6
10 Nm


INSTALLATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation
Other Electrical Equipment - Removal, replacement and installation
BODY ELECTRICAL
BACK-UP (REVERSING) LAMPS SWITCH (M66 MANUAL TRANSMISSION)
REMOVAL
Remove the air filter housing, see AIR CLEANER HOUSING
Fig. 1: Removing Back-Up Lamp Switch (1 Of 2)


2012 Volvo C30 T-5
Torque: Reversing lamp switch
24 Nm
INSTALLATION
in the illustrations is always correct.
REMOVING THE BACK-UP LAMP SWITCH, GEARBOX M56
Ignition off
Remove the air cleaner (ACL) housing.

 the gear selector cables from the levers. see 9997077

 the gear selector cables from the brackets to prevent bending them when removing the lever.
2012 Volvo C30 T-5

 pin. see 9997221 .

 the lever
Fig. 5: Identifying Back-Up Lamp Switch Connector

 the connector from the back-up lamp switch.

 the back-up light switch. see 9995543
INSTALLATION
2012 Volvo C30 T-5
INSTALLING BACK-UP (REVERSING) LAMP SWITCH

Install the new back-up light switch. see 9995543 Tighten to: 24 Nm.
INSTALLING THE CONNECTOR
Fig. 7: View Of Secondary Lock

Pull out the secondary lock. see 9512853 .

2012 Volvo C30 T-5
Fig. 8: Back-Up Lamp Switch Leads

Install the cables in the connector with the opening for the primary lock facing up as shown in the illustration.
Press in the secondary lock.
JOINING CABLES
Splice the new connector with cables to the existing wiring. See JOINING CABLES .
Fig. 9: Identifying Tie-Strap Installed

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

 transmission lever see 9997221 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

Fig. 12: Identifying Control Stalk, Left Screws

INSTALLATION
CONTROL STALK, RIGHT
REMOVAL

2012 Volvo C30 T-5
Fig. 14: Identifying Control Stalk, Right Screws

INSTALLATION

2012 Volvo C30 T-5
Fig. 16: View Of Data Link Connector (OBD-II) location



2012 Volvo C30 T-5
Fig. 19: Inserting Terminal Removal Tool


2012 Volvo C30 T-5
Fig. 20: Pressing Tab And Removing Wire

DRIVER DOOR MODULE (DDM)
REMOVAL

Remove panel side door front, see PANEL FRONT DOOR .
Fig. 22: Identifying Driver Door Module (DDM) Screws

Torque: M6
10 Nm
2012 Volvo C30 T-5
INSTALLATION
EXTRA POWER SOCKET 12V (2007)
PREPARATORY WORK
IGNITION OFF

2012 Volvo C30 T-5
Ignition off.
REMOVAL
REMOVING THE CIGARETTE LIGHTER/ELECTRICAL SOCKET
Fig. 24: View Of Ashtray Panel

Remove the rear panel.
Disconnect the connector from the ashtray panel.

2012 Volvo C30 T-5
Fig. 25: Identifying Cigarette Lighter/Electrical Socket Catches

Lift up the catches (as shown in the illustration) using a small 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)

2012 Volvo C30 T-5
Fig. 26: Extra Power Socket Remove/Install Components (1 of 2)


EXTRA POWER SOCKET 12V, LUGGAGE COMPARTMENT (2008, 2009 AND 2011, 2012)
2012 Volvo C30 T-5


FRONT POSITION SENSOR, HEADLAMP (2007-2009)
REMOVAL

Follow instructions for lifting points body frame, see JACKING POINTS BODY .
2012 Volvo C30 T-5
Fig. 31: Identifying Front Position Sensor, Headlamp Screws

Torque: M6
10 Nm
INSTALLATION
Calibrate position sensor using VIDA (Volvo scan tool).
FRONT POSITION SENSOR, HEADLAMP (2010 - 2011 EARLY)
REMOVAL

2012 Volvo C30 T-5


Torque: M6
10 Nm
INSTALLATION
2012 Volvo C30 T-5
FINISHING
FRONT POSITION SENSOR, HEADLAMP (2011 LATE - 2012)
REMOVAL

2012 Volvo C30 T-5

Torque: M6
10 Nm
INSTALLATION
INSTRUMENT PANEL CONSOLE SWITCH KNOB
Special tools
981 4071 STRAIGHTENING TOOL
Tool description: STRAIGHTENING TOOL
Tool boards: 80
2012 Volvo C30 T-5
REMOVAL
Fig. 36: Removing Instrument Panel Console Switch Knob

see 9814071
2012 Volvo C30 T-5
INSTALLATION
KEYPAD, STEERING WHEEL
REMOVAL
Remove airbag driver's side, see DRIVER'S AIRBAG
Fig. 37: Identifying Steering Wheel Keypad

