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2012 Volvo C30 T-5

ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation

Fig. 144: View Of Wiper Blade Position


Courtesy of VOLVO CARS CORPORATION

WIPER MECHANISM, WINDSHIELD

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.

CAUTION: Make sure that the motor is in the park position.

Fig. 145: Remove Key From Ignition


Courtesy of VOLVO CARS CORPORATION

Remove the plenum cover, see PLENUM CHAMBER


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation

Fig. 146: Identifying Wiper Mechanism Bolts


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm

INSTALLATION

To install, reverse the removal procedure.

WIPER MOTOR FRONT

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.

CAUTION: Make sure that the motor is in the park position.


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation

Fig. 147: Remove Key From Ignition


Courtesy of VOLVO CARS CORPORATION

Remove the wiper mechanism, windscreen, see WIPER MECHANISM, WINDSHIELD

Fig. 148: Identifying Wiper Motor Front Components


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Other Electrical Equipment - Removal, replacement and installation

Fig. 149: Identifying Wiper Motor Front Position


Courtesy of VOLVO CARS CORPORATION

NOTE: Note the position of the component before removal.

Fig. 150: Identifying Wiper Motor Front Screws


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm

INSTALLATION

To install, reverse the removal procedure.

NOTE: Make sure that this component is installed to the noted removal position.
2012 Volvo C30 T-5
General Information DTC Index

General Information

DTC Index

ACCESSORY ELECTRONIC MODULE (AEM) DTCS


ACCESSORY ELECTRONIC MODULE (AEM) - DTC INDEX
Volvo Code Description
AEM-1D01 Control module. Internal fault
AEM-1D02 Control module, software. Internal fault
AEM-1D03 Control module not fully programmed. Internal fault
AEM-1D07 Control module. Internal fault
AEM-1D08 Control module. Internal fault
AEM-1D0A Control module. Internal fault
AEM-5F10 Relay, engine block heater. Signal too low
AEM-5F11 Relay, engine block heater. Signal too high/Signal missing
AEM-6C50 Alarm output P0. Signal too low or signal missing
AEM-6C51 Alarm output P0. Signal too high
AEM-6C52 Alarm output P1. Signal too low or signal missing
AEM-6C53 Alarm output P1. Signal too high
AEM-6C54 Alarm output S0. Signal too low or signal missing
AEM-6C55 Alarm output S0. Signal too high
AEM-6C56 Alarm output S1. Signal too low
AEM-6C57 Alarm output S1. Signal too high/Signal missing
AEM-E001 Control module communication. Faulty communication
AEM-E003 Control module communication Faulty communication
AEM-E010 Power supply. Signal too low
AEM-XXXX Unknown diagnostic trouble code (DTC) for the current control module
version

AUDIO MODULE (AUD) DTCS


AUDIO MODULE (AUD) - DTC INDEX
Volvo Code Description
AUD-0001 Control module. Internal fault
AUD-0002 Loudspeaker left front. Signal missing
AUD-0003 Loudspeaker right front. Signal missing
AUD-0004 Loudspeaker left rear. Signal missing
AUD-0005 Loudspeaker right rear. Signal missing
AUD-0006 Loudspeaker left front. Short-circuit to ground
AUD-0007 Center loudspeaker. Short-circuit to ground
2012 Volvo C30 T-5
General Information DTC Index

AUD-0009 Loudspeaker left rear. Short-circuit to ground


AUD-000A Loudspeaker right rear. Short-circuit to ground
AUD-000D Control module. Over heated
AUD-000E Microphone terminal. Signal missing
AUD-000F Microphone terminal. Signal too high
AUD-0010 Microphone terminal. Signal too low
AUD-001B Configuration fault. Software fault
AUD-001C Center loudspeaker. Signal missing
AUD-001D Control module. Internal fault
AUD-001E Control module. Internal fault
AUD-001F Control module. Internal fault
AUD-0020 Control module. Internal fault
AUD-0021 Control module. Internal fault
AUD-0022 Control module. Internal fault
AUD-0023 Loudspeaker front. Shorted
AUD-0024 Loudspeaker rear. Shorted
AUD-0025 Control module. Internal fault
AUD-0025 Loudspeaker left front. Faulty signal
AUD-0026 Loudspeaker right front. Faulty signal
AUD-0027 Loudspeaker left rear. Faulty signal
AUD-0028 Loudspeaker right rear. Faulty signal
AUD-0029 Loudspeaker left front. Signal too high
AUD-002A Loudspeaker right front. Signal too low
AUD-002B Loudspeaker left rear. Signal too low
AUD-002C Loudspeaker right rear. Signal too low
AUD-002D Loudspeaker left front. Signal too high
AUD-002E Loudspeaker right front. Signal too high
AUD-002F Loudspeaker left rear. Signal too high
AUD-0030 Loudspeaker right rear. Signal too high

ACCESSORY USB UNIT (AUU) DTCS


ACCESSORY USB UNIT (AUU) - DTC INDEX
Volvo Code Description
AUU-0001 Battery Voltage. Algorithm Based Failures
AUU-0002 Control Module. System Programming Failures

BRAKE CONTROL MODULE (BCM) DTCS


BRAKE CONTROL MODULE (BCM) - DTC INDEX
Volvo Code Description
2012 Volvo C30 T-5
General Information DTC Index

BCM-0010 Wheel sensor left front. Faulty signal (B5254T7)


BCM-0011 Wheel sensor left front. Faulty signal (B5254T7)
BCM-0012 Wheel sensor left front. Mechanical fault (B5254T7)
BCM-0030 Wheel sensor left rear. Faulty signal (B5254T7)
BCM-0050 Control module. Faulty signal (B5254T7)
BCM-0052 Control module. Internal fault (B5254T7)
BCM-0057 Power supply. Voltage too low (B5254T7)
BCM-0058 Power supply. Voltage too high (B5254T7)
BCM-0061 Brake discs. Temperature too high (B5254T7)
BCM-0068 Sensor power supply. Faulty signal (B5254T7)
BCM-0070 Power supply for the pump motor. Faulty signal (B5254T7)
BCM-0071 Pump motor. Signal missing (B5254T7)
BCM-0072 Pump motor. Mechanical fault (B5254T7)
BCM-0074 Hydraulic valves. Faulty signal (B5254T7)
BCM-0076 Control module. Faulty configuration (B5254T7)
BCM-0080 Lateral accelerometer. Incorrect offset value (B5254T7)
BCM-0090 Lateral accelerometer. Faulty signal (B5254T7)
BCM-0091 Accelerometer. Faulty signal (B5254T7)
BCM-0094 Communication between control modules. Communication problems
with the differential electronic module (DEM) (B5254T7)
BCM-0095 Communication between control modules. Communication problems
with the differential electronic module (DEM) (B5254T7)
BCM-0096 Sensor cluster. Faulty signal (B5254T7)
BCM-0097 Communication between control modules. Communication problems
with the central electronic module (CEM) (B5254T7)
BCM-0100 Communication between control modules. Communication problems
with the engine control module (ECM) (B5254T7)
BCM-0101 Communication between control modules. Communication problems
with the engine control module (ECM) (B5254T7)
BCM-0103 Pedal position sensor. Faulty signal (B5254T7)
BCM-0105 Steering wheel, wheel alignment. Signal outside its permitted range
(B5254T7)
BCM-0106 Steering wheel, wheel alignment. Incorrect steering wheel or wheel
alignment (B5254T7)
BCM-0108 Communication between control modules. Communication problems
with the steering wheel module (SWM), control module not initiated
(B5254T7)
BCM-0109 Communication between control modules. Steering wheel module
(SWM), internal fault (B5254T7)
BCM-0111 Communication between control modules. AYC stability control active
for too long (B5254T7)
BCM-0112 Body sensor cluster stability sensor (BSC). Sensor not calibrated
2012 Volvo C30 T-5
General Information DTC Index

(B5254T7)
BCM-0113 Back-up (reversing) signal. Signal missing (B5254T7)
BCM-0114 Communication with the body sensor cluster stability sensor (BSC).
Signal missing (B5254T7)
BCM-0115 Communication between control modules. Communication with the
steering wheel module (SWM), signal missing (B5254T7)
BCM-0116 Communication with the body sensor cluster stability sensor (BSC).
Communication problems (B5254T7)
BCM-0117 Communication with the body sensor cluster stability sensor (BSC).
Incorrect body sensor cluster stability sensor (BSC) installed (B5254T7)
BCM-0118 Power supply for the body sensor cluster stability sensor (BSC). Voltage
too high (B5254T7)
BCM-0119 Power supply for the body sensor cluster stability sensor (BSC). Voltage
too low (B5254T7)
BCM-0121 Yaw rate sensor. Signal outside its permitted range (B5254T7)
BCM-0123 Body sensor cluster stability sensor (BSC). Internal fault (B5254T7)
BCM-0130 Brake pressure sensor. Signal missing (B5254T7)
BCM-0134 Brake pressure sensor. Incorrect offset value (B5254T7)
BCM-0135 Brake pressure sensor. Signal outside its permitted range (B5254T7)
BCM-0138 Power supply for the body sensor cluster stability sensor (BSC). Faulty
voltage (B5254T7)
BCM-0145 Stability control. Stability control has been active for too long (B5254T7)
BCM-0146 Factory test, dynamic stability and traction control (DSTC). Test cycle
not approved (B5254T7)
BCM-0147 Pedal position sensor. Signal outside its permitted range (B5254T7)
BCM-0148 Communication between control modules. Faulty configuration ID
(B5254T7)
BCM-0150 Stop lamp switch. Signal outside its permitted range
BCM-0150 Stop lamp switch. Signal outside its permitted range (B5254T7)
BCM-0151 Control module. Internal memory fault (B5254T7)
BCM-A030 Communication between control modules. The initialization check has
not been run (B5254T7)
BCM-A031 Communication between control modules. The tolerance check has not
been run (B5254T7)
BCM-A032 Communication between control modules. Stability control has been
active for too long (B5254T7)
BCM-E000 Control module communication. Faulty communication (B5254T7)
BCM-E003 Control module. Faulty configuration (B5254T7)
BCM-XXXX Unknown diagnostic trouble code (DTC) for the current control module
version (B5254T7)

BLUETOOTH PHONE MODULE (BPM) DTCS


2012 Volvo C30 T-5
General Information DTC Index

BLUETOOTH PHONE MODULE (BPM) - DTC INDEX


Volvo Code Description
BPM-1101 Control module Configuration fault
BPM-1102 Control module Internal fault
BPM-1103 Control module Internal fault
BPM-1105 Control module Configuration fault
BPM-1106 Control module Overheated
BPM-1301 Microphone input. Signal too low
BPM-1401 Control module Internal fault
BPM-B100 Control module Configuration fault
BPM-B101 Control module Configuration fault
BPM-E010 Battery voltage Faulty signal

CLIMATE CONTROL MODULE (CCM) DTCS


CLIMATE CONTROL MODULE (CCM) - DTC INDEX
Volvo Code Description
CCM-0001 Configuration fault. Non-approved value
CCM-0002 Evaporator temperature sensor. Signal too high or signal missing
CCM-0003 Evaporator temperature sensor. Signal too low
CCM-0004 Passenger compartment temperature sensor. Signal too high or signal
missing
CCM-0005 Passenger compartment temperature sensor. Signal too low
CCM-0006 Blower fan motor passenger compartment temperature sensor. Signal too
high or signal missing
CCM-0008 Blower fan motor passenger compartment temperature sensor. Signal too
low
CCM-0009 Blower fan motor passenger compartment temperature sensor. Blocked
CCM-0011 Control module. Internal fault
CCM-0012 Climate control module. Internal fault
CCM-0020 Function button. Activated too long
CCM-0021 Tunnel Control Switch Activated too long
CCM-0030 Left heater pad. Faulty signal
CCM-0031 Sensor left-hand seat heater. Faulty signal
CCM-0032 Left-hand seat heater. Internal fault
CCM-0033 Left-hand seat heater. Internal fault
CCM-0034 Right heater pad. Faulty signal
CCM-0035 Sensor right-hand seat heater. Faulty signal
CCM-0036 Right-hand seat heater. Internal fault
CCM-0037 Right-hand seat heater. Internal fault
CCM-0040 Air quality sensor. Internal fault
2012 Volvo C30 T-5
General Information DTC Index

CCM-0060 Damper motor defroster. Faulty signal


CCM-0061 Recirculation damper motor. Faulty signal
CCM-0062 Left temperature damper motor. Faulty signal
CCM-0063 Right temperature damper motor. Faulty signal
CCM-0064 Air distribution damper motor. Faulty signal (L.H.D)
CCM-006A Tunnel Control Switch 1 Internal Fault
CCM-006B Tunnel Control Switch 2 Internal Fault
CCM-0070 Configuration fault. Faulty identification (L.H.D)
CCM-0071 Damper motor. Faulty position
CCM-0071 Damper motor. Faulty position (L.H.D)
CCM-0072 Damper motor. Initiation fault
CCM-0073 Configuration fault. Calibration not done
CCM-0074 Damper motor, defroster. Internal fault
CCM-0075 Damper motor. Internal fault
CCM-0076 Damper motor, temperature left. Internal fault
CCM-0077 Damper motor, temperature right. Internal fault
CCM-0078 Damper motor distribution. Internal fault
CCM-0090 Lower switch. Faulty ID
CCM-0091 Lower switch. ID missing
CCM-DD00 LIN bus 1. Incorrect data
CCM-DD01 LIN bus 1. Signal too high/Signal too low
CCM-DD02 LIN bus 1. Incorrect check sum (L.H.D)
CCM-DD12 Left seat heater. No communication
CCM-DD15 Left temperature damper motor. No communication
CCM-DD16 Damper motor air distribution. No communication (L.H.D)
CCM-DD18 Tunnel Control Switch 1 No Communication
CCM-DD19 Tunnel Control Switch 2 No Communication
CCM-DD20 LIN bus 2. Incorrect data
CCM-DD21 LIN bus 2. Signal too high/Signal too low
CCM-DD22 LIN bus 2. Incorrect check sum (L.H.D)
CCM-DD30 Right-hand seat heater. No communication
CCM-DD31 Recirculation damper motor. No communication (L.H.D)
CCM-DD32 Right temperature damper motor. No communication
CCM-DD33 Damper motor defroster. No communication
CCM-DD34 Air quality sensor (AQS). No communication (L.H.D)
CCM-E001 Control module communication. Internal fault
CCM-E003 Configuration fault. Software fault
CCM-E010 Power supply. Faulty signal
CCM-XXXX Unknown diagnostic trouble code (DTC) for the current control module
version
2012 Volvo C30 T-5
General Information DTC Index

CENTRAL ELECTRONIC MODULE (CEM) DTCS


CENTRAL ELECTRONIC MODULE (CEM) - DTC INDEX
Volvo Code Description
CEM-1011 Control module, memory fault. Internal fault
CEM-1012 Control module, memory fault. Internal fault
CEM-101A Control module, memory fault. Internal fault
CEM-101B Control module, memory fault. Internal fault
CEM-1201 Control module. Configuration fault
CEM-1A21 Engine control module (ECM). Signal too low
CEM-1A22 Engine control module (ECM). Signal too high
CEM-1A40 50-power supply. Activated too long
CEM-1A41 Ignition switch. Faulty signal
CEM-1A42 Real time clock. Faulty signal
CEM-1B01 Main Battery Diode, General electrical failure
CEM-1B02 Main Battery Relay, General electrical failure
CEM-1B03 Main Battery Diode Or Relay, General electrical failure
CEM-1C04 30-power supply. Signal too high
CEM-1C10 Control module. Configuration fault
CEM-1D08 Control module. Internal fault
CEM-1D09 Control module. Internal fault
CEM-2E01 Relay, horn Signal too low
CEM-2E02 Relay, horn Signal too high
CEM-2E03 Comfort Relay, Signal too low
CEM-2E04 Comfort Relay, Signal too high
CEM-2F60 Twilight sensor. Signal too high
CEM-2F61 Twilight sensor. Signal too low
CEM-3A00 ECM software. Faulty signal
CEM-3A04 Fuel pump (FP). Signal too high
CEM-3A05 Fuel pump (FP). Signal too low
CEM-3A07 Fuel pump (FP). Faulty signal
CEM-3A08 Fuel pump (FP). Signal too high
CEM-3F01 Clutch pedal sensor. Signal too low
CEM-3F02 Clutch pedal sensor. Faulty signal
CEM-3F03 Clutch pedal sensor. Signal too high (B5254T7, M66)
CEM-3F0A Reverse gear inhibit. Faulty signal (M66)
CEM-3F0B Reverse gear inhibit. Signal too low (M66)
CEM-3F41 Supply pedal sensor. Signal too low
CEM-3F42 Supply pedal sensor. Signal too high
CEM-3F92 Accelerator pedal (AP) position sensor. Signal too high
CEM-3F93 Accelerator pedal (AP) position sensor. Signal too low
2012 Volvo C30 T-5
General Information DTC Index

CEM-4A33 Fuel level sensor. Faulty signal (B5254T7)


CEM-4A34 Fuel level sensor. Signal too low (B5254T7)
CEM-4C01 Outside temperature sensor. Signal too high
CEM-4C02 Outside temperature sensor. Signal too low
CEM-4E24 Malfunction indicator lamp (MIL). Faulty signal
CEM-4E25 Malfunction indicator lamp (MIL). Signal too high
CEM-4F30 Battery temperature. Signal too high
CEM-4F31 Battery temperature. Signal too low
CEM-4F32 Battery temperature. Faulty signal
CEM-4F33 Battery Temperature Faulty Signal
CEM-4F40 Seat belt buckle, right rear seat. Signal too low
CEM-4F41 Seat belt buckle, right rear seat. Signal too high
CEM-4F42 Seat belt buckle, rear right-hand. Faulty signal
CEM-4F44 Seat belt buckle, rear center. Signal too low
CEM-4F45 Seat belt buckle, rear center. Signal too high
CEM-4F46 Seat belt buckle, rear center. Faulty signal
CEM-4F48 Seat belt buckle, rear left-hand. Signal too low
CEM-4F49 Seat belt buckle, rear left-hand. Signal too high
CEM-4F4A Seat belt buckle, rear left-hand. Faulty signal
CEM-4F81 Lamp, seat belt reminder. Signal too low
CEM-4F82 Lamp, seat belt reminder. Faulty signal
CEM-5A10 Blower fan motor. Blocked
CEM-5A10 Blower fan motor. Blocked (B5254T7, L.H.D)
CEM-5A12 Blower fan motor. Over heated
CEM-5A12 Blower fan motor. Over heated (B5254T7, L.H.D)
CEM-5A13 Blower fan motor. Voltage too high
CEM-5A13 Blower fan motor. Voltage too high (B5254T7, L.H.D)
CEM-5A15 Blower fan motor. Current too high
CEM-5A15 Blower fan motor. Current too high (B5254T7, L.H.D)
CEM-5A17 Blower fan motor Signal too high/Signal missing
CEM-5E01 Sun sensor. Faulty signal
CEM-5E02 Sun sensor. Signal too low
CEM-5E03 Sun sensor Signal too high
CEM-5E04 Sun sensor Signal too low
CEM-6C05 Central locking driver's door. No locking
CEM-6C06 Central locking passenger door. No locking
CEM-6C13 Deadlock, driver's door. No locking
CEM-6C14 Deadlock, passenger door. No locking
CEM-6C28 Alarm LED. Faulty signal
CEM-6C29 Alarm LED. Signal too low
CEM-6C31 Siren. Internal fault
2012 Volvo C30 T-5
General Information DTC Index

Movement sensor. Signal missing


CEM-6C33 Movement sensor. Signal missing
CEM-6C34 Switch reduced alarm. Activated too long
CEM-6C3A Glass break wire. Signal too high
CEM-6C3B Glass break wire manipulation protection
CEM-6C41 Start control module (SCU). Incorrect key ID
CEM-6C42 Start control module (SCU). Signal missing
CEM-6C43 Start control module (SCU). Faulty signal
CEM-6C54 Engine control module (ECM) communication. Incorrect value
CEM-6C55 KVM communication. Faulty value
CEM-6C57 Phone module (PHM) not valid. Faulty signal
CEM-6F10 Sun roof. Signal too high
CEM-6F11 Sun roof. Faulty signal
CEM-6F12 Sun roof. Faulty signal
CEM-6F13 Sun roof. Signal too high
CEM-6F51 Tailgate handle. Faulty signal
CEM-6F52 Tailgate handle. Signal too low
CEM-6F53 Tailgate handle. Activated too long
CEM-6F83 Dimmer Faulty signal
CEM-6F84 Fuel Flap Driver Faulty Signal
CEM-6F85 Dimmer. Signal too low
CEM-6F86 Fuel tank filler cap. Signal too low
CEM-6F87 Fuel tank filler cap. Activated too long
CEM-8A02 Relay, high beam. Internal fault
CEM-8A03 Relay, high beam. Internal fault
CEM-8A04 LED Light Switch, Automatic Bending Light Signal too High
CEM-8A05 LED Light Switch, Automatic Bending Light Faulty Signal
CEM-8A08 Low beam right. Signal too low
CEM-8A09 Low beam right. Faulty signal
CEM-8A11 Low beam left. Signal too low
CEM-8A12 Low beam left. Faulty signal
CEM-8B02 Left parking lamps. Signal too low
CEM-8B03 Left parking lamps. Faulty signal
CEM-8B05 Right parking lamps. Faulty signal
CEM-8B06 Right parking lamps. Signal too low
CEM-8B08 Light switch module (LSM). Signal too low
CEM-8B09 Light switch module (LSM). Faulty signal
CEM-8C10 Relay, front fog lamps. Signal too high
CEM-8C11 Relay, front fog lamps. Faulty signal
CEM-8C20 Rear fog lamp. Faulty signal
CEM-8C21 Rear fog lamp. Signal too low
2012 Volvo C30 T-5
General Information DTC Index

Stop lamp switch. Comparison fault


CEM-8D03 High level stop lamp. Signal too high
CEM-8D04 High level stop lamp. Signal too low
CEM-8D05 Right-hand stop lamp. Signal too low
CEM-8D06 Right-hand stop lamp. Faulty signal
CEM-8D07 Left-hand stop lamp. Signal too low
CEM-8D08 Left-hand stop lamp. Faulty signal
CEM-8D09 Brake lamp left. Faulty signal
CEM-8D0A Brake lamp left. Faulty signal
CEM-8D10 Brake light switch Compare error
CEM-8F01 Switch, hazard warning signal flashers. Faulty signal
CEM-8F02 Switch, hazard warning signal flashers. Signal too low
CEM-8F21 Wiper motor module (WMM). Internal fault
CEM-8F22 Wiper motor module (WMM). Voltage too low
CEM-8F23 Wiper motor module (WMM). Voltage too high
CEM-8F24 Wiper motor module (WMM). Jammed
CEM-8F26 Relay, front windshield washer motor. Internal fault
CEM-8F27 Relay, front windshield washer motor. Internal fault
CEM-8F28 Tailgate washer motor relay. Internal fault
CEM-8F29 Tailgate washer motor relay. Internal fault
CEM-8F30 Relay, headlamp wash/wipe. Faulty signal
CEM-8F31 Relay, headlamp wash/wipe. Signal too high
CEM-8F33 Right-hand turn signal lamp. Faulty signal
CEM-8F34 Right-hand turn signal lamp. Signal too low
CEM-8F37 Left-hand turn signal lamp. Faulty signal
CEM-8F38 Left-hand turn signal lamp. Signal too low
CEM-8F61 Relay, heated rear windshield. Faulty signal
CEM-8F62 Relay, heated rear windshield. Signal too high
CEM-8FA2 Relay, horn. Activated too long
CEM-8FB1 Rain sensor module (RSM). Internal fault
CEM-8FB2 Rain sensor module (RSM). Faulty function
CEM-9A01 Interior lighting. Signal too high
CEM-9A02 Interior lighting. Signal too low
CEM-9D01 Communication with RRX control module. Comminicational problems
CEM-9F31 Dimmer. Signal too high
CEM-9F32 Dimmer. Faulty signal
CEM-9F33 Brake fluid level too low
CEM-AFE0 TPMS Default Values in Local Configuration
CEM-AFE1 TPMS Incorrect Configuration
CEM-AFF1 Localization failed
CEM-AFF2 Tire pressurement sensor. Faulty signal
2012 Volvo C30 T-5
General Information DTC Index