Fig. 38: View Of Steering Wheel Keypad Connectors

INSTALLATION

2012 Volvo C30 T-5
LIGHTING SWITCH
REMOVAL

Fig. 40: Identifying Lighting Switch in OFF Position

2012 Volvo C30 T-5
Fig. 41: View Of Lighting Switch Components

Fig. 42: Identifying Lighting Switch Screws

INSTALLATION
PASSENGER DOOR MODULE (PDM)
REMOVAL

2012 Volvo C30 T-5


Torque: M6
10 Nm
INSTALLATION

2012 Volvo C30 T-5
POSITION SENSOR REAR, HEADLAMP (2007-2009)
REMOVAL

Fig. 46: Identifying Position Sensor Rear, Headlamp Screws

Torque: M6
10 Nm
2012 Volvo C30 T-5
INSTALLATION
POSITION SENSOR REAR, HEADLAMP (2010 - 2011 EARLY)
REMOVAL


2012 Volvo C30 T-5
Torque: M6
10 Nm
INSTALLATION
FINISHING
POSITION SENSOR REAR, HEADLAMP (2011 LATE - 2012)
REMOVAL

2012 Volvo C30 T-5

Torque: M6
10 Nm
INSTALLATION
POWER SOCKET 12V (2007)
REMOVAL

2012 Volvo C30 T-5
Fig. 52: Identifying Power Socket Panel

Fig. 53: View Of Power Socket Clip

INSTALLATION
POWER SOCKET 12V (2008-2012)
Remove floor console, see FLOOR CONSOLE
REAR DOOR WINDOW REGULATOR ROTARY SWITCH
REMOVAL
2012 Volvo C30 T-5

Fig. 55: Window Regulator Rotary Switch, Rear Door Remove/Install Components (1 Of 3)
2012 Volvo C30 T-5
Fig. 56: Window Regulator Rotary Switch, Rear Door Remove/Install Components (2 of 3)
INSTALLATION
ROTARY SWITCH, FRONT DOOR WINDOW REGULATOR (2007 - 2011 EARLY)
REMOVAL

2012 Volvo C30 T-5
Fig. 59: Removing Door Handle Panel

Fig. 60: Identifying Door Handle Panel Clips

2012 Volvo C30 T-5
Fig. 61: Identifying Window Regulator Rotary Switch

INSTALLATION
ROTARY SWITCH, FRONT DOOR WINDOW REGULATOR (2011 LATE - 2012)
REMOVAL

2012 Volvo C30 T-5

Fig. 64: Prying Up Front Side Switch Panel Frame

2012 Volvo C30 T-5
Fig. 65: Prying Up Rear Side Switch Panel Frame


2012 Volvo C30 T-5
Fig. 67: Identifying Window Regulator Rotary Switch Screws

INSTALLATION
Fig. 68: Installing Front Door Switch Panel (1 of 2)

2012 Volvo C30 T-5
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.
ROTARY SWITCH, SUN ROOF (2007-2011)
REMOVAL
2012 Volvo C30 T-5

Remove lighting interior front, see LIGHTING, INTERNAL FRONT
Fig. 71: View Of Sun Roof Rotary Switch Release Clips

INSTALLATION
ROTARY SWITCH, SUN ROOF (2012)
PREPARATORY WORK
2012 Volvo C30 T-5
IGNITION OFF

Ignition off.
REMOVAL
REMOVING THE INTERIOR LIGHTING
Remove the interior lighting. See: LIGHTING, INTERNAL FRONT .
REMOVING THE SWITCH

2012 Volvo C30 T-5
Fig. 73: Sun Roof Switch Catches

Press the catches out.
Pull the switch outwards and upwards.
Pull out the catch. Pull out the conductive strap.
INSTALLATION
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
Remove steering wheel, see STEERING WHEEL
Remove steering wheel lever right, see CONTROL STALK, RIGHT
Remove steering wheel lever left, see CONTROL STALK, LEFT
Fig. 74: Identifying Steering Wheel Control Module Bolts

CAUTION: Make sure that the clockspring pins are not bent or damaged.
Torque: Steering wheel control module to steering column
0.9 Nm
2012 Volvo C30 T-5
Fig. 75: Identifying Steering Wheel Control Module Connectors

INSTALLATION
Perform angle sensor, steering wheel, resetting
SWITCH, CENTRAL LOCKING SYSTEM
REMOVAL


2012 Volvo C30 T-5
Fig. 77: Remove/Install Central Locking System, Switch Components

INSTALLATION
SWITCH, HAZARD WARNING FLASHERS
REMOVAL
Remove inner ventilation nozzle, see DRIVER SIDE REGISTER
Fig. 78: Identifying Hazard Warning Flashers Release

INSTALLATION

2012 Volvo C30 T-5
SWITCH TUNNEL COMPARTMENT
REMOVAL
Fig. 79: Identifying Tunnel Compartment Switches

Fig. 80: View Of Tunnel Compartment Switch Tabs

2012 Volvo C30 T-5
Fig. 81: Removing Tunnel Compartment Switches

Initiate switch using VIDA (Volvo scan tool).
INSTALLATION
COLLISION AVOIDANCE
DISTANCE SENSORS, PARKING ASSISTANCE REAR (2007 - 2011 EARLY)
REMOVAL
2012 Volvo C30 T-5
Fig. 82: View Of Ignition In "0" Position

Remove Rear Bumper Cover Upper Section, see REAR BUMPER COVER UPPER SECTION (2007 - 2011
EARLY
Fig. 83: Removing Rear Parking Assistance Distance Sensors (1 Of 2)

2012 Volvo C30 T-5

INSTALLATION
Fig. 85: Installing Rear Parking Assistance Distance Sensors (1 Of 2)

2012 Volvo C30 T-5

DISTANCE SENSORS, PARKING ASSISTANCE REAR (2011 LATE - 2012)
REMOVAL

REAR (2011 LATE - 2012) .
2012 Volvo C30 T-5


INSTALLATION
Follow instructions for paint, see PAINT

2012 Volvo C30 T-5


PARKING ASSISTANCE MODULE
REMOVAL
Remove the right side panel cargo compartment, see SIDE PANEL LOADSPACE
2012 Volvo C30 T-5
Fig. 92: Identifying Parking Assistance Module

INSTALLATION
DOOR LOCKS & ANTI-THEFT SYSTEMS

ANTENNA, LOCKING SYSTEM, KEYLESS ENTRY, FRONT

2012 Volvo C30 T-5
Fig. 93: Identifying Ignition Switch In OFF Position

Remove the tunnel console. See FLOOR CONSOLE
Fig. 94: Locating Antenna Nuts

 the 2 x nuts
 the antenna
 the connector
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
Fig. 95: Locating Keyless Entry Locking System Antenna In Luggage Compartment
ANTENNA, LOCKING SYSTEM, KEYLESS ENTRY, REAR (2007 - 2011 EARLY)
Operation Number(s): 36646-2

Remove casing bumper rear. See REAR BUMPER COVER LOWER SECTION (2007-2009) or REAR
BUMPER COVER LOWER SECTION (2010 - 2011 EARLY) .
2012 Volvo C30 T-5
Fig. 97: Identifying Bumper Bracket Module

 the antenna, fold out the catches at the lower edge

 the connector
ANTENNA, LOCKING SYSTEM, KEYLESS ENTRY, REAR (2011 LATE - 2012)
REMOVAL

REAR (2011 LATE - 2012) .
2012 Volvo C30 T-5
Fig. 99: Removing Keyless Entry Locking System Rear Antenna (1 Of 2)


INSTALLATION
2012 Volvo C30 T-5
ANTI-THEFT PROTECTION SIREN (2007-2011)
REMOVAL

Remove the plenum cover, see PLENUM CHAMBER
Fig. 102: Identifying Anti-Theft Protection Siren Bolts

Torque: M6
10 Nm
2012 Volvo C30 T-5
INSTALLATION
ANTI-THEFT PROTECTION SIREN (2012)
REMOVAL

Fig. 104: Locating Anti-Theft Protection Siren

Torque: M6
2012 Volvo C30 T-5
10 Nm
Fig. 105: Removing Anti-Theft Protection Siren (1 of 2)


INSTALLATION
FRONT INTRUSION SENSOR (2007-2011)
REMOVAL
Make sure that the vehicle is modified. See MASS MOVEMENT SENSOR (MMS), MODIFICATION .
2012 Volvo C30 T-5

Fig. 108: Front Intrusion Sensor Cover

2012 Volvo C30 T-5
Fig. 109: Front Intrusion Sensor Connector

INSTALLATION
FRONT INTRUSION SENSOR (2012)
REMOVAL
2012 Volvo C30 T-5


INSTALLATION
2012 Volvo C30 T-5
KEYLESS VEHICLE MODULE (KVM)
PREPARATORY WORK
IGNITION OFF

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
Fig. 113: View Of Keyless Vehicle Module (KVM) Connectors

Remove:
 the 2 x screws
INSTALLATION
INSTALLING THE KEYLESS VEHICLE MODULE (KVM)
CAUTION: The pins on the control module are fragile. Press the connectors in
carefully.
Install:
 the control module

 the 2 x screws
2012 Volvo C30 T-5
FINISHING
INSTALLING THE LEFT-HAND FRONT SEAT
Install the left-hand front seat. See: FRONT SEAT .
ORDERING SOFTWARE
Order software for the control module. See: 30772590
LOCKING SYSTEM RECEIVER (2007)
REMOVAL
NOTE: Is the vehicle equipped with keyless entry system, see: RECEIVER LOCK
SYSTEM KEYLESS ENTRY (RKE)
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

2012 Volvo C30 T-5
Remove:
 the 2 x screws
 the remote receiver module (RRX).
INSTALLATION
INSTALLING RECEIVER LOCK SYSTEM
Install:
 the remote receiver module (RRX)

 the 2 screws.
INSTALLING THE COMBINED INSTRUMENT PANEL
Install the combined instrument panel. See: COMBINED INSTRUMENT PANEL .
LOCKING SYSTEM RECEIVER (2008-2012)
Materials
Melting adhesive 1161656
REMOVAL
Detach front edge of headlining with roof hatch, see HEADLINING WITH SUN ROOF
Fig. 115: Locating Locking System Receiver