Tire pressurement sensor. Signal missing


CEM-AFFE Missing tire pressure sensor Signal missing
CEM-CFF0 MMS Communication Faulty Signal
CEM-DD00 LIN-bus 2. Communication fault
CEM-DD00 LIN-bus 3. Communication fault
CEM-DD01 LIN-bus 2. Communication missing
CEM-DD01 LIN-bus 3. Communication missing
CEM-DD02 LIN-bus 2. Communication fault
CEM-DD02 LIN-bus 3. Communication fault
CEM-DD03 LIN-bus 14 Communication fault
CEM-DD04 LIN-bus 14 Communication missing
CEM-DD05 LIN-bus 14 Communication fault
CEM-DD06 Communication with Battery Monitoring Sensor (BMS) Signal missing
CEM-DD07 Battery Monitoring Sensor (BMS) faulty hardware
CEM-DD0A LIN-bus 3. Communication fault
CEM-DD0B LIN-bus 3. Communication missing
CEM-DD0C LIN-bus 3. Communication fault
CEM-DD11 Communication with SCU control module. Signal missing
CEM-DD12 Communication with the left-hand gas discharge lamp module (GDL).
Signal missing
CEM-DD13 Communication with the right-hand gas discharge lamp module (GDL).
Signal missing
CEM-DD1A Communication with RRX control module. Signal missing
CEM-DD1B Communication with SCM control module. Signal missing
CEM-DD1C Communication with SCM control module Faulty signal
CEM-DD21 LIN bus 9. No communication
CEM-DD22 LIN bus 9. Communication fault
CEM-DD30 Communication with the wiper motor module (WMM). Signal missing
CEM-DD31 Communication with the rain sensor module (RSM). Signal missing
CEM-DD32 Communication with Humidity Sensor (HUS) Signal Missing
CEM-DD40 Humidity Sensor (HUS) Internal Fault
CEM-DE01 Communication with the brake control module (BCM). Signal missing
CEM-DE11 Communication with ECM control module. Signal missing
CEM-DE11 Communication with ECM control module. Signal missing (B5254T7)
CEM-DE18 Communication with the combustion preheater module (CPM). Signal
missing
CEM-DE1A Communication with DEM control module. Signal missing
CEM-DE23 Communication with the trailer module (TRM). Signal missing
CEM-DE29 Communication with the climate control module (CCM). Signal missing
CEM-DE2D Communication with KVM control module. Signal missing
CEM-DE2E Communication with the power seat module (PSM). Signal missing
2012 Volvo C30 T-5
General Information DTC Index

CEM-DE30 Communication with the electric power steering module (EPS). Signal
missing
CEM-DE43 Communication with the driver door module (DDM). Signal missing
CEM-DE45 Communication with the passenger door module (PDM). Signal missing
CEM-DE49 Communication with the steering wheel module (SWM). Signal missing
CEM-DE51 Communication with the driver information module (DIM). Signal
missing
CEM-DE52 Communication with the Accessory Electronic Module (AEM). Signal
missing
CEM-DE54 Communication with the infotainment control module (ICM). Signal
missing
CEM-DE58 Communication with the supplemental restraint system module (SRS).
Signal missing
CEM-DE63 communication with the parking assistance module (PAM). Signal
missing
CEM-DE64 Communication with the phone module (PHM). Signal missing
CEM-DE6E Communication with the transmission control module (TCM). Signal
missing
CEM-DE70 Communication with Headlamp Control Module (HCM) Signal Missing
CEM-DF01 CAN-H, low speed network. Signal missing
CEM-DF03 CAN-H, low speed network. Signal too high
CEM-DF04 CAN-L, low speed network. Signal too low
CEM-DF05 CAN-H, low speed network. Signal too low
CEM-DF06 CAN-L, low speed network. Signal too high
CEM-DF07 CAN-L, low speed network. Faulty signal
CEM-DF11 CAN-H, high speed network. Signal missing
CEM-DF13 CAN-H, high speed network. Signal too high
CEM-DF14 CAN-L, high speed network. Signal too low
CEM-DF15 CAN-H, high speed network. Signal too low
CEM-DF16 CAN-L, high speed network. Signal too high
CEM-DF17 CAN-L, high speed network. Faulty signal
CEM-E000 Communication with control module. Faulty communication
CEM-E001 Communication with control module. Faulty communication
CEM-E00A Communication with control module. Faulty communication
CEM-XXXX (A) Unknown diagnostic trouble code (DTC) for the current control
module version
CEM-XXXX (B) Unknown diagnostic trouble code (DTC) for the current control
module version

COMBUSTION PREHEATER MODULE (CPM) DTCS


COMBUSTION PREHEATER MODULE (CPM) - DTC INDEX
2012 Volvo C30 T-5
General Information DTC Index

Volvo Code Description


CPM-0018 Glow plugs. Signal too high
CPM-0102 Glow plugs. Signal too low
CPM-0204 Glow plugs. Signal missing
CPM-0318 Fuel pump. Signal too high
CPM-0402 Fuel pump. Signal too low
CPM-0504 Fuel pump. Signal missing
CPM-1001 Combustion fan. Signal too high
CPM-1128 Combustion fan. Signal too low
CPM-1204 Combustion fan. Signal missing
CPM-1308 Combustion fan. Faulty function
CPM-1418 Water pump. Signal too high
CPM-1502 Water pump. Signal too low
CPM-1604 Water pump. Signal missing
CPM-2308 Control module. Internal fault
CPM-3002 Engine coolant temperature (ECT) sensor. Signal too low
CPM-3141 Engine coolant temperature (ECT) sensor. Signal too high/Signal missing
CPM-3202 Overheat protection thermostat. Signal too low
CPM-3341 Overheat protection thermostat. Signal too high/Signal missing
CPM-3402 Flame sensor. Signal too low
CPM-3541 Flame sensor. Signal too high/Signal missing
CPM-3601 Control module. Supply voltage too high
CPM-3702 Control module. Supply voltage too low
CPM-4001 Engine coolant heater. Activated too long
CPM-4101 Engine coolant heater. Too many unsuccessful attempts
CPM-4208 Engine coolant heater. Extinguished flame
CPM-4308 Engine coolant heater. Extinguished flame
CPM-4501 Combustion fan. Activated too long
CPM-5001 Control module. Over heated
CPM-5101 Control module. Over heated
CPM-5201 Control module. Over heated
CPM-5301 Control module. Over heated
CPM-5401 Control module. Internal fault
CPM-5601 Control module. Internal fault
CPM-5701 Control module. Collision signal received
CPM-6008 Control module. Internal fault
CPM-6108 Control module. Internal fault
CPM-6208 Control module. Internal fault
CPM-6301 Control module. Internal fault
CPM-6408 Control module. Internal fault
CPM-6508 Control module. Internal fault
2012 Volvo C30 T-5
General Information DTC Index

Control module. Internal fault


CPM-8704 Control module. Internal fault
CPM-E001 Control module communication. Faulty communication
CPM-E003 Configuration fault. Faulty configuration
CPM-E010 Control module. Supply voltage too low
CPM-XXXX Unknown diagnostic trouble code (DTC) for the current control module
version

DRIVER DOOR MODULE (DDM) DTCS


DRIVER DOOR MODULE (DDM) - DTC INDEX
Volvo Code Description
DDM-0012 Control, driver's window. Stuck in the active position
DDM-0013 Control, passenger window. Stuck in the active position
DDM-0020 Control, door mirror. Stuck in the active position
DDM-0022 Control, door mirror selector. Stuck in the active position
DDM-0024 Central locking switch. Faulty signal
DDM-0025 LED, camera module Signal too low
DDM-0026 LED, camera module Signal too high
DDM-0027 LED, camera module Open circuit
DDM-002B Camera module Internal failure
DDM-002F Camera module voltage supply Signal too low
DDM-003A Camera module voltage supply Signal too high
DDM-6E01 Mirror motor. Shorted to supply
DDM-6E02 Mirror motor. Ground (GND) short
DDM-6E03 Mirror motor. Open circuit
DDM-6E04 Mirror motor. Shorted to supply
DDM-6E05 Mirror motor. Ground (GND) short
DDM-6E06 Mirror motor. Open circuit
DDM-6E07 Mirror motor. Shorted to supply
DDM-6E08 Mirror motor. Ground (GND) short
DDM-6E09 Mirror motor. Open circuit
DDM-8002 Mirror heater. Ground (GND) short
DDM-8003 Mirror heater. Shorted to supply
DDM-8021 Side turn indicator. Ground (GND) short
DDM-8022 Side turn indicator. Open circuit
DDM-DD11 Communication with switch pack Internal Fault
DDM-DD20 LIN communication camera module Internal fault
DDM-DD21 LIN communication camera module Shorted
DDM-DD22 LIN communication camera module Internal fault
DDM-DD30 Communication with camera module Internal Fault
2012 Volvo C30 T-5
General Information DTC Index

DDM-E001 Control module communication. Faulty communication


DDM-XXXX Unknown diagnostic trouble code (DTC) for the current control module
version

DRIVER DOOR MODULE/PASSENGER DOOR MODULE (DDM/PDM) DTCS


DRIVER DOOR MODULE/PASSENGER DOOR MODULE (DDM/PDM) DTCS - DIAGNOSTIC
TROUBLE CODE (DTC) INDEX
Volvo Code Description
DDM/PDM-0002 Central Locking Button. Stuck In The Active Position
DDM/PDM-0003 Central Locking Button, Unlocking. Stuck In The Active
Position
DDM/PDM-0010 Control Panel. Open-Circuit
DDM/PDM-1000 Control Module. Internal Fault
DDM/PDM-6C02 Central Locking Motor M1. Stuck In The Active Position
DDM/PDM-6C03 Central Locking Motor M1. Stuck In The Inactive Position
DDM/PDM-6C05 Central Locking Motor M2. Stuck In The Active Position
DDM/PDM-6C06 Central Locking Motor M2. Stuck In The Inactive Position
DDM/PDM-6C08 Central Locking Motor M3. Stuck In The Active Position
DDM/PDM-6C09 Central Locking Motor M3. Stuck In The Inactive Position
DDM/PDM-6D01 Power Window Mechanism. Internal Fault
DDM/PDM-6D02 Power Window Up Relay. Stuck In The Active Position
DDM/PDM-6D03 Power Window Up Relay. Stuck In The Inactive Position
DDM/PDM-6D04 Power Window Down Relay. Stuck In The Active Position
DDM/PDM-6D05 Power Window Down Relay. Stuck In The Inactive Position
DDM/PDM-6D0C Control Module. Internal Fault
DDM/PDM-6D0D Control Module. Internal Fault
DDM/PDM-6E0A Mirror Motor. Short-Circuit To Supply Voltage
DDM/PDM-6E0B Mirror Motor. Short-Circuit To Ground
DDM/PDM-6E0C Mirror Motor. Open-Circuit
DDM/PDM-6E41 Position Sensor, Mirror. Short-Circuit To Supply Voltage/Open-
Circuit
DDM/PDM-6E42 Position Sensor, Mirror. Short-Circuit To Ground
DDM/PDM-6E43 Position Sensor, Mirror. Short-Circuit To Supply Voltage/Open-
Circuit
DDM/PDM-6E44 Position Sensor, Mirror. Short-Circuit To Ground
DDM/PDM-6E45 Power Supply. Open-Circuit
DDM/PDM-8010 Mirror Lamp. Short-Circuit To Supply Voltage
DDM/PDM-8011 Mirror Lamp. Short-Circuit To Ground
DDM/PDM-8012 Mirror Lamp. Open-Circuit
DDM/PDM-E003 Configuration Fault. Faulty Communication
2012 Volvo C30 T-5
General Information DTC Index

DDM/PDM-E010 Control Module. Internal Fault

DRIVER INFORMATION MODULE (DIM) DTCS


DRIVER INFORMATION MODULE (DIM) - DTC INDEX
Volvo Code Description
DIM-0001 Mileage. Manipulated
DIM-0002 ABS warning lamp. Faulty circuit
DIM-0003 SRS warning lamp. Faulty circuit
DIM-0005 Red warning lamp. Faulty circuit
DIM-0006 Information lamp. Faulty circuit
DIM-0008 Fuel level sensor. Jammed
DIM-0009 Fuel ejector. Internal fault
DIM-000C Control module. Internal fault
DIM-E001 Control module communication. Faulty communication
DIM-E003 Software fault. Faulty communication
DIM-XXXX Unknown diagnostic trouble code (DTC) for the current control module
version

ENGINE CONTROL MODULE (ECM) DTCS - B5254T7


ENGINE CONTROL MODULE (ECM) - DTC INDEX
DTC Volvo Code Description
P2229 ECM-112C Atmospheric pressure sensor. Signal too high
P2228 ECM-112D Atmospheric pressure sensor. Signal too low
P2227 ECM-1130 Atmospheric pressure sensor. Faulty signal
P2227 ECM-113B Atmospheric pressure sensor. Signal missing
P2227 ECM-113C Atmospheric pressure sensor. Signal too high
P2227 ECM-113D Atmospheric pressure sensor. Signal too low
P0103 ECM-122C Mass air flow (MAF) sensor. Flow too high
P0102 ECM-122D Mass air flow (MAF) sensor. Flow too low
P0101 ECM-1230 Air mass. Signal too low
P0101 ECM-123B Air mass. Signal too high
P0101 ECM-123C Air mass. Signal too high
P0101 ECM-123D Air mass. Signal too low
P0238 ECM-125C Boost pressure sensor. Signal too high
P0237 ECM-125D Boost pressure sensor. Signal too low
P0236 ECM-1260 Boost pressure sensor. Signal too high
P0236 ECM-126B Boost pressure sensor. Signal too low
P0236 ECM-126C Boost pressure sensor. Signal too high
P0236 ECM-126D Boost pressure sensor. Signal too low
2012 Volvo C30 T-5
General Information DTC Index

P0113 ECM-131C Intake air temperature (IAT) sensor. Signal too high
P0112 ECM-131D Intake air temperature (IAT) sensor. Signal too low
P0110 ECM-1320 Intake Air Temperature (IAT) Sensor. Faulty signal
- ECM-132C Intake air temperature (IAT) sensor. Signal too high
P0111 ECM-133C Intake air temperature (IAT) sensor inlet. Signal too
high
P0111 ECM-133D Intake air temperature (IAT) sensor inlet. Signal too
low
- ECM-1410 Outside temperature sensor. Signal missing
- ECM-141B Outside temperature sensor. Signal missing
- ECM-142B Outside temperature sensor. Signal missing
- ECM-142C Outside temperature sensor. Signal too high
- ECM-142D Outside temperature sensor. Signal too low
- ECM-143C Outside temperature sensor. Signal too high
- ECM-143D Outside temperature sensor. Signal too low
P0201 ECM-200B Injector cyl 1. Signal missing
- ECM-200C Injector cyl 1. Signal too high
- ECM-200D Injector cyl 1. Signal too low
P2177 ECM-21AC Long-term fuel trim load, bank1. Upper limit
P2178 ECM-21AD Long-term fuel trim load, bank1. Lower limit
P2187 ECM-21CC Long-term fuel trim, idling, bank 1. Upper limit
P2188 ECM-21CD Long-term fuel trim, idling, bank 1. Lower limit
P0141 ECM-2200 Rear heated oxygen sensor (HO2S), bank 1, heating.
Faulty signal
P0140 ECM-221B Rear heated oxygen sensor (HO2S) ageing, bank 1.
Signal missing
P0140 ECM-221C Rear heated oxygen sensor (HO2S) ageing, bank 1.
Signal too high
P0140 ECM-221D Rear heated oxygen sensor (HO2S) ageing, bank 1.
Signal too low
P2232 ECM-2220 Rear heated oxygen sensor (HO2S), bank 1. Faulty
signal
P0136 ECM-222B Rear heated oxygen sensor (HO2S), bank 1. Signal
missing
P0138 ECM-222C Rear heated oxygen sensor (HO2S), bank 1. Signal
too high
P0137 ECM-222D Rear heated oxygen sensor (HO2S), bank 1. Signal
too low
P0036 ECM-223B Rear heated oxygen sensor (HO2S), bank 1. Signal
missing
P0038 ECM-223C Rear heated oxygen sensor (HO2S), bank 1. Signal
too high
2012 Volvo C30 T-5
General Information DTC Index

P0037 ECM-223D Rear heated oxygen sensor (HO2S), bank 1. Signal


too low
P0136 ECM-2250 Rear heated oxygen sensor (HO2S), bank 1
- ECM-2400 Front heated oxygen sensor (HO2S), bank 1, heating.
Faulty signal
P0053 ECM-240B Front heated oxygen sensor (HO2S), bank 1, heating.
Signal missing
P0053 ECM-240C Front heated oxygen sensor (HO2S), bank 1, heating.
Signal too high
P0133 ECM-242D Front heated oxygen sensor (HO2S), bank 1. Slow
regulation
- ECM-243B Front heated oxygen sensor (HO2S), bank 1. Signal
missing
P0135 ECM-243C Front heated oxygen sensor (HO2S). Signal too high
P0030 ECM-244B Front heated oxygen sensor (HO2S), bank 1, heating.
Signal missing
P0032 ECM-244C Front heated oxygen sensor (HO2S), bank 1, heating.
Signal too high
P0031 ECM-244D Front heated oxygen sensor (HO2S), bank 1, heating.
Signal too low
P1646 ECM-2450 Front heated oxygen sensor (HO2S), bank 1. Faulty
signal
P1646 ECM-245B Front heated oxygen sensor (HO2S), bank 1. Signal
missing
P1646 ECM-245C Front heated oxygen sensor (HO2S), bank 1. Signal
too high
P1646 ECM-245D Front heated oxygen sensor (HO2S), bank 1. Signal
too low
P2626 ECM-246B Front heated oxygen sensor (HO2S), bank 1. Signal
missing
P2238 ECM-2470 Front heated oxygen sensor (HO2S), bank 1. Faulty
signal
P2237 ECM-247B Front heated oxygen sensor (HO2S), bank 1. Signal
missing
P2239 ECM-247C Front heated oxygen sensor (HO2S), bank 1. Signal
too high
P0132 ECM-248C Front heated oxygen sensor (HO2S), bank 1. Signal
too high
P0133 ECM-248D Front heated oxygen sensor (HO2S), bank 1. Signal
too low
P2243 ECM-249B Front heated oxygen sensor (HO2S), bank 1. Signal
missing
P2251 ECM-24AB Front heated oxygen sensor (HO2S), bank 1. Signal
missing
2012 Volvo C30 T-5
General Information DTC Index

P2195 ECM-24C0 Front heated oxygen sensor (HO2S), bank 1. Faulty


signal
P2196 ECM-24CB Front heated oxygen sensor (HO2S), bank 1. Signal
missing
P2195 ECM-24CC Front heated oxygen sensor (HO2S), bank 1. Signal
too high
P2097 ECM-24CD Front heated oxygen sensor (HO2S), bank 1. Signal
too low
P2414 ECM-24D0 Front heated oxygen sensor (HO2S), bank 1. Faulty
signal
P013E ECM-24EB Rear heated oxygen sensor (HO2S). Slow regulation
P013A ECM-24EC Rear heated oxygen sensor (HO2S). Slow regulation
P0118 ECM-273C Engine coolant temperature (ECT) sensor. Signal too
high
P0117 ECM-273D Engine coolant temperature (ECT) sensor. Signal too
low
P0116 ECM-2740 Engine coolant temperature (ECT) sensor. Faulty
signal
P0116 ECM-274C Engine coolant temperature (ECT) sensor. Signal too
high
P0116 ECM-274D Engine coolant temperature (ECT) sensor. Signal too
low
P0116 ECM-275C Engine coolant temperature (ECT) sensor. Signal too
high
P0116 ECM-275D Engine coolant temperature (ECT) sensor. Signal too
low
P0191 ECM-2800 Fuel pressure sensor. Faulty signal
P0190 ECM-280B Fuel pressure sensor. Signal missing
P0193 ECM-280C Fuel pressure sensor. Signal too high
P0192 ECM-280D Fuel pressure sensor. Signal too low
P0230 ECM-281C Text message. Pressure too high
P0089 ECM-2900 Fuel pressure. Faulty signal
P0090 ECM-290B Fuel pressure. Signal missing
P0088 ECM-290C Fuel pressure. Signal too high
P0087 ECM-290D Fuel pressure. Signal too low
P0627 ECM-291B Fuel pump control module. Signal missing
P0629 ECM-291C Fuel pump control module. Signal too high
P0628 ECM-291D Fuel pump control module. Signal too low
- ECM-2A00 Fuel temperature sensor. Faulty signal
- ECM-2A0B Fuel temperature sensor. Signal missing
P0183 ECM-2A0C Fuel temperature sensor. Signal too high
P0182 ECM-2A0D Fuel temperature sensor. Signal too low
2012 Volvo C30 T-5
General Information DTC Index

P0181 ECM-2A10 Fuel temperature sensor. Signal too high


- ECM-2A1B Fuel temperature sensor. Signal too low
P0181 ECM-2A1C Fuel temperature sensor. Signal too high
P0181 ECM-2A1D Fuel temperature sensor. Signal too low
P0128 ECM-2B00 Thermostat. Faulty signal
P0328 ECM-303C Front knock sensor (KS). Signal too high
P0327 ECM-303D Front knock sensor (KS). Signal too low
P0333 ECM-304C Rear knock sensor (KS). Signal too high
P0332 ECM-304D Rear knock sensor (KS). Signal too low
P0324 ECM-3050 Knock control. Internal fault
P0324 ECM-3060 Knock control. Internal fault
- ECM-3100 Misfire, at least one cylinder. Start up
P0300 ECM-310C Misfire, at least one cylinder. Catalytic converter
damage
P0300 ECM-310D Misfire, at least one cylinder. Affects emissions
P0301 ECM-3110 Misfire cylinder 1. Start up
P0301 ECM-311C Misfire cylinder 1. Catalytic converter damage
P0301 ECM-311D Misfire cylinder 1. Emissions impact
P0728 ECM-3300 Engine speed (RPM) sensor. Signal missing
P0727 ECM-330B Engine speed (RPM) sensor. Signal missing
P0344 ECM-3400 Camshaft position (CMP) sensor, intake. Faulty
signal
P0340 ECM-340B Camshaft position (CMP) sensor, intake. Signal
missing
P0343 ECM-340C Camshaft position sensor, intake. Signal too high
P0342 ECM-340D Camshaft position sensor, intake. Signal too low
P0369 ECM-3410 Camshaft position (CMP) sensor, exhaust. Faulty
signal
P0365 ECM-341B Camshaft position (CMP) sensor, exhaust. Signal
missing
P0368 ECM-341C Camshaft position sensor, exhaust. Signal too high
P0367 ECM-341D Camshaft position sensor, exhaust. Signal too low
P2614 ECM-342B Camshaft position (CMP) sensor. Signal missing
P0351 ECM-360B Ignition coil cylinder 1. Signal missing
P2301 ECM-360C Ignition coil cylinder 1. Signal too high
P2300 ECM-360D Ignition coil cylinder 1. Signal too low
P050B ECM-365C Ignition timing control during cold start
P0420 ECM-400D Three-way catalytic converter (TWC) efficiency,
bank 1. Signal too low
P0496 ECM-420C Evaporative emission system (EVAP) valve. Open
P0497 ECM-420D Evaporative emission system (EVAP). Closed
2012 Volvo C30 T-5
General Information DTC Index

P0443 ECM-421B Canister purge (CP) valve. Signal missing


P0444 ECM-421C Evaporative emission system (EVAP) valve. Signal
too high
P0445 ECM-421D Evaporative emission system (EVAP) valve. Signal
too low
P0457 ECM-430C Fuel tank system, leakage. Fuel tank filler cap
missing
P240A ECM-431B Leak diagnostic unit, preheating. Signal missing
P240C ECM-431C Leak diagnostic unit, preheating. Signal too high
P240B ECM-431D Leak diagnostic unit, preheating. Signal too low
- ECM-432B Leak diagnostic unit, valve. Signal missing
P2420 ECM-432C Leak diagnostic unit, preheating. Signal too high
P2419 ECM-432D Leak diagnostic unit, preheating. Signal too low
P2400 ECM-433B Leak diagnostic unit, pump. Signal missing
P2402 ECM-433C Leak diagnostic unit, pump. Signal too high
P2401 ECM-433D Leak diagnostic unit, pump. Signal too low
P0456 ECM-434C Fuel tank system, leakage. Minor leak
P2404 ECM-4360 Leak diagnostic unit. Faulty signal
P2407 ECM-436B Leak diagnostic unit. Signal missing
P2406 ECM-436C Leak diagnostic unit. Signal too high
P2405 ECM-436D Leak diagnostic unit. Signal too low
P0457 ECM-4380 Fuel tank filler cap missing. Faulty signal
P0442 ECM-439C Fuel tank system, leakage. Major leak
- ECM-442B Fuel level sensor. Signal missing
- ECM-442C Fuel level sensor. Signal too high
- ECM-442D Fuel level sensor. Signal too low
- ECM-4430 Fuel level sensor. Faulty signal
P0336 ECM-5000 Engine speed (RPM) sensor signal. Faulty signal
P0335 ECM-500B Engine speed (RPM) sensor signal. Signal missing
P0338 ECM-500C Engine speed (RPM) sensor signal. Signal too high
P0700 ECM-5100 Malfunction indicator lamp (MIL), transmission
control module (TCM). Faulty signal
P0863 ECM-512B Malfunction indicator lamp (MIL) communication.
Signal missing
P0531 ECM-5200 Air conditioning (A/C) pressure sensor. Faulty signal
P0530 ECM-520B Air conditioning (A/C) pressure sensor. Signal
missing
P0533 ECM-520C Air conditioning (A/C) pressure sensor. Signal too
high
P0532 ECM-520D Air conditioning (A/C) pressure sensor. Signal too
low
P0501 ECM-5320 Vehicle speed signal (VSS). Faulty signal
2012 Volvo C30 T-5
General Information DTC Index