2012 Volvo C30 T-5
Fig. 116: Removing Locking System Receiver

CAUTION: Take extra care not to crease the headliner.
INSTALLATION
Fig. 117: Identifying Adhesive

2012 Volvo C30 T-5
Fig. 118: Melting Adhesive, 1161656

Use: Melting adhesive, 1161656
Fig. 119: Installing Locking System Receiver

RECEIVER, LOCK SYSTEM KEYLESS ENTRY (RKE)
Materials
REMOVAL
2012 Volvo C30 T-5


INSTALLATION
2012 Volvo C30 T-5



2012 Volvo C30 T-5

SUN SENSOR
REMOVAL
REMOVING THE SUN SENSOR/ALARM LED
Fig. 125: Removing The Sun Sensor/Alarm LED

Remove:
 the sun sensor/alarm LED. Use a weather strip tool

 the connector, x 1.
2012 Volvo C30 T-5
INSTALLATION
INSTALLING THE SUN SENSOR/ALARM LED
Install:
 the connector, x 1
 the sun sensor/alarm LED.
WIPER/WASHER SYSTEM
HEADLIGHT WASHERS
REMOVAL
 Headlamps, see HEADLAMPS (2007-2009) , HEADLAMPS (2010 - 2011 EARLY) , or

 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)

2012 Volvo C30 T-5

INSTALLATION
Fig. 128: Installing Headlight Washer

RAIN SENSOR
REMOVAL
2012 Volvo C30 T-5
Fig. 129: Removing Rain Sensor (1 Of 3)



2012 Volvo C30 T-5
CAUTION: The silicon surface must not be touched, any contamination of the surface
will damage the sensor.
INSTALLATION
Perform rain sensor check, see RAIN SENSOR, CHECK
REAR WIPER MOTOR
Special tools
998 7693 UNIVERSAL SEPARATOR B75
MM L80 MM
Tool description: UNIVERSAL
SEPARATOR B75 MM L80 MM
Tool boards: 08
REMOVAL

2012 Volvo C30 T-5
Fig. 132: Removing Rear Wiper Motor (1 Of 2)

see 9987693

Torque: M6
2012 Volvo C30 T-5
10 Nm
INSTALLATION
WASHER FLUID RESERVOIR (2007 - 2011 EARLY)
REMOVAL
Fig. 134: View Of Washer Fluid Reservoir Bolt

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) .
2012 Volvo C30 T-5
Fig. 135: View Of Washer Reservoir Bolts

Torque: M6
10 Nm
INSTALLATION
WASHER FLUID RESERVOIR (2011 LATE - 2012)
REMOVAL

2012 Volvo C30 T-5

RESERVOIR (2011 LATE - 2012) .
Remove casing bumper front, see COVER BUMPER FRONT (2011 LATE - 2012) .
Fig. 137: View Of Washer Reservoir Screw

2012 Volvo C30 T-5
Fig. 138: View Of Escaping Fluid

Fig. 139: Identifying Reservoir Tank Components

2012 Volvo C30 T-5
Fig. 140: Identifying Reservoir Tank Bolts

Torque: M6
10 Nm
INSTALLATION
WIPER ARM
Special tools
981 4088 Puller
Tool description: Puller
Tool boards: 80
2012 Volvo C30 T-5
REMOVAL
CAUTION: Make sure that the motor is in the park position.
Fig. 141: Remove Key From Ignition

2012 Volvo C30 T-5
Fig. 142: Identifying Windshield Wiper Arm Screws

Torque: Windshield wiper arm
21 Nm
Fig. 143: View Of Special Tool 9814088

see 9814088
INSTALLATION
2012 Volvo C30 T-5
Fig. 144: View Of Wiper Blade Position

WIPER MECHANISM, WINDSHIELD
REMOVAL


2012 Volvo C30 T-5
Fig. 146: Identifying Wiper Mechanism Bolts

Torque: M6
10 Nm
INSTALLATION
WIPER MOTOR FRONT
REMOVAL

2012 Volvo C30 T-5

Remove the wiper mechanism, windscreen, see WIPER MECHANISM, WINDSHIELD
Fig. 148: Identifying Wiper Motor Front Components

2012 Volvo C30 T-5
Fig. 149: Identifying Wiper Motor Front Position

Fig. 150: Identifying Wiper Motor Front Screws

Torque: M6
10 Nm
INSTALLATION
NOTE: Make sure that this component is installed to the noted removal position.
2012 Volvo C30 T-5
Other Electrical Equipment - Removal, replacement and installation
BODY ELECTRICAL
REMOVAL
Remove the air filter housing, see AIR CLEANER HOUSING


2012 Volvo C30 T-5
Torque: Reversing lamp switch
24 Nm
INSTALLATION
in the illustrations is always correct.
REMOVING THE BACK-UP LAMP SWITCH, GEARBOX M56
Ignition off
Remove the air cleaner (ACL) housing.

 the gear selector cables from the levers. see 9997077

 the gear selector cables from the brackets to prevent bending them when removing the lever.
2012 Volvo C30 T-5

 pin. see 9997221 .

 the lever

 the connector from the back-up lamp switch.

 the back-up light switch. see 9995543
INSTALLATION
2012 Volvo C30 T-5
INSTALLING BACK-UP (REVERSING) LAMP SWITCH

Install the new back-up light switch. see 9995543 Tighten to: 24 Nm.
Fig. 7: View Of Secondary Lock

Pull out the secondary lock. see 9512853 .

2012 Volvo C30 T-5
Fig. 8: Back-Up Lamp Switch Leads

Install the cables in the connector with the opening for the primary lock facing up as shown in the illustration.
Press in the secondary lock.
JOINING CABLES
Splice the new connector with cables to the existing wiring. See JOINING CABLES .
Fig. 9: Identifying Tie-Strap Installed

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

 transmission lever see 9997221 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

2012 Volvo C30 T-5

Fig. 12: Identifying Control Stalk, Left Screws

INSTALLATION
CONTROL STALK, RIGHT
REMOVAL

2012 Volvo C30 T-5
Fig. 14: Identifying Control Stalk, Right Screws

INSTALLATION

2012 Volvo C30 T-5
Fig. 16: View Of Data Link Connector (OBD-II) location



2012 Volvo C30 T-5
Fig. 19: Inserting Terminal Removal Tool


2012 Volvo C30 T-5
Fig. 20: Pressing Tab And Removing Wire

DRIVER DOOR MODULE (DDM)
REMOVAL


Torque: M6
10 Nm
2012 Volvo C30 T-5
INSTALLATION
EXTRA POWER SOCKET 12V (2007)
PREPARATORY WORK
IGNITION OFF

2012 Volvo C30 T-5
Ignition off.
REMOVAL
REMOVING THE CIGARETTE LIGHTER/ELECTRICAL SOCKET
Fig. 24: View Of Ashtray Panel

Remove the rear panel.
Disconnect the connector from the ashtray panel.

2012 Volvo C30 T-5
Fig. 25: Identifying Cigarette Lighter/Electrical Socket Catches

Lift up the catches (as shown in the illustration) using a small 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)

2012 Volvo C30 T-5


EXTRA POWER SOCKET 12V, LUGGAGE COMPARTMENT (2008, 2009 AND 2011, 2012)
2012 Volvo C30 T-5


FRONT POSITION SENSOR, HEADLAMP (2007-2009)
REMOVAL

2012 Volvo C30 T-5

Torque: M6
10 Nm
INSTALLATION
FRONT POSITION SENSOR, HEADLAMP (2010 - 2011 EARLY)
REMOVAL

2012 Volvo C30 T-5


Torque: M6
10 Nm
INSTALLATION
2012 Volvo C30 T-5
FINISHING
FRONT POSITION SENSOR, HEADLAMP (2011 LATE - 2012)
REMOVAL

2012 Volvo C30 T-5

Torque: M6
10 Nm
INSTALLATION
INSTRUMENT PANEL CONSOLE SWITCH KNOB
Special tools
981 4071 STRAIGHTENING TOOL
Tool description: STRAIGHTENING TOOL
Tool boards: 80
2012 Volvo C30 T-5
REMOVAL
Fig. 36: Removing Instrument Panel Console Switch Knob

see 9814071
2012 Volvo C30 T-5
INSTALLATION
KEYPAD, STEERING WHEEL
REMOVAL
Remove airbag driver's side, see DRIVER'S AIRBAG
Fig. 37: Identifying Steering Wheel Keypad

Fig. 38: View Of Steering Wheel Keypad Connectors

INSTALLATION

2012 Volvo C30 T-5
LIGHTING SWITCH
REMOVAL

Fig. 40: Identifying Lighting Switch in OFF Position

2012 Volvo C30 T-5
Fig. 41: View Of Lighting Switch Components

Fig. 42: Identifying Lighting Switch Screws

INSTALLATION
PASSENGER DOOR MODULE (PDM)
REMOVAL

2012 Volvo C30 T-5


Torque: M6
10 Nm
INSTALLATION

2012 Volvo C30 T-5
POSITION SENSOR REAR, HEADLAMP (2007-2009)
REMOVAL


Torque: M6
10 Nm
2012 Volvo C30 T-5
INSTALLATION
POSITION SENSOR REAR, HEADLAMP (2010 - 2011 EARLY)
REMOVAL


2012 Volvo C30 T-5
Torque: M6
10 Nm
INSTALLATION
FINISHING
POSITION SENSOR REAR, HEADLAMP (2011 LATE - 2012)
REMOVAL

2012 Volvo C30 T-5

Torque: M6
10 Nm
INSTALLATION
POWER SOCKET 12V (2007)
REMOVAL

2012 Volvo C30 T-5
Fig. 52: Identifying Power Socket Panel

Fig. 53: View Of Power Socket Clip

INSTALLATION
POWER SOCKET 12V (2008-2012)
REAR DOOR WINDOW REGULATOR ROTARY SWITCH
REMOVAL
2012 Volvo C30 T-5

Fig. 55: Window Regulator Rotary Switch, Rear Door Remove/Install Components (1 Of 3)
2012 Volvo C30 T-5
INSTALLATION
ROTARY SWITCH, FRONT DOOR WINDOW REGULATOR (2007 - 2011 EARLY)
REMOVAL