P250A ECM-540B Oil quality, level and temp sensor. Signal missing
P250D ECM-540C Oil quality, level and temp sensor. Signal too high
P250C ECM-540D Oil quality, level and temp sensor. Signal too low
P250B ECM-5500 Oil level sensor. Faulty
P0197 ECM-552C Oil temperature sensor. Signal too high
P0198 ECM-552D Oil temperature sensor. Signal too low
P0243 ECM-600B Turbocharger (TC) control valve. Signal missing
P0246 ECM-600C Turbocharger (TC) control valve. Signal too high
P0245 ECM-600D Turbocharger (TC) control valve. Signal too low
P0234 ECM-603C Turbocharger (TC) control system. Signal too high
P0299 ECM-603D Turbocharger (TC) control system. Signal too low
P000A ECM-6110 Camshaft position control, intake. Slow
P000A ECM-611B Camshaft control, intake. Faulty
P0075 ECM-612B Camshaft reset valve, intake. Signal missing
P0077 ECM-612C Camshaft reset valve, intake. Signal too high
P0076 ECM-612D Camshaft reset valve, intake. Signal too low
P000B ECM-6140 Camshaft control, exhaust. Slow
P000B ECM-614B Camshaft control, exhaust. Faulty
P0078 ECM-616B Exhaust camshaft reset valve. Signal missing
P0080 ECM-616C Camshaft reset valve, intake. Signal too high
P0079 ECM-616D Camshaft reset valve, intake. Signal too low
P054A ECM-618C Exhaust camshaft control during cold start
P052A ECM-619C Inlet camshaft control during cold start
P0485 ECM-620B Engine cooling fan control module. Signal missing
P0484 ECM-620C Engine cooling fan (FC) control module. Signal too
high
P0480 ECM-621B Engine cooling fan (FC). Signal missing
P0692 ECM-621C Engine cooling fan (FC). Signal too high
P0691 ECM-621D Engine cooling fan (FC). Signal too low
P0494 ECM-6220 Engine cooling fan (FC). Faulty signal
P0645 ECM-630B A/C relay. Signal missing
P0647 ECM-630C A/C relay. Signal too high
P0646 ECM-630D A/C relay. Signal too low
P2281 ECM-640C Turbocharger (TC) control system. Signal too high
P2281 ECM-640D Turbocharger (TC) control system. Signal too low
P0017 ECM-673C Camshaft position, exhaust. High
P0017 ECM-673D Camshaft position, exhaust. Low
P0016 ECM-674C Camshaft position, intake. High
P0016 ECM-674D Camshaft position, intake. Low
P0669 ECM-700C Engine control module (ECM), internal fault. Signal
too high
2012 Volvo C30 T-5
General Information DTC Index

P0668 ECM-700D Engine control module (ECM), internal fault. Signal


too low
P0634 ECM-7010 Engine control module (ECM), temperature. Faulty
signal
P0634 ECM-7020 Engine control module (ECM), temperature. Faulty
signal
P0634 ECM-7100 Immobilizer communication. Faulty signal
U0167 ECM-710B Immobilizer communication. Signal missing
P0633 ECM-710C Immobilizer Communication. Signal too high
U0326 ECM-710D Immobilizer Communication. Signal too low
U0415 ECM-7110 Immobilizer. Faulty signal
U0129 ECM-711B Immobilizer. Signal missing
U0415 ECM-711C Immobilizer. Signal too high
P0607 ECM-7300 Gear position sensor. Faulty signal
P0850 ECM-730B Gear position sensor. Signal missing
P0850 ECM-740B Communication, central electronic module (CEM).
Signal missing
U0301 ECM-740C Communication, central electronic module (CEM).
Signal too high
- ECM-800C System relay. Signal too high
- ECM-800D System relay. Signal too low
- ECM-801B System relay. Signal missing
- ECM-801C System relay. Signal too high
- ECM-801D System relay. Signal too low
P0563 ECM-820C Battery voltage. Signal too high
P0562 ECM-820D Battery voltage. Signal too low
P2510 ECM-8210 System relay. Faulty signal
P0620 ECM-8300 Alternator control module (ACM). Faulty
P2502 ECM-830B Alternator control module (ACM). Faulty
communication
P2504 ECM-830C Alternator control module (ACM). Faulty signal
P2503 ECM-830D Alternator control module (ACM). Signal too high
P0512 ECM-8410 Autostarting, engine speed. Signal too low
P0512 ECM-841B Autostarting, power supply. Signal too low
P0617 ECM-842C Starter motor relay. Signal too high
P0617 ECM-842D Starter motor relay. Signal too low
P0616 ECM-843B Starter motor relay. Open
P0616 ECM-843C Starter motor relay. Signal too high
P0616 ECM-843D Starter motor relay. Signal too low
P0641 ECM-8500 5 volt power supply. Faulty signal
P0641 ECM-851D 5 volt power supply. Signal too low
2012 Volvo C30 T-5
General Information DTC Index

P0571 ECM-9000 Brake pedal sensor. Faulty signal


P0573 ECM-900C Brake pedal sensor. Signal too high
- ECM-900D Brake pedal sensor. Signal too low
P0571 ECM-9011 Brake pedal sensor, signal via CAN. Faulty signal
P0571 ECM-901B Brake pedal sensor, signal via CAN. Signal missing
P0571 ECM-901D Brake pedal sensor, signal via CAN. Signal too low
P0573 ECM-9100 Clutch pedal switch. Faulty signal
P0808 ECM-910C Clutch pedal switch. Signal too high
P0807 ECM-910D Clutch pedal switch. Signal too low
P0805 ECM-9110 Clutch pedal position sensor. Faulty signal
P0805 ECM-911B Clutch pedal sensor. Signal missing
P0805 ECM-911C Clutch pedal sensor. Signal too high
P0805 ECM-911D Clutch pedal sensor. Signal too low
P2135 ECM-9200 Throttle position (TP) sensor. Faulty signal
P0121 ECM-9210 Electronic throttle unit, potentiometer 1. Faulty
signal
P0123 ECM-921C Electronic throttle unit, potentiometer 1. Signal too
high
P0122 ECM-921D Electronic throttle unit, potentiometer 1. Signal too
low
P0122 ECM-9220 Electronic throttle unit, potentiometer 2. Faulty
signal
P0223 ECM-922C Electronic throttle unit, potentiometer 2. Signal too
high
P0223 ECM-922D Electronic throttle unit, potentiometer 2. Signal too
low
P2101 ECM-9240 Engine control module (ECM). Faulty signal
P2111 P2112 ECM-925C Electronic throttle unit. Signal too high
P2111 ECM-925D Electronic throttle unit. Signal too low
P2112 ECM-926C Electronic throttle unit. Signal too high
P2112 ECM-926D Electronic throttle unit. Signal too low
P0638 ECM-9270 Throttle unit. Faulty signal
P2119 ECM-9280 Throttle unit. Faulty signal
P2108 ECM-929C Engine control module (ECM). Signal too high
P2108 ECM-929D Engine control module (ECM). Signal too low
P1124 ECM-92B0 Electronic throttle unit. Faulty signal
P1167 ECM-92CC Electronic throttle unit. Signal too high
P1167 ECM-92CD Electronic throttle unit. Signal too low
P1124 ECM-92D0 Electronic throttle unit. Faulty signal
P2109 ECM-92E0 Engine control module (ECM). Internal fault
P0579 ECM-9300 Control module communication problems. Faulty
signal
2012 Volvo C30 T-5
General Information DTC Index

P0564 ECM-930B Control module communication problems. Signal


missing
P0581 ECM-930C Control module, communication problems. Signal
too high
P0580 ECM-930D Control module communication problems. Signal too
low
P2138 ECM-9400 Accelerator pedal (AP) position sensor, digital
signal. Faulty signal
P2123 ECM-940C Accelerator pedal (AP) position sensor, digital
signal. Signal too high
P2122 ECM-940D Accelerator pedal (AP) position sensor, digital
signal. Signal too low
P2128 ECM-941C Accelerator pedal (AP) position sensor, analog
signal. Signal too high
P2127 ECM-941D Accelerator pedal (AP) position sensor, analog
signal. Signal too low
P2125 ECM-9430 Accelerator pedal (AP) position sensor, analog
signal. Faulty signal
P2125 ECM-943B Accelerator pedal (AP) position sensor, analog
signal. Signal missing
P2125 ECM-943C Accelerator pedal (AP) position sensor, analog
signal. Signal too high
P2125 ECM-943D Accelerator pedal (AP) position sensor, analog
signal. Signal too low
P0507 ECM-950C Engine control module (ECM), idle speed control.
Signal too high
P0506 ECM-950D Engine control module (ECM), idle speed control.
Signal too low
P2122 ECM-951C Engine control module (ECM), idle speed control.
Signal too high
P0506 P0507 ECM-951D Engine control module (ECM), idle speed control.
Signal too low
P2121 ECM-9700 Accelerator pedal (AP) position sensor, digital
signal. Faulty signal
P2121 ECM-970B Accelerator pedal (AP) position sensor, digital
signal. Signal missing
P2121 ECM-970C Accelerator pedal (AP) position sensor, digital
signal. Signal too high
P2121 ECM-970D Accelerator pedal (AP) position sensor, digital
signal. Signal too low
P0607 ECM-9800 Engine control module (ECM), torque signal.
Internal fault
P0607 ECM-9810 Engine control module (ECM), engine speed (RPM).
Internal fault
2012 Volvo C30 T-5
General Information DTC Index

P0607 ECM-9820 Engine control module (ECM), load signal. Internal


fault
P0607 ECM-9830 Engine control module (ECM). Internal fault
P0607 ECM-983C Engine control module (ECM). Internal fault
P0607 ECM-983D Engine control module (ECM). Internal fault
P0607 ECM-9840 Engine control module (ECM). Internal fault
P0607 ECM-985C Engine control module (ECM), fuel shut-off system.
Internal fault
P0607 ECM-9860 Engine control module (ECM). Internal fault
P0604 ECM-9970 Memory fault in RAM. Faulty signal
P0605 ECM-9980 Memory fault in ROM. Faulty signal
P0605 ECM-9990 engine control module (ECM). Faulty signal
P0606 ECM-999B Engine control module (ECM). Signal missing
P0606 ECM-999D Engine control module (ECM). Signal too low
P0607 ECM-9A0B Engine control module (ECM). Internal fault
U0401 ECM-A020 Configuration fault. Signal missing
P0503 ECM-A12B Speed signal. Signal missing
P0503 ECM-A12C Speed signal. Signal too high
P0503 ECM-A130 Control module communication. Faulty signal
P2610 ECM-A20B Engine control module (ECM). Signal missing
P2610 ECM-A20C Engine control module (ECM). Signal too high
U0001 ECM-E000 Control module communication. Faulty signal
U0300 ECM-E003 Configuration fault. Software fault
- ECM-XXXX Unknown diagnostic trouble code (DTC) for the
current control module version

ELECTRONIC POWER STEERING (EPS) DTCS


ELECTRONIC POWER STEERING (EPS) - DTC INDEX
Volvo Code Description
EPS-0020 Pump motor. Signal too high (B5254T7)
EPS-0021 Pump motor. Faulty signal (B5254T7)
EPS-0022 Control module, internal fault (B5254T7)
EPS-0030 Temperature sensor. Signal missing (B5254T7)
EPS-0040 High temperature. Signal too high (B5254T7)
EPS-0041 High temperature. Signal too high (B5254T7)
EPS-0050 Memory fault in ROM. Internal fault (B5254T7)
EPS-0051 Memory fault in ROM. Internal fault (B5254T7)
EPS-0053 Memory fault in ROM. Internal fault (B5254T7)
EPS-0060 Control module. Internal fault (B5254T7)
EPS-0070 Power supply. Signal too high (B5254T7)
2012 Volvo C30 T-5
General Information DTC Index

EPS-0071 Power supply. Signal too low (B5254T7)


EPS-0080 Steering wheel angle sensor. Faulty signal (B5254T7)
EPS-0081 Speed. Faulty signal (B5254T7)
EPS-0082 Engine status. Faulty signal (B5254T7)
EPS-0084 Engine status. Faulty signal (B5254T7)
EPS-E000 CAN communication. Faulty communication (B5254T7)
EPS-E003 Configuration fault. Faulty configuration (B5254T7)
EPS-XXXX Unknown diagnostic trouble code (DTC) for the present control module
version (B5254T7)

HEADLAMP CONTROL MODULE (HCM) DTCS


HEADLAMP CONTROL MODULE (HCM) - DTC INDEX
Volvo Code Description
HCM-0142 Control module. Internal fault (B5254T7)
HCM-2281 Control module. Communication fault (B5254T7)
HCM-2283 Control module. Communication fault (B5254T7)
HCM-2285 Control module. Incorrect software (B5254T7)
HCM-2287 Control module. Communication fault (B5254T7)
HCM-2289 Control module. Communication fault (B5254T7)
HCM-2291 Control module Faulty signal (B5254T7)
HCM-2293 Control module. Communication fault (B5254T7)
HCM-2295 Control module. Communication fault (B5254T7)
HCM-2297 Control module. Communication fault (B5254T7)
HCM-2687 Control module. Communication fault (B5254T7)
HCM-2987 Control module. Communication fault (B5254T7)
HCM-6401 Left headlamp Faulty Signal (B5254T7)
HCM-6402 Left headlamp Faulty Signal (B5254T7)
HCM-6403 Left headlamp Faulty Signal (B5254T7)
HCM-6501 Right headlamp Faulty signal (B5254T7)
HCM-6502 Right headlamp Faulty signal (B5254T7)
HCM-6503 Right headlamp Faulty signal (B5254T7)
HCM-8F20 Position sensor rear Signal too high (B5254T7)
HCM-8F21 Position sensor rear Signal too low (B5254T7)
HCM-8F22 Position sensor, calibration Not completed (B5254T7)
HCM-8F30 Position sensor front Signal too high (B5254T7)
HCM-8F31 Position sensor front Signal too low (B5254T7)
HCM-8F40 Power supply sensor Faulty signal (B5254T7)
HCM-8F41 Power supply sensor Faulty signal (B5254T7)
HCM-DD00 LIN Communication fault (B5254T7)
HCM-DD01 LIN Communication fault (B5254T7)
2012 Volvo C30 T-5
General Information DTC Index

HCM-DD02 LIN Communication fault (B5254T7)


HCM-DD10 LIN Communication fault (B5254T7)
HCM-DD11 LIN Communication fault (B5254T7)
HCM-E000 Control module Communication fault (B5254T7)
HCM-E003 Configuration fault Faulty configuration (B5254T7)
HCM-E010 Control module Voltage too low (B5254T7)

INTEGRATED AUDIO MODULE (IAM) DTCS


INTEGRATED AUDIO MODULE (IAM) - DTC INDEX
Volvo Code Description
IAM-1001 AM/FM antenna. No signal
IAM-1002 AM/FM antenna. Faulty signal
IAM-2001 Control module. Internal fault
IAM-2002 Control module. Internal fault
IAM-2003 Control module. Internal fault
IAM-2004 Control module. Internal fault
IAM-2005 Control module. Internal fault
IAM-3001 Front left speaker. Signal too low
IAM-3002 Front left speaker. Signal too high
IAM-3003 Front left speaker. Faulty signal
IAM-3004 Front left speaker. No signal
IAM-3005 Front left speaker. Faulty signal
IAM-3011 Front right speaker. Signal too low
IAM-3012 Front right speaker. Signal too high
IAM-3013 Front right speaker. Faulty signal
IAM-3014 Front right speaker. No signal
IAM-3015 Front right speaker. Faulty signal
IAM-3021 Rear left speaker. Signal too low
IAM-3022 Rear left speaker. Signal too high
IAM-3023 Rear left speaker. Faulty signal
IAM-3024 Rear left speaker. No signal
IAM-3025 Rear left speaker. Faulty signal
IAM-3031 Rear right speaker. Signal too low
IAM-3032 Rear right speaker. Signal too high
IAM-3033 Rear right speaker. Faulty signal
IAM-3034 Rear right speaker. No signal
IAM-3035 Rear right speaker. Faulty signal
IAM-4001 Microphone input. Signal missing
IAM-4002 Microphone input. Signal too low
IAM-4003 Microphone input. Signal too high
2012 Volvo C30 T-5
General Information DTC Index

IAM-5001 USB port. Signal too low


IAM-5002 USB port. Signal too high
IAM-9001 Control module. Configuration fault
IAM-9002 Control module. Overheated

INFOTAINMENT CONTROL MODULE (ICM) DTCS


INFOTAINMENT CONTROL MODULE (ICM) - DTC INDEX
Volvo Code Description
ICM-1A02 Control module. Faulty voltage
ICM-1A05 Display. Faulty voltage
ICM-1A06 Relay, infotainment not deactivated
ICM-1A51 Communication with the audio module (AUD). Signal missing
ICM-1A53 Communication with the multimedia module (MMM). Signal missing
ICM-1A57 Communication with the phone module (PHM). Signal missing
ICM-1A58 Communication with the global positioning system module (GPS). Signal
missing
ICM-1A59 Communication with the traffic message channel module (TMC). Signal
missing
ICM-1A5A Communication with integrated audio module (IAM). Signal missing
ICM-1A5B Communication with Remote Digital Audio Receiver (RDAR) Signal
missing
ICM-1A5C Communication with bluetooth phone module (BPM) Signal missing
ICM-1A5D Communication With Accessory USB Unit (AUU) Signal missing
ICM-1D03 Control module, not fully programmed. Internal fault
ICM-1D07 Control module. Internal fault
ICM-1F36 Heating, display. Signal missing
ICM-1F37 Display. Signal missing
ICM-1F38 Temperature sensor. Faulty signal
ICM-1F40 Receiver remote control. Short-circuit to ground
ICM-6C71 Audio module (AUD) not approved. Faulty signal
ICM-6C72 Multimedia module (MMM) not approved. Faulty signal
ICM-6C76 Phone module (PHM) not approved. Faulty signal
ICM-6C77 Global positioning system module (GPS) not approved. Faulty signal
ICM-6C78 Traffic message channel module (TMC) not approved. Faulty signal
ICM-6C79 Infotainment control module (ICM) not approved. Faulty signal
ICM-6C7A Integrated audio module (IAM) not valid. Faulty signal
ICM-6C7B Remote Digital Audio Receiver (RDAR) not valid Faulty signal
ICM-6C7C Bluetooth phone module (BPM) not valid Faulty signal
ICM-6C7D Accessory USB Unit (AUU) not valid Faulty signal
ICM-DC00 Control module communication. Internal fault
2012 Volvo C30 T-5
General Information DTC Index

ICM-DC01 Communication module. Faulty signal


ICM-DC02 Control module communication. No communication
ICM-E001 Control module communication. Faulty communication
ICM-E003 Configuration fault. Faulty configuration
ICM-E010 Power supply. Signal too low
ICM-XXXX Unknown diagnostic trouble code (DTC) for the current control module
version

KEYLESS VEHICLE MODULE (KVM) DTCS


KEYLESS VEHICLE MODULE (KVM) - DTC INDEX
Volvo Code Description
KVM-0001 Receiver. No communication
KVM-0004 Remote control receiver. No communication
KVM-0010 Inner antenna. Signal too low
KVM-0011 Inner antenna. Signal too high
KVM-0012 Inner antenna. Signal missing
KVM-001C Outer antenna rear. Signal too high
KVM-001D Outer antenna rear. Signal missing
KVM-001E Outer antenna rear. Faulty signal
KVM-0020 Switch unlocking left front. Signal missing
KVM-0021 Switch unlocking right front. Signal missing
KVM-0030 Outer lock button left front. Activated too long
KVM-0031 Outer lock button right front. Activated too long
KVM-0040 Switch unlocking left front. Activated too long
KVM-0041 Switch unlocking right front. Activated too long
KVM-0050 Switch quick lock left front. Activated too long
KVM-0051 Switch quick lock right front. Activated too long
KVM-0060 Switch unlocking tailgate. Activated too long
KVM-0080 Control module. Internal memory fault
KVM-0081 Control module. Internal memory fault
KVM-0100 Interior antennas. Signal too low
KVM-0103 Exterior left antennas. Signal too low
KVM-0104 Exterior right antennas. Signal too low
KVM-0105 Exterior trunk antenna. Signal too low
KVM-0110 Remote control invalid key code
KVM-0115 RFR Part&Serial Number conversion error
KVM-E001 Control module communication. Faulty communication
KVM-E003 Incorrect configuration. Faulty configuration
KVM-E010 Power supply. Signal too low
KVM-XXXX Unknown diagnostic trouble code (DTC) for the current control module
2012 Volvo C30 T-5
General Information DTC Index

version

MULTIMEDIA MODULE (MMM) DTCS


MULTI MEDIA MODULE (MMM) - DTC INDEX
Volvo Code Description
MMM-1000 Control module. Internal fault
MMM-1010 Control module. Internal fault
MMM-1020 Control module. Internal fault
MMM-2000 Control module. Internal fault
MMM-2010 Control module. Internal fault
MMM-2100 Control module. Internal fault
MMM-2110 Control module. Internal fault
MMM-3100 GPS-antenna. Open circuit
MMM-3110 GPS-antenna. Ground (GND) short
MMM-4000 Control module. Internal fault
MMM-5000 Control module. Internal fault
MMM-5010 Control module. Internal fault
MMM-5020 Control module. Internal fault
MMM-6000 Control module Faulty configuration

PARKING ASSIST MODULE (PAM) DTCS


PARKING ASSIST MODULE (PAM) - DTC INDEX
Volvo Code Description
PAM-0001 Control module. Internal fault
PAM-0002 Parking sensor 1. Signal too high
PAM-0003 Parking sensor 1. Signal too low/Signal missing
PAM-0004 Parking sensor 2. Signal too high
PAM-0005 Parking sensor 2. Signal too low/Signal missing
PAM-0006 Parking sensor 3. Signal too high
PAM-0007 Parking sensor 3. Signal too low/Signal missing
PAM-0008 Parking sensor 4. Signal too high
PAM-0009 Parking sensor 4. Signal too low/Signal missing
PAM-0010 Parking sensor 5. Signal too high (L.H.D)
PAM-0011 Parking sensor 5. Signal too low/Signal missing (L.H.D)
PAM-0012 Parking sensor 6. Signal too high (L.H.D)
PAM-0013 Parking sensor 6. Signal too low/Signal missing (L.H.D)
PAM-0014 Parking sensor 7. Signal too high (L.H.D)
PAM-0015 Parking sensor 7. Signal too low/Signal missing (L.H.D)
PAM-0016 Parking sensor 8. Signal too high (L.H.D)
2012 Volvo C30 T-5
General Information DTC Index

PAM-0017 Parking sensor 8. Signal too low/Signal missing (L.H.D)


PAM-0018 Configuration fault
PAM-E001 Control module communication. Faulty communication
PAM-E003 Configuration fault. Faulty configuration
PAM-E010 Power supply. Voltage difference too great
PAM-XXXX Unknown diagnostic trouble code (DTC) for the current control module
version

PASSENGER DOOR MODULE (PDM) DTCS


PASSENGER DOOR MODULE (PDM) - DTC INDEX
Volvo Code Description
PDM-0012 Control, passenger window. Stuck in the active position
PDM-0024 Central locking switch. Faulty signal
PDM-0025 LED, camera module Signal too low
PDM-0026 LED, camera module Signal too high
PDM-0027 LED, camera module Open circuit
PDM-002B Camera module Internal failure
PDM-002F Camera module voltage supply Signal too low
PDM-003A Camera module voltage supply Signal too high
PDM-DD20 LIN communication camera module Internal fault
PDM-DD21 LIN communication camera module Shorted
PDM-DD22 LIN communication camera module Internal fault
PDM-DD30 Communication with camera module Internal Fault
PDM-XXXX Unknown diagnostic trouble code (DTC) for the current control module
version

PHONE MODULE (PHM) DTCS


PHONE MODULE (PHM) - DTC INDEX
Volvo Code Description
PHM-0008 Emergency microphone Signal too high
PHM-000A Emergency microphone Signal too low/Signal missing
PHM-0013 Control module Internal fault
PHM-0015 Control module Internal fault
PHM-0030 Reserv battery Voltage too low
PHM-0040 SIM-card Internal fault
PHM-0049 Control module Internal fault
PHM-0063 Illumination buttons Signal too high/Signal missing
PHM-0064 Illumination buttons Signal too low
PHM-0065 Volvo On Call buttons Signal too low
2012 Volvo C30 T-5
General Information DTC Index

PHM-0066 Volvo On Call buttons Signal too high/Signal missing


PHM-0067 Reserv battery Not connected
PHM-0068 SIM card holder Signal missing
PHM-006B Memory fault control module Internal fault
PHM-0080 Volvo On Call buttons Wrong switches mounted
PHM-0082 Volvo On Call buttons Activated too long
PHM-0100 Control module Configuration fault
PHM-0211 Internal Backup speaker Signal too low
PHM-0215 Emergency microphone Signal too high/Signal missing
PHM-1A51 Control module Incorrect software
PHM-1A54 Control module Incorrect software
PHM-4E96 Control module Internal fault
PHM-5529 Internal backup antenna Invalid signal
PHM-5611 Telephone antenna Signal too low
PHM-5615 Telephone antenna Signal too high/Signal missing
PHM-6911 Handset hook Signal too low
PHM-6915 Handset hook Signal too high/Signal missing
PHM-6A11 Handset microphone Signal too low
PHM-6A15 Handset microphone Signal too high/Signal missing
PHM-6B11 Handset speaker Signal too low
PHM-6B15 Handset speaker Signal too high/Signal missing
PHM-7B11 Handset supply Signal too low
PHM-7B12 Handset supply Signal too high
PHM-9F11 GPS-antenna Signal too low
PHM-9F13 GPS-antenna Signal missing
PHM-A211 Crash signal Signal too low
PHM-A215 Crash signal Signal too high/Signal missing
PHM-A238 Crash signal Faulty signal
PHM-C000 Control module Software fault
PHM-E001 Control module communication Software error
PHM-E003 Configuration fault Software fault
PHM-E010 Power supply Faulty signal

POWER SEATS (PSL) DTCS


POWER SEATS (PSL) - DTC INDEX
Volvo Code Description
PSL-0001 Hall sensor 1. Faulty signal
PSL-0002 Hall sensor 2. Faulty signal
PSL-0003 Hall sensor 3. Faulty signal
PSL-0004 Hall sensor 4. Faulty signal
2012 Volvo C30 T-5
General Information DTC Index

PSL-0007 M1, M2, M3, M4 or MC. Shorted to supply


PSL-0008 M1, M2, M3, M4 or MC. Ground (GND) short
PSL-0019 Memory function 1. Internal fault
PSL-001A Memory function 2. Internal fault
PSL-001B Memory function 3. Internal fault
PSL-0020 Front-rear adjustment control, M1+. Activated too long
PSL-0021 Front-rear adjustment control, M1-. Activated too long
PSL-0022 Backrest adjustment control, M2+. Activated too long
PSL-0023 Backrest adjustment control, M2-. Activated too long
PSL-0024 Rear edge adjustment control, M3+. Activated too long
PSL-0025 Rear edge adjustment control, M3-.. Activated too long
PSL-0026 Front edge adjustment control, M4+. Activated too long
PSL-0027 Front edge adjustment control, M4-. Activated too long
PSL-0028 Operating button, memory 1. Activated too long
PSL-0029 Operating button, memory 2. Activated too long
PSL-002A Operating button, memory 3. Activated too long
PSL-002B Operating button. Activated too long
PSL-002C Front-rear adjustment, M1+ and M1-. Faulty signal
PSL-002D Backrest, M2+ and M2-.. Faulty signal
PSL-002E Seat rear edge, M3+ and M3-. Faulty signal
PSL-002F Seat front edge, M4+ and M4-. Faulty signal
PSL-0030 Front-rear adjustment, Motor 1 (M1+). Signal missing
PSL-0032 Backrest, Motor 2 (M2+). Signal missing
PSL-0034 Seat rear edge, Motor 3 (M3+). Signal missing
PSL-0036 Seat front edge, Motor 4 (M4+). Signal missing
PSL-0038 Control module. Software error
PSL-0040 Easy-entry switch forward. Activated too long
PSL-0041 Easy-entry switch backward. Activated too long
PSL-0042 Easy-Entry switch. Invalid combination
PSL-0044 Control module. Initialisation of power seat lost or not done
PSL-0045 Control module. Initialisation of power seat lost or not done
PSL-0047 Hall sensor ground backrest. Short to supply
PSL-0048 Hall sensor signal backrest. Short to supply
PSL-0049 Hall sensor signal backrest. Short to ground
PSL-004A Hall sensor backrest. Open circuit
PSL-004B Hall sensor backrest. Abnormal current
PSL-0050 Control module. Incorrect software
PSL-E001 Control module communication. Faulty communication
PSL-E003 Configuration fault. Faulty configuration
PSL-E010 Power supply. Signal too low
2012 Volvo C30 T-5
General Information DTC Index

POWER SEATS (PSR) DTCS


POWER SEATS (PSR) - DTC INDEX
Volvo Code Description
PSR-0001 Hall sensor 1. Faulty signal
PSR-0002 Hall sensor 2. Faulty signal
PSR-0003 Hall sensor 3. Faulty signal
PSR-0004 Hall sensor 4. Faulty signal
PSR-0007 M1, M2, M3, M4 or MC. Shorted to supply
PSR-0008 M1, M2, M3, M4 or MC. Ground (GND) short
PSR-0019 Memory function 1. Internal fault
PSR-001A Memory function 2. Internal fault
PSR-001B Memory function 3. Internal fault
PSR-0020 Front-rear adjustment control, M1+. Activated too long
PSR-0021 Front-rear adjustment control, M1-. Activated too long
PSR-0022 Backrest adjustment control, M2+. Activated too long
PSR-0023 Backrest adjustment control, M2-. Activated too long
PSR-0024 Rear edge adjustment control, M3+. Activated too long
PSR-0025 Rear edge adjustment control, M3-.. Activated too long
PSR-0026 Front edge adjustment control, M4+. Activated too long
PSR-0027 Front edge adjustment control, M4-. Activated too long
PSR-0028 Operating button, memory 1. Activated too long
PSR-0029 Operating button, memory 2. Activated too long
PSR-002A Operating button, memory 3. Activated too long
PSR-002B Operating button. Activated too long
PSR-002C Front-rear adjustment, M1+ and M1-. Faulty signal
PSR-002D Backrest, M2+ and M2-.. Faulty signal
PSR-002E Seat rear edge, M3+ and M3-. Faulty signal
PSR-002F Seat front edge, M4+ and M4-. Faulty signal
PSR-0030 Front-rear adjustment, Motor 1 (M1+). Signal missing
PSR-0032 Backrest, Motor 2 (M2+). Signal missing
PSR-0034 Seat rear edge, Motor 3 (M3+). Signal missing
PSR-0036 Seat front edge, Motor 4 (M4+). Signal missing
PSR-0038 Control module. Software error
PSR-0040 Easy-entry switch forward. Activated too long
PSR-0041 Easy-entry switch backward. Activated too long
PSR-0042 Easy-Entry switch. Invalid combination
PSR-0044 Control module. Initialisation of power seat lost or not done
PSR-0045 Control module. Initialisation of power seat lost or not done
PSR-0047 Hall sensor ground backrest. Short to supply
PSR-0048 Hall sensor signal backrest. Short to supply
2012 Volvo C30 T-5
General Information DTC Index

PSR-0049 Hall sensor signal backrest. Short to ground


PSR-004A Hall sensor backrest. Open circuit
PSR-004B Hall sensor backrest. Abnormal current
PSR-0050 Control module. Incorrect software
PSR-E001 Control module communication. Faulty communication
PSR-E003 Configuration fault. Faulty configuration
PSR-E010 Power supply. Signal too low

REAR ELECTRONIC MODULE (REM) DTCS


REAR ELECTRONIC MODULE (REM) - DTC INDEX
Volvo Code Description
REM-8E01 Relay, back-up (reversing) lamp. Internal fault
REM-8E02 Relay, back-up (reversing) lamp. Internal fault

SRS DTC CODES


DTC INDEX
Volvo Code Description
SRS-0001 SRS indicator lamp. Faulty function
SRS-0002 SRS indicator lamp. Signal missing
SRS-0003 PAD/PAE lamp Faulty function
SRS-0004 PAD lamp. Signal missing
SRS-0005 Power supply from the battery. Voltage too low
SRS-0006 Power supply from the battery. Voltage too high
SRS-0010 Driver airbag stage 1. Signal too low
SRS-0011 Driver airbag stage 1. Signal too high
SRS-0012 Driver airbag stage 1. Resistance too low
SRS-0013 Driver airbag stage 1. Resistance too high
SRS-0014 Driver airbag stage 1. Short-circuit to adjacent SRS ignition cable
SRS-0015 Driver's airbag stage 1. Configuration fault
SRS-0016 Driver airbag stage 2. Signal too low
SRS-0017 Driver airbag stage 2. Signal too high
SRS-0018 Driver airbag stage 2. Resistance too low
SRS-0019 Driver airbag stage 2. Resistance too high
SRS-001A Driver airbag stage 2. Short-circuit to adjacent SRS ignition cable
SRS-001B Driver's airbag stage 2. Configuration fault
SRS-001C Driver's seat belt tensioner. Signal too low
SRS-001D Driver's seat belt tensioner. Signal too high
SRS-001E Driver's seat belt tensioner. Resistance too low
SRS-001F Driver's seat belt tensioner. Resistance too high
2012 Volvo C30 T-5
General Information DTC Index

SRS-0020 Driver's seat belt tensioner. Short-circuit to adjacent SRS ignition cable
SRS-0021 Driver's seat belt tensioner. Configuration fault
SRS-0022 Driver's lap belt tensioner. Signal too low
SRS-0023 Driver's lap belt tensioner. Signal too high
SRS-0024 Driver's lap belt tensioner. Resistance too low
SRS-0025 Driver's lap belt tensioner. Resistance too high
SRS-0026 Driver's lap belt tensioner. Short-circuit to adjacent SRS ignition cable
SRS-0027 Driver's lap belt tensioner. Configuration fault
SRS-0028 Driver's seat belt force limiter. Signal too low
SRS-0029 Driver's seat belt force limiter. Signal too high
SRS-002A Driver's seat belt force limiter. Resistance too low
SRS-002B Driver's seat belt force limiter. Resistance too high
SRS-002C Driver's seat belt force limiter. Short-circuit to adjacent SRS ignition cable
SRS-002D Driver's seat belt force limiter. Configuration fault
SRS-002E Adaptive steering column. Signal too low
SRS-002F Adaptive steering column. Signal too high
SRS-0030 Adaptive steering column. Resistance too low
SRS-0031 Adaptive steering column. Resistance too high
SRS-0032 Adaptive steering column. Short-circuit to adjacent SRS ignition cable
SRS-0033 Adaptive steering column. Configuration fault
SRS-0034 Passenger airbag stage 1. Signal too low
SRS-0035 Passenger airbag stage 1. Signal too high
SRS-0036 Passenger airbag stage 1. Resistance too low
SRS-0037 Passenger airbag stage 1. Resistance too high
SRS-0038 Passenger airbag stage 1. Short-circuit to adjacent SRS ignition cable
SRS-0039 Passenger airbag stage 1. Configuration fault
SRS-003A Passenger airbag stage 2. Signal too low
SRS-003B Passenger airbag stage 2. Signal too high
SRS-003C Passenger airbag stage 2. Resistance too low
SRS-003D Passenger airbag stage 2. Resistance too high
SRS-003E Passenger airbag stage 2. Short-circuit to adjacent SRS ignition cable
SRS-003F Passenger airbag stage 2. Configuration fault
SRS-0040 Passenger seat belt tensioner. Signal too low
SRS-0041 Passenger seat belt tensioner. Signal too high
SRS-0042 Passenger seat belt tensioner. Resistance too low
SRS-0043 Passenger seat belt tensioner. Resistance too high
SRS-0044 Passenger seat belt tensioner. Short-circuit to adjacent SRS ignition cable
SRS-0045 Passenger seat belt tensioner. Configuration fault
SRS-004A Passenger lap belt tensioner. Short-circuit to adjacent SRS ignition cable
SRS-004B Passenger lap belt tensioner. Configuration fault
SRS-004C Passenger seat belt force limiter. Signal too low
2012 Volvo C30 T-5
General Information DTC Index

Passenger seat belt force limiter. Signal too high


SRS-004E Passenger seat belt force limiter. Resistance too low
SRS-004F Passenger seat belt force limiter. Resistance too high
SRS-0050 Passenger seat belt force limiter. Short-circuit to adjacent SRS ignition
cable
SRS-0051 Passenger seat belt force limiter. Configuration fault
SRS-0052 Front left side impact protection (SIPS) bag. Signal too low
SRS-0053 Front left side impact protection (SIPS) bag. Signal too high
SRS-0054 Front left side impact protection (SIPS) bag. Resistance too low
SRS-0055 Front left side impact protection (SIPS) bag. Resistance too high
SRS-0056 Front left side impact protection (SIPS) bag. Short-circuit to adjacent SRS
ignition cable
SRS-0057 Front left side impact protection (SIPS) bag. Configuration fault
SRS-0058 Front right side impact protection (SIPS) bag. Signal too low
SRS-0059 Front right-hand side impact protection (SIPS) bag. Signal too high
SRS-005A Front right-hand side impact protection (SIPS) bag. Resistance too low
SRS-005B Front right-hand side impact protection (SIPS) bag. Resistance too high
SRS-005C Front right-hand side impact protection (SIPS) bag. Short-circuit to
adjacent SRS ignition cable
SRS-005D Front right-hand side impact protection (SIPS) bag. Configuration fault
SRS-005E Left-hand inflatable curtain. Signal too low
SRS-005F Left-hand inflatable curtain. Signal too high
SRS-0060 Left-hand inflatable curtain. Resistance too low
SRS-0061 Left-hand inflatable curtain. Resistance too high
SRS-0062 Left-hand inflatable curtain. Short-circuit to adjacent SRS ignition cable
SRS-0063 Left-hand inflatable curtain. Configuration fault
SRS-0064 Right-hand inflatable curtain. Signal too low
SRS-0065 Right-hand inflatable curtain. Signal too high
SRS-0066 Right-hand inflatable curtain. Resistance too low
SRS-0067 Right-hand inflatable curtain. Resistance too high
SRS-0068 Right-hand inflatable curtain. Short-circuit to adjacent SRS ignition cable
SRS-0069 Right-hand inflatable curtain. Configuration fault
SRS-006A Rear left-hand seat belt tensioner. Signal too low
SRS-006B Rear left-hand seat belt tensioner. Signal too high
SRS-006C Rear left-hand seat belt tensioner. Resistance too low
SRS-006D Rear left-hand seat belt tensioner. Resistance too high
SRS-006E Rear left-hand seat belt tensioner. Short-circuit to adjacent SRS ignition
cable
SRS-006F Rear left-hand seat belt tensioner. Configuration fault
SRS-0076 Rear right-hand seat belt tensioner. Signal too low
SRS-0077 Rear right-hand seat belt tensioner. Signal too high
2012 Volvo C30 T-5
General Information DTC Index

SRS-0078 Rear right-hand seat belt tensioner. Resistance too low


SRS-0079 Rear right-hand seat belt tensioner. Resistance too high
SRS-007A Rear right-hand seat belt tensioner. Short-circuit to adjacent SRS ignition
cable
SRS-007B Rear right-hand seat belt tensioner. Configuration fault
SRS-0090 Driver's seat belt buckle. Signal too high
SRS-0091 Driver's seat belt buckle. Current outside the permitted range
SRS-0092 Driver's seat belt buckle. Signal too low
SRS-0093 Driver's seat belt buckle. Configuration fault
SRS-0094 Passenger seat belt buckle. Signal too high
SRS-0095 Passenger seat belt buckle. Current outside the permitted range
SRS-0096 Passenger seat belt buckle. Signal too low
SRS-0097 Passenger seat belt buckle. Configuration fault
SRS-0098 Seat belt buckle, front. Shorted
SRS-009A Rear seat belt buckle. Signal missing
SRS-009C Driver's seat position sensor. Signal too high
SRS-009D Driver's seat position sensor. Current outside the permitted range
SRS-009E Driver's seat position sensor. Signal too low
SRS-009F Driver's seat position sensor. Configuration fault
SRS-00A0 Passenger seat position sensor. Signal too high
SRS-00A1 Passenger seat position sensor. Current outside the permitted range
SRS-00A2 Passenger seat position sensor. Signal too low
SRS-00A3 Passenger seat position sensor. Configuration fault
SRS-00A4 Switch for airbag in the On position. Signal too high
SRS-00A5 Switch for airbag in the On position. Current outside the permitted range
SRS-00A6 Switch for airbag in the On position. Signal too low
SRS-00A7 Switch for airbag in the On/Off position. Configuration fault
SRS-00A8 Switch for airbag in the Off position. Signal too high
SRS-00A9 Switch for airbag in the Off position. Current outside the permitted range
SRS-00AA Switch for airbag in the Off position. Signal too low
SRS-00AB Switch for passenger airbag. Faulty function
SRS-00B0 Front left side impact sensor. Communication fault
SRS-00B1 Front left side impact sensor. Signal too low
SRS-00B2 Front left side impact sensor. Signal too high
SRS-00B3 Front left side impact sensor. Internal fault
SRS-00B4 Front left side impact sensor. Incorrect measurement range
SRS-00B5 Front left side impact sensor. Configuration fault
SRS-00B9 Rear left side impact sensor. Communication fault
SRS-00BA Rear left side impact sensor. Signal too low
SRS-00BB Rear left side impact sensor. Signal too high
SRS-00BC Rear left side impact sensor. Internal fault
2012 Volvo C30 T-5
General Information DTC Index

SRS-00BD Rear left side impact sensor. Incorrect measurement range


SRS-00BE Rear left side impact sensor. Configuration fault
SRS-00C2 Front right side impact sensor. Communication fault
SRS-00C3 Front right side impact sensor. Signal too low
SRS-00C4 Front right side impact sensor. Signal too high
SRS-00C5 Front right side impact sensor. Internal fault
SRS-00C6 Front right side impact sensor. Incorrect measurement range
SRS-00C7 Front right side impact sensor. Configuration fault
SRS-00CB Rear right side impact sensor. Communication fault
SRS-00CC Rear right side impact sensor. Signal too low
SRS-00CD Rear right side impact sensor. Signal too high
SRS-00CE Rear right side impact sensor. Internal fault
SRS-00CF Rear right side impact sensor. Incorrect measurement range
SRS-00D0 Rear right side impact sensor. Configuration fault
SRS-00D4 Front left front impact sensor. Communication fault
SRS-00D5 Front left front impact sensor. Signal too low
SRS-00D6 Front left front impact sensor. Signal too high
SRS-00D7 Front left front impact sensor. Internal fault
SRS-00D8 Front left front impact sensor. Incorrect measurement range
SRS-00D9 Front left front impact sensor. Configuration fault
SRS-00DD Front right front impact sensor. Communication fault
SRS-00DE Front right front impact sensor. Signal too low
SRS-00DF Front right front impact sensor. Signal too high
SRS-00E0 Front right front impact sensor. Internal fault
SRS-00E1 Front right front impact sensor. Incorrect measurement range
SRS-00E2 Front right front impact sensor. Configuration fault
SRS-00E6 Driver's seat belt (inertia) reel sensor. Signal too low
SRS-00E7 Driver's seat belt (inertia) reel sensor. Signal too high
SRS-00E8 Driver's seat belt (inertia) reel sensor. Configuration fault
SRS-00E9 Driver's seat belt (inertia) reel sensor. Communication fault
SRS-00EA Driver's seat belt (inertia) reel sensor. Internal fault
SRS-00EB Driver's seat belt (inertia) reel sensor. Internal fault
SRS-00EC Driver's seat belt (inertia) reel sensor. Internal fault
SRS-00ED Driver's seat belt (inertia) reel sensor. Internal fault
SRS-00EF Passenger seat belt (inertia) reel sensor. Signal too low
SRS-00F0 Passenger seat belt (inertia) reel sensor. Signal too high
SRS-00F1 Passenger seat belt (inertia) reel sensor. Configuration fault
SRS-00F2 Passenger seat belt (inertia) reel sensor. Communication fault
SRS-00F3 Passenger seat belt (inertia) reel sensor. Internal fault
SRS-00F4 Passenger seat belt (inertia) reel sensor. Internal fault
SRS-00F5 Passenger seat belt (inertia) reel sensor. Internal fault
2012 Volvo C30 T-5
General Information DTC Index

Passenger seat belt (inertia) reel sensor. Internal fault


SRS-0120 Local CAN network, SRS. Communication fault
SRS-0128 CAN signal. Signal missing
SRS-0129 CAN signal. Signal missing
SRS-012A CAN signal. Signal missing
SRS-012B CAN signal. Configuration fault
SRS-012C CAN signal. Configuration fault
SRS-012D CAN signal. Signal missing
SRS-0131 Control module. Internal fault
SRS-0132 Control module. Internal fault
SRS-013A Collision signal. Communication fault
SRS-013B Control module. Collision memory full
SRS-014A Weight sensor/Passenger airbag switch. Invalid combination
SRS-014B Force limiter/lap tensioner. Invalid combination
SRS-CFFF Control module. Internal fault
SRS-E001 Control module communication. Faulty communication
SRS-E003 Configuration fault. Faulty configuration
SRS-E010 Power supply. Voltage difference too great
SRS-XXXX Unknown diagnostic trouble code (DTC) for the current control module
version

STEERING WHEEL MODULE (SWM) DTCS


STEERING WHEEL MODULE (SWM) - DTC INDEX
Volvo Code Description
SWM-0001 Reset button. Activated too long (B5254T7)
SWM-0002 Read button. Activated too long (B5254T7)
SWM-0003 Headlamp flash. Activated too long (B5254T7)
SWM-0004 Turn signal lamp stalk. Invalid combination (B5254T7)
SWM-0005 Windshield wiper lever. Invalid combination (B5254T7)
SWM-0006 Rain sensor button. Activated too long (B5254T7)
SWM-000C Windshield wiper lever. Invalid combination (B5254T7)
SWM-000D Windshield wiper lever. Invalid combination (B5254T7)
SWM-000E Windshield wiper lever. Invalid combination (B5254T7)
SWM-000F Windshield wiper lever. Invalid combination (B5254T7)
SWM-0014 RTI multi-button. Invalid combination (B5254T7)
SWM-0016 Cruise control ON/OFF button. Activated too long (B5254T7)
SWM-0017 Cruise control Resume button. Activated too long (B5254T7)
SWM-0018 Cruise control Cancel button. Activated too long (B5254T7)
SWM-0019 Cruise control Set+ button. Activated too long (B5254T7)
SWM-001A Cruise control Set- button. Activated too long (B5254T7)
2012 Volvo C30 T-5
General Information DTC Index

SWM-001B Carphone YES-button. Activated too long (B5254T7)


SWM-001C Carphone NO button. Activated too long (B5254T7)
SWM-001D Volume+ button. Activated too long (B5254T7)
SWM-001E Volume- button. Activated too long (B5254T7)
SWM-0020 Scan+ button. Activated too long (B5254T7)
SWM-0021 Scan- button. Activated too long (B5254T7)
SWM-0022 RTI Enter button. Activated too long (B5254T7)
SWM-0023 RTI Reset button. Activated too long (B5254T7)
SWM-0024 RTI Up button. Activated too long (B5254T7)
SWM-0025 RTI Down button. Activated too long (B5254T7)
SWM-0026 RTI Left button. Activated too long (B5254T7)
SWM-0027 RTI Right button. Activated too long (B5254T7)
SWM-0031 Cruise control. Communication problems (B5254T7)
SWM-0032 Cruise control. Initiation fault (B5254T7)
SWM-0033 Windshield wiper lever. Faulty signal (B5254T7)
SWM-0200 Steering wheel angle sensor. Faulty signal (B5254T7)
SWM-0201 Steering wheel angle sensor. Faulty signal (B5254T7)
SWM-0202 Steering wheel angle sensor. Faulty signal (B5254T7)
SWM-0203 Steering wheel angle sensor. Faulty signal (B5254T7)
SWM-0204 Steering wheel angle sensor. Current too low (B5254T7)
SWM-0206 Steering wheel module (SWM). Internal fault (B5254T7)
SWM-0207 Steering wheel module (SWM). Internal fault (B5254T7)
SWM-0208 Steering wheel module (SWM). Internal fault (B5254T7)
SWM-0209 Steering wheel module (SWM). Internal fault (B5254T7)
SWM-020A Steering wheel module (SWM). Calibration fault (B5254T7)
SWM-0A01 Steering wheel module (SWM). Internal fault (B5254T7)
SWM-0A03 Rear windshield wiper. No function (B5254T7)
SWM-0A04 Rear windshield wiper. No function (B5254T7)
SWM-0A06 Cruise control. No function (B5254T7)
SWM-0A07 Reset button. No function (B5254T7)
SWM-0A08 Reset button. No function (B5254T7)
SWM-0A09 Rain sensor button. No function (B5254T7)
SWM-0A0A Rain sensor. No function (B5254T7)
SWM-0A0B Steering wheel switch right (SWSR). No function (B5254T7)
SWM-0A0C Steering wheel switches. Invalid combination (B5254T7)
SWM-0A0D Steering wheel switches. Incorrect keypad installed (B5254T7)
SWM-0A0E Steering wheel module (SWM). Wrong version mounted (B5254T7)
SWM-0A10 Communication with control modules. Signal missing (B5254T7)
SWM-0A11 Communication with control modules. Signal missing (B5254T7)
SWM-0A12 Communication with control modules. Faulty signal (B5254T7)
SWM-DD00 Communication with control modules. Communication problems
2012 Volvo C30 T-5
General Information DTC Index