2012 Volvo C30 T-5

Fig. 60: Identifying Door Handle Panel Clips

2012 Volvo C30 T-5

INSTALLATION
ROTARY SWITCH, FRONT DOOR WINDOW REGULATOR (2011 LATE - 2012)
REMOVAL

2012 Volvo C30 T-5

Fig. 64: Prying Up Front Side Switch Panel Frame

2012 Volvo C30 T-5
Fig. 65: Prying Up Rear Side Switch Panel Frame


2012 Volvo C30 T-5
Fig. 67: Identifying Window Regulator Rotary Switch Screws

INSTALLATION

2012 Volvo C30 T-5
CAUTION: Only use moderate force.

CAUTION: Make sure that equal pressure is applied to the full length of the
component.
ROTARY SWITCH, SUN ROOF (2007-2011)
REMOVAL
2012 Volvo C30 T-5

Remove lighting interior front, see LIGHTING, INTERNAL FRONT
Fig. 71: View Of Sun Roof Rotary Switch Release Clips

INSTALLATION
ROTARY SWITCH, SUN ROOF (2012)
PREPARATORY WORK
2012 Volvo C30 T-5
IGNITION OFF

Ignition off.
REMOVAL
REMOVING THE INTERIOR LIGHTING
Remove the interior lighting. See: LIGHTING, INTERNAL FRONT .
REMOVING THE SWITCH

2012 Volvo C30 T-5
Fig. 73: Sun Roof Switch Catches

Press the catches out.
Pull the switch outwards and upwards.
Pull out the catch. Pull out the conductive strap.
INSTALLATION
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
Remove steering wheel, see STEERING WHEEL
Remove steering wheel lever right, see CONTROL STALK, RIGHT
Remove steering wheel lever left, see CONTROL STALK, LEFT
Fig. 74: Identifying Steering Wheel Control Module Bolts

CAUTION: Make sure that the clockspring pins are not bent or damaged.
Torque: Steering wheel control module to steering column
0.9 Nm
2012 Volvo C30 T-5
Fig. 75: Identifying Steering Wheel Control Module Connectors

INSTALLATION
Perform angle sensor, steering wheel, resetting
SWITCH, CENTRAL LOCKING SYSTEM
REMOVAL


2012 Volvo C30 T-5
Fig. 77: Remove/Install Central Locking System, Switch Components

INSTALLATION
SWITCH, HAZARD WARNING FLASHERS
REMOVAL
Remove inner ventilation nozzle, see DRIVER SIDE REGISTER
Fig. 78: Identifying Hazard Warning Flashers Release

INSTALLATION

2012 Volvo C30 T-5
SWITCH TUNNEL COMPARTMENT
REMOVAL
Fig. 79: Identifying Tunnel Compartment Switches

Fig. 80: View Of Tunnel Compartment Switch Tabs

2012 Volvo C30 T-5
Fig. 81: Removing Tunnel Compartment Switches

Initiate switch using VIDA (Volvo scan tool).
INSTALLATION
COLLISION AVOIDANCE
DISTANCE SENSORS, PARKING ASSISTANCE REAR (2007 - 2011 EARLY)
REMOVAL
2012 Volvo C30 T-5
Fig. 82: View Of Ignition In "0" Position

Remove Rear Bumper Cover Upper Section, see REAR BUMPER COVER UPPER SECTION (2007 - 2011
EARLY

2012 Volvo C30 T-5

INSTALLATION

2012 Volvo C30 T-5

DISTANCE SENSORS, PARKING ASSISTANCE REAR (2011 LATE - 2012)
REMOVAL

REAR (2011 LATE - 2012) .
2012 Volvo C30 T-5


INSTALLATION
Follow instructions for paint, see PAINT

2012 Volvo C30 T-5


PARKING ASSISTANCE MODULE
REMOVAL
Remove the right side panel cargo compartment, see SIDE PANEL LOADSPACE
2012 Volvo C30 T-5
Fig. 92: Identifying Parking Assistance Module

INSTALLATION
DOOR LOCKS & ANTI-THEFT SYSTEMS

ANTENNA, LOCKING SYSTEM, KEYLESS ENTRY, FRONT

2012 Volvo C30 T-5

Remove the tunnel console. See FLOOR CONSOLE
Fig. 94: Locating Antenna Nuts

 the 2 x nuts
 the antenna
 the connector
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
Fig. 95: Locating Keyless Entry Locking System Antenna In Luggage Compartment
ANTENNA, LOCKING SYSTEM, KEYLESS ENTRY, REAR (2007 - 2011 EARLY)
Operation Number(s): 36646-2