(B5254T7)
SWM-DD01 Communication with control modules. Communication problems
(B5254T7)
SWM-DD02 Communication with control modules. Communication problems
(B5254T7)
SWM-DD10 Communication with control modules. Communication problems
(B5254T7)
SWM-DD11 Communication with control modules. Communication problems
(B5254T7)
SWM-E001 Communication with control module. Faulty communication (B5254T7)
SWM-E003 Configuration fault. Faulty configuration (B5254T7)
SWM-E010 Steering wheel module (SWM). Voltage too low (B5254T7)
SWM-XXXX Unknown diagnostic trouble code (DTC) for the current control module
version (B5254T7)

TRANSMISSION CONTROL MODULE (TCM) DTCS


TRANSMISSION CONTROL MODULE (TCM) - DTC INDEX
Volvo Code Description
TCM-0002 Shift solenoid S1. Signal missing (AW55-50/51SN)
TCM-0003 Shift solenoid S1. Signal too low (AW55-50/51SN)
TCM-0008 Shift solenoid S2. Signal missing (AW55-50/51SN)
TCM-0009 Shift solenoid S2. Signal too low (AW55-50/51SN)
TCM-001E Transmission output speed sensor. Signal missing (AW55-50/51SN)
TCM-001F Vehicle speed sensor (VSS). Signal missing (AW55-50/51SN)
TCM-0020 Transmission output speed sensor. Faulty signal (AW55-50/51SN)
TCM-0022 Transmission speed sensor. Signal missing (AW55-50/51SN)
TCM-0023 Transmission input speed sensor. Signal missing (AW55-50/51SN)
TCM-0024 Transmission speed sensor. Faulty signal (AW55-50/51SN)
TCM-0027 Back-up gear. Incorrect gear ratio (AW55-50/51SN)
TCM-0028 1st gear. Incorrect gear ratio (AW55-50/51SN)
TCM-002E Lock-up function. Jerks or does not engage (AW55-50/51SN)
TCM-002F Lock-up function. Slips or does not engage (AW55-50/51SN)
TCM-0039 Gear-shift position sensor. Faulty signal (AW55-50/51SN)
TCM-0042 Counter, oil quality. The counter exceeds the limit value (AW55-
50/51SN)
TCM-0043 Oil temperature sensor. Temperature too high (AW55-50/51SN)
TCM-0044 Oil temperature sensor. Temperature too low (AW55-50/51SN)
TCM-0045 Oil temperature sensor. Faulty signal (AW55-50/51SN)
TCM-0046 Oil temperature sensor. Temperature too high (AW55-50/51SN)
TCM-0048 Transmission control module (TCM). Faulty software (AW55-50/51SN)
TCM-0049 Transmission control module (TCM). Internal fault (AW55-50/51SN)
2012 Volvo C30 T-5
General Information DTC Index

TCM-0070 Function, immobilizer. Signal missing (AW55-50/51SN)


TCM-0071 Function, immobilizer. Faulty signal (AW55-50/51SN)
TCM-0075 Function, Shift-lock. Signal missing (AW55-50/51SN)
TCM-0076 Function, Shift-lock. Faulty signal (AW55-50/51SN)
TCM-0081 Transmission output speed sensor. Signal missing (AW55-50/51SN)
TCM-0082 Transmission output speed sensor. Signal missing (AW55-50/51SN)
TCM-0087 Transmission speed sensor. Signal missing (AW55-50/51SN)
TCM-0088 Transmission speed sensor. Signal missing (AW55-50/51SN)
TCM-0090 Shift lock solenoid. Signal too high (AW55-50/51SN)
TCM-0091 Shift-lock solenoid. Signal missing (AW55-50/51SN)
TCM-0092 Shift-lock solenoid. Signal too low (AW55-50/51SN)
TCM-0096 Gear selector module (GSM). Signal missing (AW55-50/51SN)
TCM-0099 Transmission control module (TCM). Internal fault (AW55-50/51SN)
TCM-009A Power supply. Faulty voltage (AW55-50/51SN)
TCM-009B Power supply. Signal too high (AW55-50/51SN)
TCM-0100 Transmission. Poor gear shifting quality (AW55-50/51SN)
TCM-0102 Shift solenoid S3. Signal missing (AW55-50/51SN)
TCM-0103 Shift solenoid S3. Signal too low (AW55-50/51SN)
TCM-0108 Shift solenoid S4. Signal missing (AW55-50/51SN)
TCM-0109 Shift solenoid S4. Signal too low (AW55-50/51SN)
TCM-010B Shift solenoid S5. Signal missing (AW55-50/51SN)
TCM-010C Shift solenoid S5. Signal too low (AW55-50/51SN)
TCM-010F Lock-up solenoid SLU. Signal missing (AW55-50/51SN)
TCM-0113 Linear pressure solenoid SLS. Signal missing (AW55-50/51SN)
TCM-0117 Linear pressure solenoid SLT. Signal missing (AW55-50/51SN)
TCM-0122 Linear pressure solenoid SLS. Faulty signal (AW55-50/51SN)
TCM-0123 Lock-up solenoid SLU. Faulty signal (AW55-50/51SN)
TCM-0124 Linear pressure solenoid SLT. Faulty signal (AW55-50/51SN)
TCM-0190 Gear selector module (GSM). Internal fault (AW55-50/51SN)
TCM-0191 Gear selector module (GSM). Internal fault (AW55-50/51SN)
TCM-0192 Gear selector module (GSM). Faulty signal (AW55-50/51SN)
TCM-0194 Gear selector module (GSM). Faulty signal (AW55-50/51SN)
TCM-019B Gear selector module (GSM). Signal too low (AW55-50/51SN)
TCM-019C Gear selector module (GSM). Signal missing (AW55-50/51SN)
TCM-0212 Shift solenoid S3. Hydraulic fault (AW55-50/51SN)
TCM-0286 Hall sensor in gear selector. Internal fault (AW55-50/51SN)
TCM-0287 Hall sensor in the gear selector. Internal fault (AW55-50/51SN)
TCM-0291 Hall sensor in the gear selector. Internal fault (AW55-50/51SN)
TCM-0292 Hall sensor in the gear selector. Internal fault (AW55-50/51SN)
TCM-029A Transmission control module (TCM). Internal fault (AW55-50/51SN)
TCM-0A01 Communication control module. Signal missing (AW55-50/51SN)
2012 Volvo C30 T-5
General Information DTC Index

Gear position sensor. Calibration fault (AW55-50/51SN)


TCM-0A12 Gear-shift position sensor. Calibration fault (AW55-50/51SN)
TCM-0A30 Control module communication. Signal missing from Engine Control
Module (ECM) (AW55-50/51SN)
TCM-0A31 Control module communication. Signal missing from Engine Control
Module (ECM) (AW55-50/51SN)
TCM-DD00 Control module communication. Communication fault (AW55-50/51SN)
TCM-DD01 Control module communication. Communication fault (AW55-50/51SN)
TCM-DD02 Control module communication. Communication fault (AW55-50/51SN)
TCM-DD10 Control module communication. Communication fault (AW55-50/51SN)
TCM-E000 Control module communication. Faulty communication (AW55-
50/51SN)
TCM-E003 Control module communication. Faulty configuration (AW55-50/51SN)
TCM-E010 Power supply. Faulty voltage (AW55-50/51SN)
TCM-XXXX Unknown diagnostic trouble code (DTC) for the current control module
version (AW55-50/51SN)

TRAILER MODULE (TRM) DTCS


TRAILER MODULE (TRM) - DTC INDEX
Volvo Code Description
TRM-1A03 Control module. Internal fault
TRM-1A04 Control module. Internal fault
TRM-8D05 Stop lamps. Faulty signal
TRM-E001 Control module communication. Faulty communication
TRM-E003 Configuration fault. Faulty configuration
TRM-E010 Power supply. Voltage difference too great
TRM-XXXX Unknown diagnostic trouble code (DTC) for the current control module
version
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

ACCESSORIES AND EQUIPMENT

Other Electrical Equipment - Installation Instructions, Accessories

ALARM, BASIC KIT

NOTE: This accessory is connected to the car's electrical system. It requires software
unique to the car.

 Turn the ignition key to position 0.

Fig. 1: Identifying Windshield Wipers


Courtesy of VOLVO CARS CORPORATION

 Remove the windshield wipers.

Fig. 2: Identifying Clips


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

 Remove the four clips (1) in the panel over the wiper motor.
 Rotate the two clips (2) 90° towards each other.

 Detach the panel over the wiper motor on the right side and pull it up from the right wiper shaft.
 Pull the panel up from the left-hand wiper shaft.

NOTE: The panel has little space on the left-hand side. Pull carefully so that the
clips on the underneath/rear edge do not break.

 Remove the panel carefully. Pull it up at the front edge and then pull it forwards.

Fig. 3: Identifying Alarm Siren Nuts (Newer Model)


Courtesy of VOLVO CARS CORPORATION

Fig. 4: Identifying Alarm Siren Nuts (Older Model)


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

 Take two nuts from the kit and install the alarm siren at the windshield's leading edge. The alarm siren
should be installed on the right side for left-hand drive cars.
 Slide the alarm siren as far as possible in the bracket's groove.
 Torque-tighten the nuts with 10 Nm (7 lbf. ft.) .
 Plug in the pre-wired connector to the alarm siren.

 Reinstall the panel above the wiper motor.


 Reinstall the windscreen wipers and set them in the correct position.

Fig. 5: Identifying Clips And Screws


Courtesy of VOLVO CARS CORPORATION

 Remove the five clips (1) by pressing in their center and pull.
 Remove the two screws (2).

Fig. 6: Identifying Front Bumper Cover Screws


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

 Remove the five screws securing the bumper casing and air baffle at the wheel housing's leading edge, on
right and left sides.

Fig. 7: Identifying Cover For Nozzles For Headlamp Washers


Courtesy of VOLVO CARS CORPORATION

 Carefully remove the cover for the nozzle for the headlights' high-pressure washer, and pull it out until its
lock catch is accessible, on right and left side.

Fig. 8: Identifying Catch Pressed Up


Courtesy of VOLVO CARS CORPORATION

 Press up the catches and remove the covers. Do not damage the painted surfaces or the high-pressure
washer nozzles.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 9: Identifying Bumper Cover And Air Baffle


Courtesy of VOLVO CARS CORPORATION

 Detach the ends of the bumper casing on the left and right sides, by grabbing the end of the bumper
casing inside the wing liner. Pull carefully so that the two catches on the inside release.
 Remove the bumper casing with air baffle, by pulling them forward until the remaining catch under the
lights release.
 Disconnect the connectors for the fog lamps if applicable.

Fig. 10: Identifying Intake Manifold Screws


Courtesy of VOLVO CARS CORPORATION

 Remove the two screws in the intake manifold.


 Remove the intake manifold.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 11: Identifying Removal Of Bonnet Catch Cover


Courtesy of VOLVO CARS CORPORATION

 Remove the two screws for the panel over the bonnet catch.
 Remove the panel. Lift it up at the rear edge and then pull it backwards.

Fig. 12: Identifying Removal Of Wire Sleeve From Hood Lock


Courtesy of VOLVO CARS CORPORATION

 Pull loose the wire sleeve and the wire from the mounting in the hood lock.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 13: Locating Bonnet Catch Screws


Courtesy of VOLVO CARS CORPORATION

 Remove the bonnet catch screws


 Remove the bonnet catch.

Fig. 14: Identifying Pre-Routed Connector


Courtesy of VOLVO CARS CORPORATION

 Unplug the pre-routed connector from the parking module in the bonnet catch by pressing in the catch
and pulling.
 Place the bonnet catch to one side, it shall not be used again.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 15: Identifying Connectors


Courtesy of VOLVO CARS CORPORATION

 Take the new bonnet catch from the kit and secure it with the existing screws.
 Torque tighten the screws to 24 Nm (18 lbf. ft.) .
 Plug the bonnet catch's connector (1) into the pre-routed connector (2).
 Secure the wire and the sleeve in the new bonnet catch.
 Reinstall the panel above the bonnet catch.
 Reinstall the intake manifold.
 Reinstall the bumper cover using the five clips and the two screws in the upper edge.
 Reconnect the connectors for the fog lamps if applicable.
 Make sure that the air baffle ends up correctly in its mounting.
 Press the end faces for the bumper cover into the body and reinstall the five screws at the front edge of
the wheel housing (on the right and left-hand sides).

 Program the software in accordance with the service information in VIDA (Volvo Scan Tool).

ALARM, MOVEMENT SENSOR

NOTE: This accessory is connected to the car's electrical system. It requires software
unique to the car.

 Turn the ignition switch to position 0.

NOTE: Wait at least five minutes before disconnecting the connectors or


removing other electrical equipment.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 16: Identifying Headlining Cover Panel


Courtesy of VOLVO CARS CORPORATION

 Carefully pry off the cover panel (1) from the headlining with a weatherstrip tool.

The pre-routed connector is attached to the inside of the cover panel.

Fig. 17: Identifying Installation Of Movement Sensor


Courtesy of VOLVO CARS CORPORATION

 Take the sensor with the green connection from the kit.
 Loosen the connector from its position on the inside of the cover panel.
 Press the movement sensor onto the cover panel and ensure that all the fasteners take hold.
 Plug in the connector to the movement sensor.
 Replace the cover panel with the movement sensor in the headlining.
 Program the function with VCT 2000 in VIDA (Volvo Scan Tool).
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 18: Identifying Tailgate Sill Trim Panel Clips


Courtesy of VOLVO CARS CORPORATION

Removing the sill trim panel from the tailgate:

 Pry off the four external clips at the front edge/bottom edge of the sill trim panel on the tailgate.
 Pry up one of the corners of the sill trim panel so that the two clips at that end release. Use a weatherstrip
tool.
 Pull up the sill trim panel so the remaining six clips release. Remove the panel.
 Detach the rubber strip where it covers the right-hand side panel in the boot opening.

Fig. 19: Identifying Removal Of Rear Roof Panel


Courtesy of VOLVO CARS CORPORATION

Removing the rear roof panel:

 Grip the edges of the rear roof panel and pull downwards, so that the nine clips release. Pry using a
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

NOTE: Do not damage the panels.

 Disconnect the connector from the lighting and move the roof panel to one side.

Fig. 20: Identifying Folded Seat Cushion And Backrest


Courtesy of VOLVO CARS CORPORATION

 Fold the seat cushion and backrest on the right-hand side of the rear seat forward.

Fig. 21: Identifying Removal Of Side Cushion


Courtesy of VOLVO CARS CORPORATION

Removing the side cushion:

 Grip the upper edge of the right-hand side cushion (A). Pull the side cushion backwards so that the clip on
the reverse releases.
 Slide the side cushion upwards.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Removing the panel at the front/top of the side panel:

 Remove the screw (B) at the rear edge of the panel at the front/top of the right-hand side panel.
 Pull the panel upwards so that the four clips on the inside release.

Fig. 22: Identifying Rubber Strip


Courtesy of VOLVO CARS CORPORATION

 Pull off the rubber strip (A) at the rear of the opening for the right-hand rear door.

Removing the lower panel on the C-post:

 Carefully pry off the lower panel on the C-post (B) on the right-hand side. Carefully pry at the top edge.
Use a plastic weatherstrip tool.
 Pull the panel on the C-post so that the two upper clips release. Then continue pulling downwards until
the last two clips release.

Removing the upper panel on the C-post:

 Repeat for the panel on the lower C-post (C), but now three clips should release.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 23: Identifying Anchorage Eyelet Screws


Courtesy of VOLVO CARS CORPORATION

Removing the side panel:

 Fold out the load securing eyelets on the right-hand side panel.
 Insert a scriber with an angled tip into the holes in the top of the covers (1). Turn the scriber so that the tip
engages the reverse of the cover. Pull the covers off.
 Remove the screws in the load securing eyelets.
 Remove the screw (2) at the front/top edge of the side panel.
 Pull off the side panel at the top so that the two clips at the rear/bottom of the side window and the clip at
the bottom of the D-post release.
 Lift out the side panel.

Fig. 24: Identifying Removal Of Panel On D-Post


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Removing the panel on the D-post:

 Carefully pry off the right-hand panel on the D-post at the lower edge. Use a plastic weatherstrip tool.
 Pull the panel on the D-post forwards so that the two clips on the lower edge release. Continue to pull
forwards, until the two clips further up release.
 Unhook the panel on the D-post backwards from the roof panel.

NOTE: Do not damage the panels.

Fig. 25: Identifying Removal Of Screw


Courtesy of VOLVO CARS CORPORATION

 Pry up the cover on the attachment over the cargo compartment's right-hand side window and remove the
screw beneath.

Fig. 26: Identifying Removal Of Rear Door's Courtesy Handle


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Removing the rear door courtesy handle:

 Hold down the courtesy handle over the right-hand rear door. Pry loose the screw cover using a small
screwdriver and remove the screws.
 Carefully pull off the handle (some force is required to remove it).

NOTE: Do not damage the roof panel.

Lowering the roof panel:

 Turn the clip in the center of the roof panel 90° and pull off.
 Loosen the rubber strip on the top edge of the right-hand rear door.
 Carefully lower the roof panel.

NOTE: Exercise care so that the roof panel does not break further forward in its
fasteners.

 Hang up the roof panel by the rear edge if necessary.

Fig. 27: Identifying Installation Of Sensor


Courtesy of VOLVO CARS CORPORATION

Installing the sensor

NOTE: Do not damage the roof panel or the rear window washer hose.

 Take the sensor with the blue connection from the kit.
 Loosen the ready routed, taped connector from the roof panel.
 Plug in the connector to the sensor.
 Remove the protective paper from the tape on the sensor.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

 Place the sensor in the four recesses in the roof panel, where the blue connector was located. Ensure the
senor is straight.

NOTE: In order for the sensor to work correctly, it must be located within the
corner markings and must not be misaligned by more than 5 degrees.

 Hold the underside of the roof panel and push on the sensor.

Reinstall:

 clip in the center of the roof panel.


 the screws in the attachment above the rear side window. Tighten with 50 Nm (37 lbf. ft.) and push on
the cover.
 courtesy handle over the rear door. Tighten the screws with 8 ± 2 Nm (6 ± 1.5 lbf. ft.) and push on the
cover.
 side panel and tighten. Tighten the screws on the load securing eyelets with 24 Nm (18 lbf. ft.) and push
on the cover.
 panels on the C and D-posts and connect the connector if necessary.
 the rubber strip at the rear edge of the opening for the rear door.
 the panel at the front/top of the side panel.
 side cushion.

 Fold back the backrest and seat cushion on the rear seat.
 Connect the connector for the lighting in the rear roof panel.

Reinstall:

 the rear headlining


 the sill trim panel for the tailgate.
 the rubber strip in the cargo compartment opening.

 Download the software for the accessory's function following the service information in VIDA (Volvo
Scan Tool).

ACCESSORY ELECTRONIC MODULE (AEM), INSTALLATION KIT


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 28: Identifying Ignition Switch Turned To Position 0


Courtesy of VOLVO CARS CORPORATION

NOTE: Wait at least three minutes before unplugging the connectors or removing other
electrical equipment.

Fig. 29: Identifying Trunk Cover


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 30: Identifying Trunk Floor Cover


Courtesy of VOLVO CARS CORPORATION

Fig. 31: Identifying Tailgate's Sill Panel


Courtesy of VOLVO CARS CORPORATION

 Remove the tailgate sill panel by pulling it up until the four clips on the upper side and the eight catches
at the lower edge release.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 32: Identifying Spare Tire


Courtesy of VOLVO CARS CORPORATION

Fig. 33: Identifying Rear Seat Cushion


Courtesy of VOLVO CARS CORPORATION

 Pull off the rear seat's seat cushion by first pulling it at the rear edge where it is positioned with a holder,
then at the front edge where it is positioned with two holders.
 Remove the seat cushion.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 34: Identifying Central Arm Rest


Courtesy of VOLVO CARS CORPORATION

 Fold the central arm rest forward.


 Remove the central arm rest by grasping each end and pulling upwards until it releases at the rear edge
from the backrest's lugs (1).
 Then pull forwards until the holders (2) on the sides of the backrest have slid out of the corresponding
cut-out (3) in the central arm rest.

Fig. 35: Identifying Backrest Cover


Courtesy of VOLVO CARS CORPORATION

 Fold the backrest forward.


 Remove the cover for the backrest's right-hand mounting.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 36: Identifying Locking Sleeve And Screw


Courtesy of VOLVO CARS CORPORATION

 Remove the screws and the locking sleeve. Tightening torque 15 Nm (11.0 lbf. ft.) .

Fig. 37: View Of Backrest Stowed


Courtesy of VOLVO CARS CORPORATION

 Fold the backrest away from the right-hand mounting.


 Pull the backrest out from the mounting at the arm rest and remove it.

NOTE: The backrest may be securely attached.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 38: Identifying Rubber Door Molding RH


Courtesy of VOLVO CARS CORPORATION

 Pull off the rubber molding at the rear edge of the right-hand door opening.

Fig. 39: Identifying B Pillar Panel


Courtesy of VOLVO CARS CORPORATION

 Detach the B pillar panel at the rear edge by prying the sides using a weatherstrip tool until the two clips
release.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 40: View Of Safety Clip Strap


Courtesy of VOLVO CARS CORPORATION

 Unhook the safety clip from the panel.


 Angle out the panel at the lower edge, and unhook it at the upper edge so that the upper clip releases.

Fig. 41: Identifying Rear Seat RH Panel


Courtesy of VOLVO CARS CORPORATION

 Remove the screw from the right-hand panel in the rear seat.
 Carefully pull the panel from the body side and unhook it from the sill panel at the front edge. It is
secured by eleven clips on the inside.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 42: Identifying Right-Hand Rear Side Panel


Courtesy of VOLVO CARS CORPORATION

 Remove the clips at the rear edge on the right-hand rear side panel.
 Carefully pull the side panel off, starting at the front edge of the upper edge and then straight back until
all clips at the top edge have released.
 Fold the panel inwards. Release it from the anchorage eyelets and lift it out of the spare wheel well.

Fig. 43: Identifying Square Sound Insulation


Courtesy of VOLVO CARS CORPORATION

 Remove the square sound insulation.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 44: Identifying Sound Insulation


Courtesy of VOLVO CARS CORPORATION

 Remove the sound insulation.

APPLIES TO CARS WITHOUT A TRAILER MODULE (TRM) AND PARKING ASSISTANCE (PAS)

Fig. 45: Identifying Grey 2-Pin And Green 5-Pin Connector


Courtesy of VOLVO CARS CORPORATION

 Locate the grey 2-pin and green 5-pin connector under the corner of the spare wheel well.
 Then pull up the spare wheel well as far as possible for better access.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 46: Identifying Adapter Wiring And Routed Cables


Courtesy of VOLVO CARS CORPORATION

 Connect the adapter wiring to the car's routed cables.

APPLIES TO CARS WITH A TRAILER MODULE (TRM)

Fig. 47: Identifying Green 5-Pin And Grey 2-Pin Connectors


Courtesy of VOLVO CARS CORPORATION

 Disconnect the green 5-pin and grey 2-pin connectors from the control module and connect these to the
adapter wiring.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 48: Connecting Adapter Wiring


Courtesy of VOLVO CARS CORPORATION

 Connect the adapter wiring to the TRM.

APPLIES TO CARS WITH PARKING ASSISTANCE (PAS) WITHOUT TRAILER MODULE (TRM)

Fig. 49: Locating 5-Pin Green Connector Taped Onto Parking Assistance Cable Harness
Courtesy of VOLVO CARS CORPORATION

 Locate the 5-pin green connector that is taped onto the parking assistance cable harness. Connect this to
the adapter wiring (B).

NOTE: It is important that parking assistance (PAS) is connected the same way as the
first unit.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 50: Identifying Grey 2-Pin Connector


Courtesy of VOLVO CARS CORPORATION

 Locate the grey 2-pin connector under the corner on the spare wheel well.
 Then pull up the spare wheel well as far as possible for better access.

Fig. 51: Connecting Adapter Wiring To Car's Routed Grey 2-Pin Connector
Courtesy of VOLVO CARS CORPORATION

 Connect the adapter wiring to the car's routed grey 2-pin connector.

APPLIES TO ALL MODELS


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 52: Applying Foam Tape To Adapter Wiring's Connectors


Courtesy of VOLVO CARS CORPORATION

 Apply foam tape to the adapter wiring connectors.


 Cut off any foam tape excess.

Fig. 53: Identifying Screw For Ground Terminal Under Rear Light
Courtesy of VOLVO CARS CORPORATION

 Remove the screw for the ground terminal under the rear light.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 54: Connecting Ground Terminal From Adapter Wiring To Ground Terminal And Tightening
Screw
Courtesy of VOLVO CARS CORPORATION

 Connect the ground terminal from the adapter wiring to the ground terminal.
 Tighten the screw. Tightening torque 10 Nm (7.3 lbf. ft.) .

Fig. 55: Cleaning Marked Surface On Body Panel


Courtesy of VOLVO CARS CORPORATION

 Clean the marked surface on the body panel using isopropanol and wipe dry.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 56: Cleaning Marked Surface On Control Module


Courtesy of VOLVO CARS CORPORATION

 Clean the marked surface on the control module using isopropanol and wipe dry.

Fig. 57: Identifying Velcro Pieces


Courtesy of VOLVO CARS CORPORATION

 Take the Velcro pieces from the kit and attach them edge to edge with each other.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 58: Cutting Tape


Courtesy of VOLVO CARS CORPORATION

Fig. 59: Identifying Protective Backing Tape


Courtesy of VOLVO CARS CORPORATION

 Remove the protective backing tape from one side of the Velcro pieces.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 60: Identifying Velcro


Courtesy of VOLVO CARS CORPORATION

 Secure the Velcro onto the control module properly.

Fig. 61: Identifying Protective Film


Courtesy of VOLVO CARS CORPORATION

 Remove the protective film.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 62: Identifying Control Module


Courtesy of VOLVO CARS CORPORATION

 Position the control module along the rear edge of the rectangular storage compartment in the spare wheel
well (dotted line 1).
 Position the control module vertically with the lower panel edge on the wheel housing (dotted line 2).
 Press the control module into place properly.

Fig. 63: Positioning Control Module Along Spare Wheel Well And Wheel Housing
Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 64: Identifying 4-Pin Black Connector


Courtesy of VOLVO CARS CORPORATION

 Plug the 4-pin black connector from adapter wiring (B) into the control module.

Fig. 65: Identifying 50-Pin Black Connector


Courtesy of VOLVO CARS CORPORATION

 Install the 50-pin black connector in the control module.

APPLIES TO CARS WITH CHASSIS NUMBERS FROM 39000->


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 66: Identifying Fuse Box In The Engine Compartment


Courtesy of VOLVO CARS CORPORATION

 Pull up the catch on the cover on the fuse box in the engine compartment. Pull up the cover and remove
it.

Fig. 67: Identifying Terminal 14


Courtesy of VOLVO CARS CORPORATION

 Take a 40A fuse from the kit and install it in position 14 in the fuse holder.
 Reinstall the cover.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 68: Identifying VIDA (Service Information) To Program Software


Courtesy of VOLVO CARS CORPORATION

 Reinstall the removed components in reverse order.


 Download the software for the accessory's function following the service information in VIDA (Volvo
Scan Tool).

PARKING ASSISTANCE, FRONT, SWITCH


PARKING ASSISTANCE, FRONT, SWITCH

PREPARATIONS

Fig. 69: Identifying Ignition Key In 0 Position


Courtesy of VOLVO CARS CORPORATION

 Set the ignition key to position 0.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

NOTE: Wait at least one minute before unplugging the connectors or removing other
electrical equipment

Fig. 70: Identifying Rear Center CONSOLE Panel


Courtesy of VOLVO CARS CORPORATION

 Remove the panel inside the center console. It is secured by four hidden clips.

Fig. 71: Identifying Display And Media Player Surround


Courtesy of VOLVO CARS CORPORATION

 Remove the surround from around the display and media player. Use a small screwdriver and press in the
catch in one of the surround's upper corners. Carefully bend loose the surround on the same side with a
plastic weatherstrip tool.

NOTE: Do not damage the panel and dashboard.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

HINT: If the panel is difficult to remove, press the panel on both sides again and repeat the
procedure starting at the other side.

 Fold the surround backwards. Remove by pulling upwards.

Fig. 72: Identifying Display Module


Courtesy of VOLVO CARS CORPORATION

 Remove the infotainment control module (ICM). It is secured by two hidden clips. Disconnect the
connectors.

HINT: Grip the control module with both hands. Pull the control module straight out of the center
console.

Fig. 73: Identifying Hand Brake Panel


Courtesy of VOLVO CARS CORPORATION

 Detach the panel by pulling it carefully sideways.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 74: Identifying Rear Edge Screw Cover


Courtesy of VOLVO CARS CORPORATION

 Fold up the tunnel console's armrest and remove the cover.

Fig. 75: Identifying Center Console Rear Edge Screws


Courtesy of VOLVO CARS CORPORATION

 Remove the screws.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 76: View Of Storage Compartment Prying


Courtesy of VOLVO CARS CORPORATION

 Remove the front storage compartment by prying it off at the front edge using a weatherstrip tool and
lifting it out.

Fig. 77: Identifying Front Edge Tunnel Console Screws


Courtesy of VOLVO CARS CORPORATION

 Remove the two screws along the front edge of the tunnel console.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 78: Identifying Tunnel Console Lock Catch


Courtesy of VOLVO CARS CORPORATION

 Carefully lift the catches at the front edge of the tunnel console.

HINT: Use special tool: P/N 9995919.

Fig. 79: Identifying Console Pulled Backwards


Courtesy of VOLVO CARS CORPORATION

 At the same time pull the console backwards approximately 20 mm.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 80: Identifying Center Console Screws


Courtesy of VOLVO CARS CORPORATION

 Remove the screws.

Fig. 81: Identifying Gear Selector Lever Boot


Courtesy of VOLVO CARS CORPORATION

Applies to cars with manual gearbox

 Remove the gear selector lever boot from the center console. First pry it off at the front edge using a
weatherstrip tool and then unhook it at the rear edge.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 82: Identifying Center Console Screws


Courtesy of VOLVO CARS CORPORATION

Remove:

 the two screws.


 the connector to the center console at the rear.
 the center console.

Fig. 83: Identifying Big Gray Connector At Front


Courtesy of VOLVO CARS CORPORATION

 Lift up the tunnel console and pull it back slightly.


 Unplug the big gray connector at the front.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 84: Identifying Direction To Lift Out Tunnel Console


Courtesy of VOLVO CARS CORPORATION

 Lift out the tunnel console and turn it upside down.

NOTE: Protect hand brake and gear lever when removing and installing the tunnel
console.

Fig. 85: Identifying Installing Switch


Courtesy of VOLVO CARS CORPORATION

 Take the switch housing, switch and blind cover plug from the kit. Install the switch (1) and the blind
cover plug (2) in the switch housing.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 86: Identifying Installing Switch Housing


Courtesy of VOLVO CARS CORPORATION

 Install the switch housing on the tunnel console by first hooking it at the rear edge.

Fig. 87: Identifying Green Connector Attached To Switch Housing


Courtesy of VOLVO CARS CORPORATION

 Take the cable harness from the kit and connect the green connector to the switch housing.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 88: Identifying Secured Cable Harness


Courtesy of VOLVO CARS CORPORATION

 Secure the cable harness using four cable ties at the existing cable harness.

Fig. 89: Identifying Attachment Of Connectors


Courtesy of VOLVO CARS CORPORATION

 Connect the connector (1) from the tunnel console's cable harness to the connector (2) on the prerouted
cable harness.
 Take a piece of foam tape from the kit and wrap it around the connected connectors.

INSTALLING THE SWITCH

APPLIES TO VEHICLES WITH BLIS OR DRIVE (NOT BOTH)


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 90: Identifying Switch Housing Catches


Courtesy of VOLVO CARS CORPORATION

 Release the catches holding the switch housing and lift out.

Fig. 91: Identifying Blind Cover Plug


Courtesy of VOLVO CARS CORPORATION

 Remove the blind cover plug by pulling it straight out.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 92: Identifying Installation Of Switch


Courtesy of VOLVO CARS CORPORATION

 Install the switch from the kit.


 Reinstall the switch housing on the tunnel console.

APPLIES TO VEHICLES WITH BOTH BLIS AND DRIVE, AS WELL AS VEHICLES WITHOUT BLIS OR DRIVE

Fig. 93: Identifying Removal Of Storage Compartment


Courtesy of VOLVO CARS CORPORATION

 Remove the storage compartment from the tunnel console by releasing the catches.

FINISHING WORK
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 94: Identifying VIDA (Service Information) To Program Software


Courtesy of VOLVO CARS CORPORATION

Reinstall:

 the tunnel console and the large connector.


 the center console with its screws, two up and two down.
 gear lever gaiter, starting at the trailing edge.
 and slide the tunnel console forward so that the lugs secure it. At the same time align the floor carpet on
the right and left-hand sides.
 the two screws at the front edge of the tunnel console.
 the cover at the parking brake.
 the panel at the parking brake.
 the two screws and the cover under the armrest.
 the ignition control module (ICM) with the connectors, screws and panel.
 front storage compartment inside of the center console.
 the panel inside the center console.

Applies to vehicles with both BLIS and DRIVe, as well as vehicles without BLIS or DRIVe

 Run the identification and configuration procedure for the accessory's function according to the service
information in VIDA (Volvo Scan Tool).

Applies to vehicles with BLIS or DRIVe (not both)

 Run the configuration procedure for the accessory's function according to the service information in
VIDA (Volvo Scan Tool).

ALCOGUARD (2008-09)
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

ALCOGUARD

NOTE: The work is carried out the same way on left-hand drive cars. Left-hand drive
car shown.

Fig. 95: Identifying Application Of Alcohol Lock


Courtesy of VOLVO CARS CORPORATION

 Activate (and calibrate) the alcohol lock


 After installing the software on the PC according to TJ, connect the alcohol lock to the PC using the
communication cable.

Fig. 96: Identifying Ignition Switch Turned To Position 0


Courtesy of VOLVO CARS CORPORATION

 Turn the ignition switch to position 0.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

NOTE: Wait at least three minutes before unplugging the connectors or removing other
electrical equipment.

Fig. 97: Locating Cradle


Courtesy of VOLVO CARS CORPORATION

 Place the cradle centrally between the two vertical lines at the front edge of the tunnel console and
parallel with the panel at the upper edge.
 Mark out for drilling holes.

Fig. 98: Identifying Rear Center Console Panel


Courtesy of VOLVO CARS CORPORATION

 Open the glovebox.


 Carefully pry off the panel inside the center console. Use a plastic weatherstrip tool. The panel is secured
by two clips on each of the short sides.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 99: Identifying Screws


Courtesy of VOLVO CARS CORPORATION

 Remove the screws.

Fig. 100: Identifying Folded Back Front Edge Of Tunnel Console


Courtesy of VOLVO CARS CORPORATION

 Carefully fold back the front edge on the tunnel console and ensure that no cable harnesses or anything
else is in the way when drilling.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 101: Identifying Tools And Location Of Holes


Courtesy of VOLVO CARS CORPORATION

 Drill out the holes.


 Remove any shavings.

Fig. 102: Identifying Panel


Courtesy of VOLVO CARS CORPORATION

 Remove the panel on the right end of the dashboard. Carefully pry it loose all around with a weatherstrip
tool, until the three legs release.

NOTE: Do not damage the dashboard.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 103: Identifying Vent Clip


Courtesy of VOLVO CARS CORPORATION

 Detach the clip holding the vent from the glove compartment.

Fig. 104: Locating Glovebox Screws


Courtesy of VOLVO CARS CORPORATION

 Remove the glove compartment's rubber mat.


 Remove the five screws in the opening to the glovebox.
 Pull the glove compartment straight back to loosen the two hidden clips in the upper edge.
 Remove the outer section of the glovebox.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 105: Identifying Connectors


Courtesy of VOLVO CARS CORPORATION

 Unplug the connectors on the top.

Fig. 106: Identifying Cut Out For Cable In Panel


Courtesy of VOLVO CARS CORPORATION

 Make a cut out for the cable in the panel. Do not cut out more than necessary so that the cable can be
secured slightly.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 107: Identifying Hole Dimensions


Courtesy of VOLVO CARS CORPORATION

 Drill a 10 mm (25/64") hole on the left side of the glove compartment's outer part.
 Remove any shavings.

Fig. 108: Identifying Plugged In Connector


Courtesy of VOLVO CARS CORPORATION

 Get the adapter wire from the kit and plug in one connector to the connection for the glove compartment
lighting.
 Route the wires at the lower edge to the other side.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 109: Identifying Wires And Connector Fastened With Butyl Tape
Courtesy of VOLVO CARS CORPORATION

 Fasten the wires and the little green connector with pieces of butyl tape.

Fig. 110: Identifying Insertion Of Small Connector And Cable


Courtesy of VOLVO CARS CORPORATION

 Insert the small connector and the whole cable in the glove compartment's outer part.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 111: Identifying Wire Fastened With Butyl Tape


Courtesy of VOLVO CARS CORPORATION

 Fasten the wire at the hole with a piece of butyl tape.

Fig. 112: Identifying Attachment Of Connector To Courtesy Lighting


Courtesy of VOLVO CARS CORPORATION

 Get the outer glove compartment and plug in the connector from the glove compartment lighting to the
corresponding in the new adapter wire.
 Connect the remaining connector to the courtesy lighting.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 113: Identifying Cable Secured With Ties


Courtesy of VOLVO CARS CORPORATION

 Take the cradle with cable and connect the green connector to the corresponding one that was secured in
the glove compartment.
 Secure the cable at the existing cable harness using cable ties. The cable must run along the right-hand
mounting of the tunnel console.
 Secure the grey connector in the glove compartment.

Fig. 114: Locating Glovebox Screws


Courtesy of VOLVO CARS CORPORATION

 Reinstall and tighten down the glove compartment's outer part.


 Roll up the wire in the glove compartment and fasten it with the Velcro strap.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 115: Identifying Excess Cable Storage Behind Tunnel Console


Courtesy of VOLVO CARS CORPORATION

 Pull in the cable to the cradle and place it on the right-hand side of the tunnel console inside the carpet. If
it is a tight fit, carefully cut off a piece from the glove compartment's left-hand corner.
 Tighten the tunnel console at the front edge.

Fig. 116: Identifying Re-Attachment Of Panel


Courtesy of VOLVO CARS CORPORATION

 Place the cable in the cut out in the panel and secure.
 Fold back the carpet.
 Tighten the cradle. Ensure that the cable is correctly routed in the cut out.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 117: Locating And Orienting Cradle


Courtesy of VOLVO CARS CORPORATION

Fig. 118: Identifying Vent Clip


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 119: Identifying Dashboard Side Panel


Courtesy of VOLVO CARS CORPORATION

Fig. 120: Identifying VIDA (Service Information) To Program Software


Courtesy of VOLVO CARS CORPORATION

 Download the software for the accessory's function following the service information in VIDA (Volvo
Scan Tool).

ALCOGUARD, KIT NUMBER 30756979 (2009-12)


ALCOGUARD, KIT NUMBER 30756979
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 121: Identifying Application Of Alcohol Lock


Courtesy of VOLVO CARS CORPORATION

 Activate (and calibrate) the alcohol lock.

The necessary software can also be found there.

 After installing the software on a PC according to the TJ, connect the alcohol lock to the PC using the
supplied communication cable. A question asking whether to activate appears automatically (if the lock is
not activated), otherwise nothing special happens.

Fig. 122: Identifying Ignition Switch Turned To Position 0


Courtesy of VOLVO CARS CORPORATION

 Turn the ignition switch to position 0.

NOTE: Wait at least three minutes before unplugging the connectors or removing other
electrical equipment.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 123: Identifying Rear Center CONSOLE Panel


Courtesy of VOLVO CARS CORPORATION

 Open the glovebox.


 Carefully pry off the panel inside the center console. Use a plastic weatherstrip tool. The panel is secured
by two clips on each of the short sides.
 Pull the panel off downwards.

Fig. 124: Identifying Panel


Courtesy of VOLVO CARS CORPORATION

 Remove the panel on the right end of the dashboard. Carefully pry it loose all around with a weatherstrip
tool, until the three legs release.

NOTE: Do not damage the dashboard.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 125: Identifying Vent Clip


Courtesy of VOLVO CARS CORPORATION

 Detach the clip holding the nozzle from the glove compartment.

Fig. 126: Locating Glovebox Screws


Courtesy of VOLVO CARS CORPORATION

 Remove the glove compartment's rubber mat.


 Remove the five screws in the opening to the glovebox.
 Pull the glove compartment straight back to loosen the two hidden clips in the upper edge.
 Remove the outer section of the glovebox.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 127: Identifying Connectors


Courtesy of VOLVO CARS CORPORATION

 Unplug the connectors on the top.

Fig. 128: Identifying Center Console Screws


Courtesy of VOLVO CARS CORPORATION

 Remove the two remaining screws at the rear of the center console.
 Put away the screws and get new ones from the kit.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 129: Identifying Wire Hooked And Routed To Slot


Courtesy of VOLVO CARS CORPORATION

 Take the holder from the kit and insert the green connector in the lower hole and pull through the whole
wire.
 Hook on the wire around the lip in the upper hole and place it in the slot at the top.

Fig. 130: Identifying Secured Wire


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 131: Identifying Installation Of Holder With Screws


Courtesy of VOLVO CARS CORPORATION

NOTE: Be careful when tightening the bolts, as it is easy to tighten them in too far.

 Take the two longer screws from the kit.


 Install the holder with the two screws in the upper edge and tighten.
 Tighten the bolts so that the head just has contact against the holder.
 Then tighten the bolts slightly more.
 Check that the holder is fastened at the top.

Fig. 132: Identifying Adjustment Of Holder


Courtesy of VOLVO CARS CORPORATION

NOTE: The lower holes are angled 45° .


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

middle of the hole in the holder with a scribe to get the self-tapping screw to center better.
 Repeat the operation on the other side.

Fig. 133: Identifying Installment Of Screws


Courtesy of VOLVO CARS CORPORATION

 Take the self-tapping screws from the kit and tighten them.

Fig. 134: Identifying Filed Slot


Courtesy of VOLVO CARS CORPORATION

 File a slot in the panel for the holder's wire as shown.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 135: Identifying Wire Secured With Tie


Courtesy of VOLVO CARS CORPORATION

 Pull up the wire from the holder to the green connector for the display.
 Clamp the wire to the connector's cable harness so that the wire reaches down to the holder and so that it
fits in the slot in the panel.

Fig. 136: Identifying Wire Secured With Tie


Courtesy of VOLVO CARS CORPORATION

 Get the wire coming from the holder and attach it on the right side of the center console. The wire shall be
attached to the existing cable harness with a cable tie from the kit.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 137: Identifying Hole Dimensions


Courtesy of VOLVO CARS CORPORATION

 Drill a 10 mm (25/64") hole on the left side of the glove compartment's outer part.
 Remove any shavings.

Fig. 138: Identifying Plugged In Connector


Courtesy of VOLVO CARS CORPORATION

 Get the adapter wire from the kit and plug in one connector to the connection for the glove compartment
lighting.
 Route the wires at the lower edge to the other side.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 139: Identifying Wires And Connector Fastened With Butyl Tape
Courtesy of VOLVO CARS CORPORATION

 Fasten the wires and the little green connector with pieces of butyl tape.

Fig. 140: Identifying Insertion Of Small Connector And Cable


Courtesy of VOLVO CARS CORPORATION

 Insert the little green connector and the whole wire in the glove compartment's outer part.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 141: Identifying Wire Fastened With Butyl Tape


Courtesy of VOLVO CARS CORPORATION

 Fasten the wire at the hole with a piece of butyl tape.

Fig. 142: Identifying Attachment Of Connector To Courtesy Lighting


Courtesy of VOLVO CARS CORPORATION

 Get the outer glove compartment and plug in the connector from the glove compartment lighting to the
corresponding in the new adapter wire.
 Plug in remaining connector in the adapter wire for the glove compartment lighting.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 143: Identifying Attachment Of Green Connector


Courtesy of VOLVO CARS CORPORATION

 Plug in the green connector from the holder to corresponding on the adapter wire for the glove
compartment lighting.
 Fasten the grey connector on the glove compartment's outer part.

Fig. 144: Locating Glovebox Screws


Courtesy of VOLVO CARS CORPORATION

 Install and tighten down the glove compartment's outer part.


 Roll up the wire in the glove compartment and fasten it with the Velcro strap.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 145: Identifying Rear Center Panel


Courtesy of VOLVO CARS CORPORATION

 Fit the wire from the holder in the slot on the panel and press to fasten.

Fig. 146: Identifying Routed Cable


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 147: Identifying Vent Clip


Courtesy of VOLVO CARS CORPORATION

Fig. 148: Identifying Dashboard Side Panel


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 149: Identifying VIDA (Service Information) To Program Software


Courtesy of VOLVO CARS CORPORATION

 Download the software for the accessory's function following the service information in VIDA (Volvo
Scan Tool).

ALCOLOCK, INSTALLATION KIT


ALCOLOCK, INSTALLATION KIT

PREPARATIONS

Fig. 150: Disconnect Battery Negative Lead


Courtesy of VOLVO CARS CORPORATION

 Turn the ignition key to position 0.


 Disconnect the battery negative lead.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

NOTE: Wait at least five minutes before disconnecting the connectors or removing
other electrical equipment.

Fig. 151: Locating Screws In Soundproofing Panel


Courtesy of VOLVO CARS CORPORATION

 Remove the three screws in the soundproofing panel on the left-hand side.
 Push the carpet on the left-hand side of the center console to one side.
 Carefully pry off the soundproofing panel from the top edge of the dashboard. Use a weatherstrip tool.
The panel is secured by two clips at the top edge.

Fig. 152: Identifying Lighting Connectors


Courtesy of VOLVO CARS CORPORATION

 Disconnect the connector for lighting (1) and remove the soundproofing panel.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 153: Identifying Carpet


Courtesy of VOLVO CARS CORPORATION

 Fold the carpet to one side on the left-hand side.

INSTALLATION

Fig. 154: Identifying Cable Harness Connectors


Courtesy of VOLVO CARS CORPORATION

 Place the fuse holder and connector for the alcolock on the member and secure them with tie straps.
 Place the ground connection for the cable harness at the front ground terminal in the A post.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 155: Identifying Installation Of Ground Lead


Courtesy of VOLVO CARS CORPORATION

 Install the ground lead, use new screws from the kit.

Tighten the M6 screw to 10 Nm .

 Fold back the carpet.

Fig. 156: Identifying Ignition Switch Cable And Connector


Courtesy of VOLVO CARS CORPORATION

 Disconnect the existing connector from the ignition switch.


 Connect the connectors from the new cable harness to the corresponding connector in the ignition switch
and the existing disconnected cable.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 157: Identifying Lighting Connectors


Courtesy of VOLVO CARS CORPORATION

 Connect the connectors from the new cable harness to the corresponding connector for lighting (1), which
was previously disconnected.
 Reinstall the soundproofing panel.

Fig. 158: Connecting Negative Battery Lead


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Other Electrical Equipment - Installation Instructions, Accessories

Fig. 159: Identifying Alcolock Connector Terminals


Courtesy of VOLVO CARS CORPORATION

Connector for alcolock

1. 30+ feed (battery supply)


2. 15+ feed (ignition supply)
3. Start-in (kl50)
4. Start-out (kl50)
5. Preheat, act-low
6. Ground-, (31)
7. 30+ feed, controlled

NOTE: 30+ battery supply (1) must only be used in exceptional cases when log
function for disconnection of the alcolock is required. In all other cases, 30+
battery supply (7) should be used, to prevent shortening the service life of the
battery.
2012 Volvo C30 T-5
ENGINE Engine Mechanical

ENGINE

Engine Mechanical

ENGINE MECHANICAL
RELAY ELECTRICAL ENGINE BLOCK HEATER, REPLACING

NOTE: As the illustrations in this service information are used for different model years
and / or models, some variation may occur. However, the essential information
in the illustrations is always correct.

REMOVAL

PREPARATORY WORK

Fig. 1: Pulling Locking Plate Straight Up


Courtesy of VOLVO CARS CORPORATION

Remove the locking plate for the headlamp as shown in the illustration.

Disconnect the connector.


2012 Volvo C30 T-5
ENGINE Engine Mechanical

Remove the headlamp.

REMOVING THE RELAY FOR THE ELECTRIC ENGINE BLOCK HEATER

Fig. 2: Removing Relay For Electric Engine Block Heater


Courtesy of VOLVO CARS CORPORATION

Remove:

 the tie straps


 2 screws. Pull out the engine block heater relay
 the locking sleeves for the cable splices. Disconnect the wiring
 the engine block heater relay.

INSTALLATION

INSTALLING THE RELAY FOR THE ELECTRIC ENGINE BLOCK HEATER


2012 Volvo C30 T-5
ENGINE Engine Mechanical

Fig. 3: Installing Relay For Electric Engine Block Heater (1 Of 2)


Courtesy of VOLVO CARS CORPORATION

Connect the wiring:

 front engine block heater socket (1)


 engine block heater (2)
 passenger compartment socket (3) if applicable.
2012 Volvo C30 T-5
ENGINE Engine Mechanical

Fig. 4: Installing Relay For Electric Engine Block Heater (2 Of 2)


Courtesy of VOLVO CARS CORPORATION

Connect the ground lead (4).

Install locking sleeves for the cable splices.