Remove casing bumper rear. See REAR BUMPER COVER LOWER SECTION (2007-2009) or REAR
BUMPER COVER LOWER SECTION (2010 - 2011 EARLY) .
2012 Volvo C30 T-5
Fig. 97: Identifying Bumper Bracket Module

 the antenna, fold out the catches at the lower edge

 the connector
ANTENNA, LOCKING SYSTEM, KEYLESS ENTRY, REAR (2011 LATE - 2012)
REMOVAL

REAR (2011 LATE - 2012) .
2012 Volvo C30 T-5


INSTALLATION
2012 Volvo C30 T-5
ANTI-THEFT PROTECTION SIREN (2007-2011)
REMOVAL

Fig. 102: Identifying Anti-Theft Protection Siren Bolts

Torque: M6
10 Nm
2012 Volvo C30 T-5
INSTALLATION
ANTI-THEFT PROTECTION SIREN (2012)
REMOVAL

Fig. 104: Locating Anti-Theft Protection Siren

Torque: M6
2012 Volvo C30 T-5
10 Nm


INSTALLATION
FRONT INTRUSION SENSOR (2007-2011)
REMOVAL
Make sure that the vehicle is modified. See MASS MOVEMENT SENSOR (MMS), MODIFICATION .
2012 Volvo C30 T-5


2012 Volvo C30 T-5

INSTALLATION
FRONT INTRUSION SENSOR (2012)
REMOVAL
2012 Volvo C30 T-5


INSTALLATION
2012 Volvo C30 T-5
KEYLESS VEHICLE MODULE (KVM)
PREPARATORY WORK
IGNITION OFF

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
Fig. 113: View Of Keyless Vehicle Module (KVM) Connectors

Remove:
 the 2 x screws
INSTALLATION
INSTALLING THE KEYLESS VEHICLE MODULE (KVM)
CAUTION: The pins on the control module are fragile. Press the connectors in
carefully.
Install:
 the control module

 the 2 x screws
2012 Volvo C30 T-5
FINISHING
INSTALLING THE LEFT-HAND FRONT SEAT
Install the left-hand front seat. See: FRONT SEAT .
ORDERING SOFTWARE
Order software for the control module. See: 30772590
LOCKING SYSTEM RECEIVER (2007)
REMOVAL
NOTE: Is the vehicle equipped with keyless entry system, see: RECEIVER LOCK
SYSTEM KEYLESS ENTRY (RKE)
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

2012 Volvo C30 T-5
Remove:
 the 2 x screws
 the remote receiver module (RRX).
INSTALLATION
INSTALLING RECEIVER LOCK SYSTEM
Install:
 the remote receiver module (RRX)

 the 2 screws.
INSTALLING THE COMBINED INSTRUMENT PANEL
Install the combined instrument panel. See: COMBINED INSTRUMENT PANEL .
LOCKING SYSTEM RECEIVER (2008-2012)
Materials
REMOVAL

2012 Volvo C30 T-5

INSTALLATION

2012 Volvo C30 T-5


RECEIVER, LOCK SYSTEM KEYLESS ENTRY (RKE)
Materials
REMOVAL
2012 Volvo C30 T-5


INSTALLATION
2012 Volvo C30 T-5



2012 Volvo C30 T-5

SUN SENSOR
REMOVAL
REMOVING THE SUN SENSOR/ALARM LED
Fig. 125: Removing The Sun Sensor/Alarm LED

Remove:
 the sun sensor/alarm LED. Use a weather strip tool

 the connector, x 1.
2012 Volvo C30 T-5
INSTALLATION
INSTALLING THE SUN SENSOR/ALARM LED
Install:
 the connector, x 1
 the sun sensor/alarm LED.
WIPER/WASHER SYSTEM
HEADLIGHT WASHERS
REMOVAL
 Headlamps, see HEADLAMPS (2007-2009) , HEADLAMPS (2010 - 2011 EARLY) , or

 Cover bumper front, see COVER BUMPER FRONT (2007 - 2011 EARLY) or COVER BUMPER
FRONT (2011 LATE - 2012) .