Position the engine block heater relay under the plate (1).

Install the screws (2). Clamp the cables (3, 4).

FINISHING WORK

Connect the connector for the headlamp.

Install the headlamp.

Install the locking plate for the headlamp.

Test the function.


2012 Volvo C30 T-5
ENGINE Cooling System (Mechanical)

ENGINE

Cooling System (Mechanical)

COOLING SYSTEM
ENGINE COOLING FAN (FC)

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

Remove the expansion tank cap.

Block the 2 coolant hoses using lock grip pliers.

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 OIL COOLER FOR AUTOMATIC TRANSMISSIONS

NOTE: Applies only to cars with automatic transmissions

Remove the oil cooler. See: OIL COOLER, ENGINE .

REMOVING THE RADIATOR HOSES

Remove the 2 radiator hoses.

REMOVING THE ENGINE COOLING FAN (FC)


2012 Volvo C30 T-5
ENGINE Cooling System (Mechanical)

Fig. 1: Removing Engine Cooling Fan


Courtesy of VOLVO CARS CORPORATION

Remove the 2 connectors for the engine cooling fan.

Press in the two retaining clips. Lift the engine cooling fan from the catches.

Remove the fan downwards.

INSTALLATION

NOTE: For tightening torques, see: TIGHTENING TORQUE .

INSTALLING THE ENGINE COOLANT FAN (FC)


2012 Volvo C30 T-5
ENGINE Cooling System (Mechanical)

Fig. 2: Installing Engine Cooling Fan


Courtesy of VOLVO CARS CORPORATION

Press the fan shroud into the mounting points.

NOTE: Ensure that the 2 retaining clips secure the fan shroud.

Install the 2 radiator hoses on both sides. Remove the lock grip pliers from the radiator hoses.

INSTALLING THE OIL COOLER FOR AUTOMATIC TRANSMISSIONS

NOTE: Applies only to cars with automatic transmissions.

Install the oil cooler for the automatic transmission. See: OIL COOLER, ENGINE .

FINISHING

Fill with coolant and run the engine until the thermostat opens. Top up as necessary.

NOTE: Automatic cars only. Check the oil level in the transmission. Top up if required.
2012 Volvo C30 T-5
ENGINE PERFORMANCE General - Specifications, Mechanical

ENGINE PERFORMANCE

General - Specifications, Mechanical

LUBRICANTS, ENGINE
USA AND CDN

C30
Engine Service interval Volume Grade Viscosity Part number
(km/miles) (liters)
Petrol 12.000/7.500 Approx. 5.8 ILSAC GF-4 API SAE 5W-30 1161754, -755, -
SL/ACEA A1/B1 756

SPECIFICATIONS, MECHANICAL (B5244S4; 2007-10)


GENERAL DATA
- B5244S4 B5244S5 B5244S7
Engine code 38 66 39
Power (kw/rpm) 125/6000 103/6000 123/6000
Max torque (Nm/rpm) 230/1500-4800 220/4000 230/4000
Max rpm 6500/6800 6500/6800 6500/6800
Idling (rpm) 720 720 720
Cylinder bore (mm) 83 83 83
Stroke (mm) 90 90 90
Swept volume (liters) 2, 435 2, 435 2, 435
Firing sequence 1-2-4-5-3 1-2-4-5-3 1-2-4-5-3
Engine control system Denso Denso Denso
Weight, complete,
150 150 150
including oil (kg)

ENGINE MANUFACTURE NUMBER, ENGINE SERIAL NUMBER AND TYPE


2012 Volvo C30 T-5
ENGINE PERFORMANCE General - Specifications, Mechanical

Fig. 1: Engine Manufacture Number, Engine Serial Number & Type


Courtesy of VOLVO CARS CORPORATION

The engine serial number and type are stamped on the left side of the cylinder block at the top of the mounting
for the water pump.

There is also a decal on the timing casing with the engine type, manufacturing number, and serial number.

CLASSIFICATION OF MAIN BEARINGS

The marking is stamped in the engine block and crankshaft. The classification marking is in the engine block
above the oil cooler and crankshaft. The classification shall be read from the digit 1 to 7.

The first letter after the digit 1 is the classification of main bearing 1. The bearing positions are numbered
starting at the engine's leading edge.

MAIN BEARING
- Class A - Class B - Class C -
block block block
small average large
diameter diameter diameter
- block intermediate block intermediate block intermediate
section section section
2012 Volvo C30 T-5
ENGINE PERFORMANCE General - Specifications, Mechanical

Class A yellow yellow yellow blue blue blue


crankshaft medium medium medium thick thick thick
small
Class B red yellow yellow yellow yellow blue
crankshaft thin medium medium medium medium thick
medium
Class C red red red yellow yellow yellow
crankshaft thin thin thin medium medium medium
large

CYLINDER BLOCK

Fig. 2: Cylinder Block


Courtesy of VOLVO CARS CORPORATION

CYLINDER BORE (D)


Standard -
C-marked........ mm 83.000-83.010
D-marked........ mm 83.010-83.020
E-marked........ mm 83.020-83.030

CYLINDRICALLY
2012 Volvo C30 T-5
ENGINE PERFORMANCE General - Specifications, Mechanical

Maximum deviation -
Cylinder bore........ mm 0.013

PISTONS

Fig. 3: Identifying Piston


Courtesy of VOLVO CARS CORPORATION

PISTONS
Standard The diameter is measured 12 mm from the bottom
of the piston
C-marked1 ........ mm 82.950-82.960
D-marked1 ........ mm 82.960-82.970
E-marked1 ........ mm 82.970-82.980
1 Classification is marked on the top of the piston.

PISTON RUNNING CLEARANCE


Tolerance piston/cylinder - top........ mm 0.010 - 0.030

PISTON RINGS
Top ring........ mm 1.2 -0.01/-0.03
1st ring........ mm 1.5 -0.01/-0.03
Oil ring........ mm 2 -0.01/-0.136

PISTON PIN
Diameter........ mm 21.000 0.000/-0.004
Length........ mm 57.0 0.0/+0.2

VALVES
2012 Volvo C30 T-5
ENGINE PERFORMANCE General - Specifications, Mechanical

Fig. 4: Identifying Valve


Courtesy of VOLVO CARS CORPORATION

VALVES
Intake
Length (A)........ mm 102.00 ± 0.07
Diameter on crown (B)........ mm 31 ± 0.15
Diameter on shaft (C)........ mm 5.94 ± 0.07
Valve angle (D)........° 45.5 ± 0.17
Clearance in guide........µm 50 - 70
Valve clearance........ mm 0.20 ± 0.03
Exhaust
Length (A)........ mm 101.05 ± 0.07
Diameter on crown (B)........ mm 27 ± 0.15
Diameter on shaft (C)........ mm 5.94 ± 0.07
Valve angle (D)........° 45.5 ± 0.17
Clearance in guide........µm 50 - 70
Valve clearance........ mm 0.40 ± 0.03

VALVE SEATS
Seat angle........° 45.5 ± 0.17

TAPPETS
Diameter........ mm 32 -0.025/-0.040
Length........ mm 2.950 - 3.685 ± 0.01

CAMSHAFTS
Max. lift height inlet........ mm 8.68
Max. lift height exhaust........ mm 9.05
2012 Volvo C30 T-5
ENGINE PERFORMANCE General - Specifications, Mechanical

CYLINDER HEAD

CYLINDER HEAD
Max. distortion........ mm 0.5
Max. distortion, transverse........ mm 0.2
Height........ mm 149.4 ± 0.15

CRANKSHAFT
Radial run-out main bearing journal........ mm max. 0.040
Axial play (Measured in the engine with the 0.08-0.19
intermediate section tightened)........ mm
Main bearing journal, radial runout........ mm 0.020-0.043

BIG END JOURNALS


Diameter, standard1 ........ mm 50.000 0.000/-0.016
Bearing recess width........ mm 26.0 ± 0.1
Maximum out-of-round........ mm 0.004
Maximum taper........ mm 0.004
1 The variation in diameter for each bearing journal must not exceed 0.008 mm.

MAIN BEARING JOURNALS


Diameter, standard 1 ........ mm 65.000 +0.003/-0.016
Axial bearing width........ mm 26.00 0.00/-0.04
Maximum out-of-round........ mm 0.004
Maximum taper........ mm 0.004
1 The variation in diameter for each bearing journal must not exceed 0.008 mm.

CONNECTING RODS
Diameter, bearing recesses
Big end........ mm 53.000 0.000/+0.013
Small-end........ mm 21.000 +0.005/+0.011
Maximum ovality in the bearing recesses........ mm 0.006
Length
Big end - Small end........ mm 147

OIL PRESSURE
Oil pressure (min.)
13.3 r/s (800 rpm)........ Mpa 1 0.10
14.2 r/s (850 rpm)........ Mpa 1 0.10
66.7 r/s (4000 rpm)........ Mpa 1 0.35
2012 Volvo C30 T-5
ENGINE PERFORMANCE General - Specifications, Mechanical

Maximum oil pressure (the relief valve opens)........ 0.48


Mpa 1
1 The oil pressure given is for an oil temperature of 100°C, which is reached after 10-15 minutes driving.

FUEL LINE PRESSURE


Desired value
relative pressure 380 kPa
absolute pressure 480 kPa

THERMOSTAT
Begins to open at 90°C
Fully open at 105°C

TIGHTENING TORQUE (B5244S4; 2007-10, B5254T7; 2008-12)


GENERAL TIGHTENING TORQUES

NOTE: Screws coated with a locking fluid or self locking nuts must be replaced with
new when reinstalled.

See the table below to find the tightening torques for components not included in the summary.

Nuts and bolts which are not self-locking can be reused provided that they are in good condition.

Applies to bolted joints with tensile strength class 8.8.


Thread Tightening Torque (Nm)
M5 5
M6 10
M7 17
M8 24
M10 50
M12 80
M14 130

SUMMARY OF TIGHTENING TORQUES FOR SPECIFIC COMPONENTS

NOTE: Screws coated with locking fluid or sealant must be replaced with new ones
when reinstalled.

Always use new bolts and nuts when angle tightening. Any exceptions to this rule will be indicated in the
method.
2012 Volvo C30 T-5
ENGINE PERFORMANCE General - Specifications, Mechanical

Angle tightening in tight spaces, see SCREWED JOINT, TORQUE/ANGLE TIGHTENING .

Exhaust system (turbocharger/manifold) 24 Nm


Center nut/Vibration damper (crankshaft's front 180 Nm
end)
Cylinder head Step 1........20 Nm
Step 2........60 Nm
NOTE: Step 3 angle tightening 130°
Tighten the screws in sequence from the center
and outwards.
Fuel pump, plastic nut 70 Nm
Fuel filter (D5244Tx) 35 Nm
Manifold (against cylinder head) 24 Nm
Stay (Manifold/Engine block) M8x16........20 Nm
M10x16........40 Nm
Subframe front, front screw 120 Nm
Subframe front, rear screw Step 1 140 Nm
Step 2 angle tightening 120°
Hollow screw M14x1.5 (coolant pipe/turbo) 38 Nm
Hollow screw M12x1.5 (water-heated crankcase 26 Nm
ventilation)
Hollow screw M12x1.5 (oil pressure pipe/turbo) 26 Nm
Hollow screw M14x1.5 (oil pressure pipe/engine 38 Nm
block)
Intake manifold (lower section, against cylinder 19 Nm
head) 10 Nm
(upper section)
Camshaft bearing housing/valve cover 14 Nm
Knock sensor Turned to the 8 o'clock position.
Tighten to 20 Nm
Piston cooling valve (piston cooling oil channel, in 32 Nm
block)
Piston ring nozzle 17 Nm
Timing belt gear (camshafts without variable valve 20 Nm
timing)
Timing belt gear (camshafts with variable valve 10 Nm
timing)
Heated oxygen sensor (HO2S) 45 Nm
Temperature and/or pressure sensor for intake air 2 Nm
Carrier plate Step 1 45 Nm
Step 2 angle tightening 50°
Intermediate section M10 Step 1........20 Nm
M10 Step 2........45 Nm
2012 Volvo C30 T-5
ENGINE PERFORMANCE General - Specifications, Mechanical

NOTE: M8 Step 3........24 Nm


Tighten the screws in sequence from the center M7 Step 4........17 Nm
and outwards. M10 Step 5 angle tightening 90°
Oscillating bracket, engine mounting (M10 for Step 1........35 Nm
cylinder head) Step 2 angle tightening 75°
Engine pad for the oscillating bracket right hand Step 1........70 Nm
side (M12) Step 2 angle tightening 90 °
Engine pad to cylinder block (M12) Step 1........70 Nm
Step 2 angle tightening 50 °
Engine pad to frame member, right-hand, (M12). Step 1........90 Nm
Applies to D5244Tx.
Engine pad, right side (2 screws in frame member 90 Nm
M12)
Engine pad, right-hand side (2 nuts to the mounting 65 Nm 90°
in the engine M12)
Engine pad, left side (screw M12) 80 Nm
Engine pad, right-hand side (2 nuts to the mounting 133 Nm
in the engine M14)
Engine pad, left side (screw M14) Step 1........60 Nm
Step 2........50°
Engine pad, left side (4 nuts M10) 35 Nm 60°
Torque rod, lower (screw M12) Step 1........30 Nm
Step 2........80 Nm
Torque rod, lower (screw M12) 80 Nm
Torque rod, lower (screw M10) 60 Nm
Torque rod, upper to frame member (screw M12) 130 Nm
Oil filter (environmental filter) 35 Nm
Oil trap 16 Nm
Oil plug 38 Nm
Oil pump (countersunk Allen, M6x20, holds the 6 Nm
pump housing together)
Oil return line (turbocharger) 12 Nm
Stud (at exhaust port, manifold, turbocharger) 20 Nm
Plug (gauge hole/crankshaft adjustment) 38 Nm
Plug (Oil pressure line, engine block) 38 Nm
Belt tensioner (mechanical) 20 Nm
Belt tensioner accessory drive belt 42 Nm
Throttle body Tighten the screws crosswise. Tighten to 8 Nm
Flywheel Step 1........45 Nm
Step 2 angle tightening 65°
Vibration damper (flange bolt M8x25) Step 1........25
Step 2 angle tightening 60°
2012 Volvo C30 T-5
ENGINE PERFORMANCE General - Specifications, Mechanical

Timing gear casing (rear) 2 X M7x20........12 Nm


M8x30........25 Nm
Timing gear casing (upper) 10 Nm
Timing gear casing (front) 8 Nm
Spark plugs 28 Nm
Connecting rod cap Step 1........15 Nm
Step 2........25 Nm
Step 3 angle tightening 100°
VVT-module (center screw) 120 Nm
VVT-module (center plug) 35 Nm

SPECIFICATIONS, MECHANICAL (B5254T3; 2007-08, B5254T7; 2008-12)


GENERAL DATA
- B5254T3
Engine code 68
Power (kw/rpm) 162/5000
Max torque (Nm/rpm) 320/1500-4800
Max rpm 6500/6800
Idling (rpm) 720
Cylinder bore (mm) 83
Stroke (mm) 93, 2
Swept volume (liters) 2, 521
Firing sequence 1-2-4-5-3
Engine control system Bosch ME 9
Weight, complete, including oil (kg) 170

ENGINE MANUFACTURE NUMBER, ENGINE SERIAL NUMBER AND TYPE


2012 Volvo C30 T-5
ENGINE PERFORMANCE General - Specifications, Mechanical

Fig. 5: Engine Manufacture Number, Engine Serial Number & Type


Courtesy of VOLVO CARS CORPORATION

The engine serial number and type are stamped on the left side of the cylinder block at the top of the mounting
for the water pump.

There is also a decal on the timing casing with the engine type, manufacturing number, and serial number.

CLASSIFICATION OF MAIN BEARINGS

The marking is stamped in the engine block and crankshaft. The classification marking is in the engine block
above the oil cooler and crankshaft. The classification shall be read from the digit 1 to 7.

The first letter after the digit 1 is the classification of main bearing 1. The bearing positions are numbered
starting at the engine's leading edge.

MAIN BEARING
- Class A - Class B - Class C -
block block block
small average large
diameter diameter diameter
- block intermediate block intermediate block intermediate
section section section
2012 Volvo C30 T-5
ENGINE PERFORMANCE General - Specifications, Mechanical

Class A yellow yellow yellow blue blue blue


crankshaft medium medium medium thick thick thick
small
Class B red yellow yellow yellow yellow blue
crankshaft thin medium medium medium medium thick
medium
Class C red red red yellow yellow yellow
crankshaft thin thin thin medium medium medium
large

CYLINDER BLOCK

Fig. 6: Cylinder Block


Courtesy of VOLVO CARS CORPORATION

CYLINDER BORE (D)


Standard -
C-marked........ mm 83.000-83.010
D-marked........ mm 83.010-83.020
E-marked........ mm 83.020-83.030

CYLINDRICALLY
2012 Volvo C30 T-5
ENGINE PERFORMANCE General - Specifications, Mechanical

Maximum deviation -
Cylinder bore........ mm 0.013

PISTONS

Fig. 7: Identifying Piston


Courtesy of VOLVO CARS CORPORATION

PISTONS
Standard The diameter is measured 12 mm from the bottom
of the piston
C-marked 1 ........ mm 82.950-82.960
D-marked 1 ........ mm 82.960-82.970
E-marked 1 ........ mm 82.970-82.980
1 Classification is marked on the top of the piston.

PISTON RUNNING CLEARANCE


Tolerance piston/cylinder - top........ mm 0.010 - 0.030

PISTON RINGS
Top ring........ mm 1.2 -0.01/-0.03
1st ring........ mm 1.5 -0.01/-0.03
Oil ring........ mm 2 -0.01/-0.136

PISTON PIN
Diameter........ mm 21.000 0.000/-0.004
Length........ mm 57.0 0.0/+0.2

VALVES
2012 Volvo C30 T-5
ENGINE PERFORMANCE General - Specifications, Mechanical

Fig. 8: Identifying Valve


Courtesy of VOLVO CARS CORPORATION

VALVES
Intake
Length (A)........ mm 102.00 ± 0.07
Diameter on crown (B)........ mm 31 ± 0.15
Diameter on shaft (C)........ mm 5.94 ± 0.07
Valve angle (D)........° 45.5 ± 0.17
Clearance in guide........µm 50 - 70
Valve clearance........ mm 0.20 ± 0.03
Exhaust
Length (A)........ mm 101.05 ± 0.07
Diameter on crown (B)........ mm 27 ± 0.15
Diameter on shaft (C)........ mm 5.94 ± 0.07
Valve angle (D)........° 45.5 ± 0.17
Clearance in guide........µm 50 - 70
Valve clearance........ mm 0.40 ± 0.03

VALVE SEATS
Seat angle........° 45.5 ± 0.17

TAPPETS
Diameter........ mm 32 -0.025/-0.040
Length........ mm 2.950 - 3.685 ±0.010

CAMSHAFTS
Max. lift height inlet........ mm 8.68
Max. lift height exhaust........ mm 9.05
2012 Volvo C30 T-5
ENGINE PERFORMANCE General - Specifications, Mechanical

CYLINDER HEAD

CYLINDER HEAD
Max. distortion........ mm 0.5
Max. distortion, transverse........ mm 0.2
Height........ mm 149.4 ± 0.15

CRANKSHAFT
Radial run-out main bearing journal........ mm max. 0.040
Axial play (Measured in the engine with the intermediate 0.08-0.19
section tightened)........ mm
Main bearing journal, radial runout........ mm 0.020-0.043

BIG END JOURNALS


Diameter, standard1 ........ mm 50.000 0.000/-0.016
Bearing recess width........ mm 26.0 ± 0.1
Maximum out-of-round........ mm 0.004
Maximum taper........ mm 0.004
1 The variation in diameter for each bearing journal must not exceed 0.008 mm.

MAIN BEARING JOURNALS


Diameter, standard1 ........ mm 65.000 +0.003/-0.016
Axial bearing width........ mm 26.00 0.00/-0.04
Maximum out-of-round........ mm 0.004
Maximum taper........ mm 0.004
1 The variation in diameter for each bearing journal must not exceed 0.008 mm.

CONNECTING RODS
Diameter, Bearing Recesses
Big end........ mm 53.000 0.000/+0.013
Small-end........ mm 21.000 +0.005/+0.011
Maximum ovality in the bearing recesses........ mm 0.006
Length
Big end - Small end........ mm 147

OIL PRESSURE
Oil pressure (min.)
13.3 r/s (800 rpm)........ Mpa1 0.10
14.2 r/s (850 rpm)........ Mpa1 0.10
66.7 r/s (4000 rpm)........ Mpa1 0.35
2012 Volvo C30 T-5
ENGINE PERFORMANCE General - Specifications, Mechanical

Maximum oil pressure (the relief valve opens)........ 0.48


Mpa1
1 The oil pressure given is for an oil temperature of 100°C, which is reached after 10-15 minutes driving.

FUEL LINE PRESSURE


Desired Value
relative pressure 300 kPa
absolute pressure 400 kPa

THERMOSTAT
Begins to open at 90°C
Fully open at 105°C
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

ENGINE

Engine - Overhaul Instructions

ENGINE
CAULKING

Operation Number(s):

Fig. 1: Bearing Housing, Cylinder Block And Intermediate Section


Courtesy of VOLVO CARS CORPORATION

On engines manufactured of aluminum the camshaft bearing housing (1) cylinder block (2) and the intermediate
section (3) may be caulked.

NOTE: The cylinder heads that are chill-cast may not be caulked.

Each individual case is assessed as to whether caulking can be carried out or not depending on the location of
the oil leakage.
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 2: Identifying Center Punch And Rounded Tips


Courtesy of VOLVO CARS CORPORATION

Caulking involves in the event of leakage knocking the material together using a special caulking tool.

Two caulking tools are required. Use center punches (1). Grind down the tips so they become round. One is to
be ground so the rounded tip (A) is 2 mm. The other is ground so the rounded tip (B) is 4 mm.

NOTE: Use the protective goggles supplied with the leak tracing kit.

Use: Isopropanol, 1161721

Use an UV light to localize the pore. Carefully wash round the pore with Isopropanol. Check with a UV light
that all the oil has been removed.

Fig. 3: Identifying Tool Angle And Pores


Courtesy of VOLVO CARS CORPORATION

WARNING: Use protective goggles.


2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

If the pore is small, it is sufficient to place the tool (2 mm) directly on the pore and hit it with a copper or plastic
hammer. If the pore is larger, angle the tool (2 mm) and drive the material in a circle toward the pore (2). If
there is a lip around the pore, caulking (tool 4 mm) should be carried out in a spiral form toward the pore (3).

Fig. 4: Driving Material Toward Pore Using 2 mm Tool


Courtesy of VOLVO CARS CORPORATION

Drive the material toward the pore (1) using the 2 mm tool. Seal using the 4 mm tool (2).

Use: Isopropanol, 1161721

Wash with Isopropanol. Check with a UV lamp that there is no oil around the leakage point.

Test drive for 45 minutes as set out below to reach an oil temperature of about 80°C.

1. Allow the engine to idle for 20 minutes.


2. Test drive the car for 15 minutes.
3. Allow the engine to idle for a further 10 minutes.

Check using a UV light that the sealed area no long leaks. If leakage remains, repeat the caulking.

ENGINE BLOCK, INSTALLING COMPONENTS (B5244S4, 2007-10)

NOTE: As the graphics in this service information are used for different model years
and / or models, some variation may occur. However, the essential information
in the graphics is always correct.

INSTALLATION

INFORMATION
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 5: Identifying Ignition Coil Harness Routing


Courtesy of VOLVO CARS CORPORATION

The ignition coils' direction and the routing of the cables are shown.

INSTALLING PARTS ON ENGINE BLOCK

Fig. 6: Identifying Engine Components


Courtesy of VOLVO CARS CORPORATION

Install:

 the alternator, alternator bracket and auxiliary unit bracket


 the thermostat housing with coolant hose
 the oil filter housing
 the knock sensors
 the ignition coils
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

 the camshaft sensor


 the oil filler cap and the VVT-unit's control valve
 the crankcase ventilation hose
 cable harness engine, complete
 the upper and lower intake pipe
 the dipstick tube

INSTALLING PARTS ON ENGINE BLOCK, CONTINUED

Fig. 7: Identifying Engine Block Components


Courtesy of VOLVO CARS CORPORATION

Install:

 the oil cooler and the rubber seals


 the coolant pipe (inlet water pump), including hoses, parted at the hoses to the oil cooler
 the bearing carrier for the right drive shaft
 the heat shield plate and exhaust manifold
 the upper and front timing gear casing

Fill oil.

INSTALLING THE FLYWHEEL AND CARRIER PLATE

Install:

 the flywheel according to FLYWHEEL


 the carrier plate according to CARRIER PLATE

ENGINE BLOCK, INSTALLING COMPONENTS (B5254T7, 2008-12)


2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

NOTE: As the graphics in this service information are used for different model years
and/or models, some variation may occur. However, the essential information in
the graphics is always correct.