2012 Volvo C30 T-5

INSTALLATION
Fig. 128: Installing Headlight Washer

RAIN SENSOR
REMOVAL
2012 Volvo C30 T-5



2012 Volvo C30 T-5
CAUTION: The silicon surface must not be touched, any contamination of the surface
will damage the sensor.
INSTALLATION
Perform rain sensor check, see RAIN SENSOR, CHECK
REAR WIPER MOTOR
Special tools
998 7693 UNIVERSAL SEPARATOR B75
MM L80 MM
Tool description: UNIVERSAL
SEPARATOR B75 MM L80 MM
Tool boards: 08
REMOVAL

2012 Volvo C30 T-5

see 9987693

Torque: M6
2012 Volvo C30 T-5
10 Nm
INSTALLATION
WASHER FLUID RESERVOIR (2007 - 2011 EARLY)
REMOVAL
Fig. 134: View Of Washer Fluid Reservoir Bolt

Remove casing bumper front, see COVER BUMPER FRONT (2007 - 2011 EARLY) .
RESERVOIR (2007 - 2011 EARLY) .
2012 Volvo C30 T-5
Fig. 135: View Of Washer Reservoir Bolts

Torque: M6
10 Nm
INSTALLATION
WASHER FLUID RESERVOIR (2011 LATE - 2012)
REMOVAL

2012 Volvo C30 T-5

RESERVOIR (2011 LATE - 2012) .
Remove casing bumper front, see COVER BUMPER FRONT (2011 LATE - 2012) .
Fig. 137: View Of Washer Reservoir Screw

2012 Volvo C30 T-5
Fig. 138: View Of Escaping Fluid

Fig. 139: Identifying Reservoir Tank Components

2012 Volvo C30 T-5
Fig. 140: Identifying Reservoir Tank Bolts

Torque: M6
10 Nm
INSTALLATION
WIPER ARM
Special tools
981 4088 Puller
Tool description: Puller
Tool boards: 80
2012 Volvo C30 T-5
REMOVAL

2012 Volvo C30 T-5
Fig. 142: Identifying Windshield Wiper Arm Screws

Torque: Windshield wiper arm
21 Nm
Fig. 143: View Of Special Tool 9814088

see 9814088
INSTALLATION

FTV ZTs HNL 6 R14 M5 P

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FTV ZTs HNL 6 R14 M5 P

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2007-2013 VOLVO C30 SERVICE

AND REPAIR MANUAL

Engine Control - Removal, Replacement And Installation

Fig. 1: Identifying Accelerator Pedal

Alternator And Regulator - Removal, Replacement And Installation

NOTE: Removal steps in this procedure may contain installation details.

Battery, disconnection. See BATTERY DISCONNECTING AND CONNECTING

Fig. 1: Identifying Bolts

Remove the auxiliaries belt. See ACCESSORY DRIVE BELT TENSIONER

Fig. 2: Identifying Generator B+ Terminal And Bolts

Remove the following items:

1. Torque: Generator B+ terminal

To install, reverse the removal procedure.

GENERATOR (B5254T3; 2007, B5254T7; 2008-12)

NOTE: Removal steps in this procedure may contain installation details.

Fig. 3: Identifying Ignition In OFF Position

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

Fig. 4: Identifying Oil Stick Bracket Bolt

Fig. 5: Identifying Generator B+ Terminal And Nuts

Remove the following items:

1. Torque: Generator B+ terminal

To install, reverse the removal procedure.

GENERATOR PULLEY, GENERATOR (B5244S4; 2007-11, B5254T7; 2008-12)

999 7113 Spanner

REMOVAL AND INSTALLATION

Fig. 6: Identifying Spanner 9997113

see 9997113 see 9997113

NOTE: Removal steps in this procedure may contain installation details.

Fig. 7: Identifying Nuts

Fig. 8: Identifying M4 Generator Bolts

To install, reverse the removal procedure

Battery And Mounting - Removal, Replacement And Installation

NOTE: Removal steps in this procedure may contain installation details.

See SAFETY INFORMATION BATTERY AND CHARGING

Fig. 1: Identifying Underhood Torsion Rod, Nuts And Cover

Fig. 2: View Of Battery And Cover

Courtesy of VOLVO CARS CORPORATION

Fig. 3: Locating Battery Box And Terminal Connector Bolts

Fig. 4: Identifying Battery, Holder And Bolts

To install, reverse the removal procedure.

VEHICLES WITH BATTERY MONITORING SENSOR (BMS)

Reset according to DIAGNOSTICS/VEHICLE COMMUNICATION/CEM/Advanced/Resetting information

NOTE: Removal steps in this procedure may contain installation details.

Remove left-hand drive shaft, see DRIVESHAFT LEFT

Remove the right drive shaft, see DRIVE SHAFT RIGHT

Fig. 1: Identifying M7 Bolts

Fig. 2: Identifying Hose Strap

Fig. 3: Identifying Hose

Fig. 4: Identifying M8 And M10 Bolts

Remove the following items:

Fig. 5: Identifying M10 Bolts

Fig. 6: Removing Bevel Gear

Fig. 7: Identifying Bevel Gear

For information about transmission lubricants, see LUBRICANT TRANSMISSION

To install, reverse the removal procedure.

Automatic HVAC System

REMOVING THE COMBUSTION PREHEATER MODULE (CPM)

REMOVING THE GLOW PLUG/PRESSURE EQUALIZER

Fig. 1: Identifying Screws For Cover Over Fan Housing

Fig. 2: Identifying Fan Housing

Fig. 3: Identifying Cable Terminals And Cables