NOTE: For tightening torques, see Tightening torques

INSTALLATION

INSTALLING PARTS ON ENGINE BLOCK

Fig. 8: Identifying Ignition Coil Harness Routing


Courtesy of VOLVO CARS CORPORATION

The ignition coils' direction and the routing of the cables are shown in the sketch.

INSTALLING PARTS ON ENGINE BLOCK, CONTINUED

Fig. 9: Locating Components


2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Courtesy of VOLVO CARS CORPORATION

Install:

 alternator, alternator bracket and auxiliary unit bracket


 thermostat housing with coolant hose
 the oil filter housing
 the knock sensors
 the ignition coils
 the camshaft sensor
 oil filler cap and the VVT-unit's control valves
 the crankcase ventilation hose
 complete cable harness engine
 the intake pipe
 oil dipstick tube

INSTALLING PARTS ON ENGINE BLOCK, CONTINUED

Fig. 10: Locating Components


Courtesy of VOLVO CARS CORPORATION

Install:

 the oil cooler and the rubber seals.


 the coolant pipe (inlet to water pump) including hoses
 the bearing carrier for the right drive shaft.
 exhaust manifold including turbo with control hoses and valve
 Oil delivery pipe and coolant pipe (outlet to turbo)
 oil delivery pipe and coolant pipe (inlet to turbo)
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

 the lifting eyes


 upper and front timing gear casing

Fill oil.

INSTALLING THE FLYWHEEL/CARRIER PLATE

Install, see FLYWHEEL

Install, see CARRIER PLATE

ENGINE BODY, EXPOSING (B5244S4, 2007-10)

Special tools:

see 9989721

see 9992520

see 9995112

see 9995297

NOTE: The graphics in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the graphics is always correct.

REMOVAL

REMOVING THE GEARBOX

HINT: Suitably, loosen the lower hard-to-reach screws in the transmission/engine before the
engine/transmission unit is placed on a suitable surface.

Relieve the transmission.

Loose the remaining screws and carefully remove the transmission.

Remove the clutch, according to CLUTCH DISC AND PRESSURE PLATE

REMOVING THE FLYWHEEL AND CARRIER PLATE


2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 11: Identifying Flywheel


Courtesy of VOLVO CARS CORPORATION

Remove the impulse sensor.

Install: see 9995112 .

Remove all screws, except the top screw which holds the flywheel to the crankshaft. Loose the top screw and
leave it in place, screwed in a few revolutions.

It is suitable to use two screwdrivers. Fit these between the engine block and the flywheel/carrier plate.

Hold the flywheel/carrier plate, and screw out the last screw.

Install the engine in a stand. Use: see 9992520 , see 9995297 and see 9989721 .

Drain the engine oil.

EXPOSING THE ENGINE


2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 12: Identifying Engine Block Components


Courtesy of VOLVO CARS CORPORATION

Remove:

 the heat shield plate and exhaust manifold


 the coolant pipe (inlet water pump), including hoses, parted at the hoses to the oil cooler
 the oil cooler and the rubber seals
 the bearing carrier for the right drive shaft
 the lifting eyes
 the upper and front timing gear casing.

Fig. 13: Identifying Engine Components


Courtesy of VOLVO CARS CORPORATION

Remove:
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

 the alternator, alternator bracket and auxiliary unit bracket


 the upper and lower intake pipe
 the dipstick tube
 the knock sensors
 the thermostat housing with coolant hose
 the crankcase ventilation hose
 cable harness engine, complete
 the oil filter housing
 the ignition coils
 the camshaft sensor
 the oil filler cap and the VVT-unit's control valve.

ENGINE BODY, EXPOSING (B5254T3, 2007-08; B5254T7, 2008-12)

Special tools:

see 9989721

see 9992520

see 9995112

see 9995297

NOTE: The graphics in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the graphics is always correct.

REMOVAL

REMOVING THE GEARBOX

HINT: Suitably, loosen the lower hard-to-reach screws in the transmission/engine before the
engine/transmission unit is placed on a suitable surface.

HINT: Relieve the transmission. Loose the remaining screws and carefully remove the transmission.

HINT: Remove the clutch according to CLUTCH DISC AND PRESSURE PLATE .

REMOVING FLYWHEEL AND CARRIER PLATE


2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 14: Identifying Flywheel


Courtesy of VOLVO CARS CORPORATION

Remove the impulse sensor.

Install: see 9995112

Remove all screws except the top screw which holds the flywheel to the crankshaft. Loose the top screw and
leave it in place, screwed in a few revolutions.

Carefully wiggle loose the flywheel and the carrier plate. It is suitable to use 2 screwdrivers. Fit these between
the engine block and the flywheel/carrier plate.

Hold the flywheel and carrier plate, and screw out the last screw.

TRANSFERRING ENGINE

INSTALLING ENGINE IN STAND

Use: see 9992520 , see 9995297 and see 9989721

Drain the engine oil.

REMOVAL

EXPOSING THE ENGINE


2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 15: Locating Components


Courtesy of VOLVO CARS CORPORATION

Remove:

 the oil delivery pipe and the coolant pipe (at the outlet to the turbo)
 the oil delivery pipe and coolant pipe (at the inlet to the turbo)
 the exhaust manifold including turbo with control hoses and valves
 the coolant pipe (at the inlet to the water pump) including hoses. The hoses are parted at the oil cooler
 the oil cooler and the rubber seals
 the lifting eyes
 upper and front timing gear casing as well as the cover over the ignition coils.

EXPOSING THE ENGINE, CONTINUED

Fig. 16: Locating Components


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Remove:

 the alternator, alternator bracket and auxiliary unit bracket


 the intake pipe
 the dipstick tube
 the knock sensors
 the thermostat housing with the coolant hose
 the crankcase ventilation hose
 complete engine cable harness
 the oil filter housing
 the ignition coils
 the camshaft sensor
 the oil filler cap and the VVT-unit's control valves.

CYLINDER HEAD
CYLINDER HEAD, DISASSEMBLY/ASSEMBLY

Special tools:

see 9986052

see 9995219

see 9995748

see 9997012

NOTE: The graphics in this service information are used for different model years and /
or models. Therefore there may be some variation. However, the essential
information in the graphics is always correct.

REMOVING TAPPETS
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 17: Arranging/Tagging Removed Valve Lifters For Re-Installation


Courtesy of VOLVO CARS CORPORATION

NOTE: Magnets must not be used when lifting out the tappets.

Lift out the tappets. Mark up the tappets so that the original positions can be established.

Use a suction cup to remove the tappets.

Check for wear on the tappets.

REMOVING VALVES

Fig. 18: 998 6052-0 - Valve Spring B21 D16 D24


Courtesy of VOLVO CARS CORPORATION

Use valve spring compressor see 9986052 with attachment claw see 9995748 .

Remove:
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

 the valve locks


 the upper valve collars
 the valve springs
 the valves.

NOTE: Keep careful track of the position of the moving parts.

REMOVING VALVE STEM SEALS

Fig. 19: Identifying Valve Stem Seal Special Tool 999 5219
Courtesy of VOLVO CARS CORPORATION

Use tool see 9995219 .

Remove the valve stem seals and the lower valve collars.

Clean the cylinder head:

 the gasket faces


 the combustion chambers
 the inlet and exhaust ports
 the valve seats.

CHECKING THE CYLINDER HEAD


2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 20: Identifying Combustion Chamber


Courtesy of VOLVO CARS CORPORATION

Clean the spark plug threads (tap M14 x 1.25).

Clean the valves, valve springs and collars.

Visually check for damage.

If you are unsure, replace the cylinder head.

CHECKING FOR WEAR IN THE VALVE GUIDES

Fig. 21: Identifying Measurement Of Wear In Valve Guides Using A Dial Indicator And Magnetic Holder
Courtesy of VOLVO CARS CORPORATION

Measure the wear in the valve guides. Use a dial indicator and magnetic holder. Lift the valve approximately 2-
3 mm from the seat when carrying out the check.

Clearance between the valve and valve guide:


2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Clearance between new components: Inlet/Exhaust: 0.03 -0.06 mm .

Maximum play for used components: Inlet/Exhaust: 0.15 mm .

INSTALLING VALVE STEM SEALS

Fig. 22: Identifying Valve Stem Seal


Courtesy of VOLVO CARS CORPORATION

Lubricate:

 the upper end of the valve guides


 the valve stem seal.

Install:

 the lower valve spring collars


 the valve stem seal.

Press down the seal. Use tool see 9997012 . Press with hand force until the tool stops against the lower valve
spring washer. Remove the tool.

Repeat the procedure with the remaining valve stem seals.

INSTALLING THE VALVE/VALVE SPRINGS


2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 23: Compressing Valve Spring Using Valve Spring Compressor (9986052) and Adapter (9995748)
Courtesy of VOLVO CARS CORPORATION

Lubricate the valve stem.

Install:

 the valve
 the valve spring
 the upper valve spring washer.

CAUTION: Do not compress more than is absolutely necessary, the valve stem seal
may be damaged.

Compress the valve spring so that the three valve lock tracks are visible.

Use valve spring compressor see 9986052 and press foot see 9995748 . Install the valve collets. Check that
valve collets are in the correct position when the spring is not loaded.

Repeat the procedure with the remaining valves.

REMOVING THE CYLINDER HEAD (B5244S4, 2007-10)

REMOVAL

Remove the cylinder head. See CYLINDER HEAD

INSTALLING THE CYLINDER HEAD (B5244S4, 2007-10)

INSTALLATION

Install cylinder head. See CYLINDER HEAD


2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

REMOVING THE CYLINDER HEAD (B5254T3, 2007-08; B5254T7, 2008-12)

REMOVAL

Remove the cylinder head. See CYLINDER HEAD

INSTALLING THE CYLINDER HEAD (B5254T3, 2007-08; B5254T7, 2008-12)

INSTALLATION

Install cylinder head. See CYLINDER HEAD

CYLINDER BLOCK
CYLINDER BLOCK, MEASUREMENT (B5244S4, 2007-10)

RECONDITIONING

CAUTION: Make sure that the area around the component is clean and free of foreign
material.

NOTE: If the specified value is exceeded, a new component must be installed.

For information about specifications. See ENGINE

Fig. 24: Identifying Cylinder Measurement


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 25: Identifying Cooling Duct


Courtesy of VOLVO CARS CORPORATION

CYLINDER BLOCK, MEASUREMENT (B5254T3, 2007-08; B5254T7, 2008-12)

RECONDITIONING

CAUTION: Make sure that the area around the component is clean and free of foreign
material.

NOTE: If the specified value is exceeded, a new component must be installed.

For information about specifications. See ENGINE

Fig. 26: Identifying Cylinder Measurement


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 27: Identifying Cooling Duct


Courtesy of VOLVO CARS CORPORATION

TRANSMISSION
TIMING BELT, DISMANTLING (B5244S4, 2007-10)

REMOVAL

Remove timing belt. See TIMING BELT

TIMING BELT, ASSEMBLING (B5244S4, 2007-10)

INSTALLATION

Install timing belt. See TIMING BELT

TIMING BELT, DISMANTLING (B5254T3, 2007-08; B5254T7, 2008-12)

REMOVAL

Remove timing belt. See TIMING BELT

TIMING BELT, ASSEMBLING (B5254T3, 2007-08; B5254T7, 2008-12)

INSTALLATION

Install timing belt. See TIMING BELT

CRANK MECHANISM
CRANK MECHANISM, DISMANTLING (B5244S4, 2007-10)
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Special Tools
999 5746 Holder remove. piston/connecting rod) B 200-B
6304
Tool number: 999 5746
Tool description: Holder remove. piston/connecting rod) B
200-B 6304
Tool boards: 21

REMOVAL

Fig. 28: Identifying 9995651


Courtesy of VOLVO CARS CORPORATION

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


2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 29: Axle Support Installed


Courtesy of VOLVO CARS CORPORATION

Fig. 30: Identifying Oil Cooler Bolts


Courtesy of VOLVO CARS CORPORATION

Fig. 31: Identifying Oil Pan Bolts


2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Courtesy of VOLVO CARS CORPORATION

Fig. 32: Identifying Pick-Up Tube Bolts


Courtesy of VOLVO CARS CORPORATION

Fig. 33: Installing Connecting Rod Cap And Bolts


Courtesy of VOLVO CARS CORPORATION

CAUTION: Note the position of the components before removal.


2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 34: Identifying Connecting Rod Special Tool (9995746)


Courtesy of VOLVO CARS CORPORATION

CAUTION: Take extra care when handling the components.

see 9995746

Fig. 35: Locating Intermediate Section Bolts


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 36: 1st Step Loosening Bolts in Sequence


Courtesy of VOLVO CARS CORPORATION

Fig. 37: 2nd Step-Loosening Bolts in Sequence


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 38: Gently Removing Intermediate Section


Courtesy of VOLVO CARS CORPORATION

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

CAUTION: Take extra care when handling the components.

NOTE: Only use moderate force.

Fig. 39: Identifying Lower Bearing Halves


Courtesy of VOLVO CARS CORPORATION

Fig. 40: Handling the Crankshaft


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

CAUTION: Take extra care when handling the components.

Fig. 41: Identifying Upper Bearing Halves


Courtesy of VOLVO CARS CORPORATION

Fig. 42: Locating Nozzle Bolt


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 43: Locating Sprayer Bolts


Courtesy of VOLVO CARS CORPORATION

CRANK MECHANISM, ASSEMBLING (B5244S4, 2007-10)

Special Tools
951 2767 Roller (Applying liquid gasket) B234, 5234, 6304

Tool number: 951 2767


Tool description: Roller (Applying liquid gasket) B234,
5234, 6304
Tool boards: 08

999 5746 Holder remove. piston/connecting rod) B 200-B


6304
Tool number: 999 5746
Tool description: Holder remove. piston/connecting rod) B
200-B 6304
Tool boards: 21

999 7273 Guide pin


Tool number: 999 7273
Tool description: Guide pin
Tool boards: 21
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

999 7174 Drift


Tool number: 999 7174
Tool description: Drift
Tool boards: 23

Materials
Designation Part Number
Cleaning agent 1161721
Chemical gasket 1161059

INSTALLATION

Fig. 44: Locating Sprayer Bolts


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

CAUTION: Make sure that the area around the component is clean and free of foreign
material.

Torque: M7

17 Nm

Fig. 45: Locating Nozzle Bolt


Courtesy of VOLVO CARS CORPORATION

CAUTION: Make sure that the area around the component is clean and free of foreign
material.

Torque: Piston cooling nozzle

32 Nm

Fig. 46: Identifying Main Bearing Classification


2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Courtesy of VOLVO CARS CORPORATION

NOTE: Make sure that the classification of the components correspond with each
other.

For information about engine. See ENGINE

Fig. 47: Identifying Main Bearing Classification On Crankshaft


Courtesy of VOLVO CARS CORPORATION

NOTE: Make sure that the classification of the components correspond with each
other.

For information about engine. See ENGINE

Fig. 48: Identifying Upper Main Bearing Halves


Courtesy of VOLVO CARS CORPORATION

CAUTION: Make sure that the area around the component is clean and free of foreign
material.
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 49: Identifying Crankshaft


Courtesy of VOLVO CARS CORPORATION

CAUTION: Take extra care when handling the components.

CAUTION: Make sure that the crankshaft is not rotated.

Fig. 50: Identifying Lower Main Bearing Halves


Courtesy of VOLVO CARS CORPORATION

CAUTION: Make sure that the area around the component is clean and free of foreign
material.
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 51: Cleaning Agent, 1161721


Courtesy of VOLVO CARS CORPORATION

NOTE: Make sure that the component is clean, free of foreign material and lubricant.

Use: Cleaning agent, 1161721

see 9512767

Use: Chemical gasket, 1161059

Fig. 52: Identifying Torque Sequence


Courtesy of VOLVO CARS CORPORATION

Torque: Intermediate section for engine block step 1

20 Nm
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 53: Identifying Torque Sequence


Courtesy of VOLVO CARS CORPORATION

Torque: Intermediate section for engine block step 2

40 Nm

Fig. 54: Identifying Torque Sequence, 3rd Step


Courtesy of VOLVO CARS CORPORATION

Torque: Intermediate section for engine block step 3

24 Nm
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 55: Identifying Torque Sequence, 4th Step


Courtesy of VOLVO CARS CORPORATION

Torque: Intermediate section for engine block step 4

17 Nm

Fig. 56: Identifying Torque Sequence


Courtesy of VOLVO CARS CORPORATION

Torque: Intermediate section for engine block step 5

90°
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 57: Identifying Cylinder Bore Classification


Courtesy of VOLVO CARS CORPORATION

NOTE: Make sure that the classification of the components correspond with each
other.

For information about engine. See ENGINE

Fig. 58: Installing Pin And Snap Ring


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 59: Identifying Piston Ring Arrangement


Courtesy of VOLVO CARS CORPORATION

For information about engine. See ENGINE

Fig. 60: Locating Direction of Arrow


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 61: Identifying Connecting Rod Bearing Halves Installed


Courtesy of VOLVO CARS CORPORATION

NOTE: Make sure that the classification of the components correspond with each
other.

Fig. 62: Identifying Ring Compressor Tool


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 63: Identifying Connecting Rod Special Tool (9995746)


Courtesy of VOLVO CARS CORPORATION

see 9995746

Fig. 64: Installing Connecting Rod Cap And Bolts


Courtesy of VOLVO CARS CORPORATION

NOTE: Make sure that the classification of the components correspond with each
other.

Torque: Cap connecting rod

• Stage 1: 30 Nm

• Stage 2: 90°
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 65: Identifying Pick-Up Tube Bolts


Courtesy of VOLVO CARS CORPORATION

Torque: M7

17 Nm

Fig. 66: Guide Pins (9997273)


Courtesy of VOLVO CARS CORPORATION

see 9997273
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 67: Identifying Gasket Locations


Courtesy of VOLVO CARS CORPORATION

CAUTION: Make sure that the gaskets are correctly located.

Fig. 68: Cleaning Agent, 1161721 And (Applying Liquid Gasket)


Courtesy of VOLVO CARS CORPORATION

NOTE: Make sure that the component is clean, free of foreign material and lubricant.

Use: Cleaning agent, 1161721

see 9512767

Use: Chemical gasket, 1161059


2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 69: Identifying Oil Pan Bolts


Courtesy of VOLVO CARS CORPORATION

Torque: M7

17 Nm

Fig. 70: Identifying Oil Cooler Bolts


Courtesy of VOLVO CARS CORPORATION

Torque: M7

17 Nm
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 71: Axle Support Installed


Courtesy of VOLVO CARS CORPORATION

Torque: M10

50 Nm

Fig. 72: Identifying Rear Main Seal Tool 9997174


Courtesy of VOLVO CARS CORPORATION

see 9997174

CRANK MECHANISM, DISMANTLING (B5254T3, 2007-08; B5254T7, 2008-12)

Special Tools
999 5651 Extractor (crankshaft rear seal) D5252T
Tool number: 999 5651
Tool description: Extractor (crankshaft rear seal) D5252T
Tool boards: 21
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

999 5746 Holder remove. piston/connecting rod) B 200-B


6304
Tool number: 999 5746
Tool description: Holder remove. piston/connecting rod) B
200-B 6304
Tool boards: 21

REMOVAL

Fig. 73: Identifying 9995651


2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

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

see 9995651

Fig. 74: Axle Support Installed


Courtesy of VOLVO CARS CORPORATION

Fig. 75: Identifying Oil Cooler Bolts


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 76: Identifying Oil Pan Bolts


Courtesy of VOLVO CARS CORPORATION

Fig. 77: Identifying Pick-Up Tube Bolts


Courtesy of VOLVO CARS CORPORATION

Fig. 78: Installing Connecting Rod Cap And Bolts


2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

CAUTION: Note the position of the components before removal.

Fig. 79: Identifying Connecting Rod Special Tool (9995746)


Courtesy of VOLVO CARS CORPORATION

CAUTION: Take extra care when handling the components.

see 9995746

Fig. 80: Locating Intermediate Section Bolts


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 81: 1st Step Loosening Bolts in Sequence


Courtesy of VOLVO CARS CORPORATION

Fig. 82: 2nd Step-Loosening Bolts in Sequence


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 83: Gently Removing Intermediate Section


Courtesy of VOLVO CARS CORPORATION

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

CAUTION: Take extra care when handling the components.

NOTE: Only use moderate force.

Fig. 84: Identifying Lower Bearing Halves


Courtesy of VOLVO CARS CORPORATION

Fig. 85: Handling the Crankshaft


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

CAUTION: Take extra care when handling the components.

Fig. 86: Identifying Upper Bearing Halves


Courtesy of VOLVO CARS CORPORATION

Fig. 87: Locating Nozzle Bolt


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 88: Locating Sprayer Bolts


Courtesy of VOLVO CARS CORPORATION

CRANK MECHANISM, ASSEMBLING (B5254T7, 2008-12)

Special Tools
951 2767 Roller (Applying liquid gasket) B234, 5234,
6304
Tool number: 951 2767
Tool description: Roller (Applying liquid gasket) B234,
5234, 6304
Tool boards: 08

999 5746 Holder remove. piston/connecting rod) B 200-B


6304
Tool number: 999 5746
Tool description: Holder remove. piston/connecting rod) B
200-B 6304
Tool boards: 21

999 7273 Guide pin


Tool number: 999 7273
Tool description: Guide pin
Tool boards: 21
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

999 7174 Drift


Tool number: 999 7174
Tool description: Drift
Tool boards: 23

Materials
Designation Part Number
Cleaning agent 1161721
Chemical gasket 1161059

INSTALLATION

Fig. 89: Locating Sprayer Bolts


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

CAUTION: Make sure that the area around the component is clean and free of foreign
material.

Torque: M7

17 Nm

Fig. 90: Locating Nozzle Bolt


Courtesy of VOLVO CARS CORPORATION

CAUTION: Make sure that the area around the component is clean and free of foreign
material.

Torque: M7

17 Nm

Fig. 91: Identifying Main Bearing Classification


2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Courtesy of VOLVO CARS CORPORATION

NOTE: Make sure that the classification of the components correspond with each
other.

For information about engine. See ENGINE

Fig. 92: Identifying Main Bearing Classification On Crankshaft


Courtesy of VOLVO CARS CORPORATION

NOTE: Make sure that the classification of the components correspond with each
other.

For information about engine. See ENGINE

Fig. 93: Identifying Upper Main Bearing Halves


Courtesy of VOLVO CARS CORPORATION

CAUTION: Make sure that the area around the component is clean and free of foreign
material.
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 94: Identifying Crankshaft


Courtesy of VOLVO CARS CORPORATION

CAUTION: Take extra care when handling the components.

CAUTION: Make sure that the crankshaft is not rotated.

Fig. 95: Identifying Lower Main Bearing Halves


Courtesy of VOLVO CARS CORPORATION

CAUTION: Make sure that the area around the component is clean and free of foreign
material.
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 96: Cleaning agent, 1161721


Courtesy of VOLVO CARS CORPORATION

NOTE: Make sure that the component is clean, free of foreign material and lubricant.

Use: Cleaning agent, 1161721

see 9512767

Use: Chemical gasket, 1161059

Fig. 97: Identifying Torque Sequence


Courtesy of VOLVO CARS CORPORATION

Torque: Intermediate section for engine block step 1

20 Nm
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 98: Identifying Torque Sequence


Courtesy of VOLVO CARS CORPORATION

Torque: Intermediate section for engine block step 2

40 Nm

Fig. 99: Identifying Torque Sequence, 3rd Step


Courtesy of VOLVO CARS CORPORATION

Torque: Intermediate section for engine block step 3

24 Nm
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 100: Identifying Torque Sequence, 4th Step


Courtesy of VOLVO CARS CORPORATION

Torque: Intermediate section for engine block step 4

17 Nm

Fig. 101: Identifying Torque Sequence


Courtesy of VOLVO CARS CORPORATION

Torque: Intermediate section for engine block step 5

90°
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 102: Identifying Cylinder Bore Classification


Courtesy of VOLVO CARS CORPORATION

NOTE: Make sure that the classification of the components correspond with each
other.

For information about engine. See ENGINE

Fig. 103: Installing Pin And Snap Ring


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 104: Arrangement of Piston Ring Assembly


Courtesy of VOLVO CARS CORPORATION

For information about engine. See ENGINE

Fig. 105: Locating Direction of Arrow


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 106: Identifying Connecting Rod Bearing Halves Installed


Courtesy of VOLVO CARS CORPORATION

NOTE: Make sure that the classification of the components correspond with each
other.

Fig. 107: Identifying Ring Compressor Tool


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 108: Identifying Connecting Rod Special Tool (9995746)


Courtesy of VOLVO CARS CORPORATION

see 9995746

Fig. 109: Installing Connecting Rod Cap And Bolts


Courtesy of VOLVO CARS CORPORATION

NOTE: Make sure that the classification of the components correspond with each
other.

Torque: Cap connecting rod

• Stage 1: 30 Nm

• Stage 2: 90°
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 110: Identifying Pick-Up Tube Bolts


Courtesy of VOLVO CARS CORPORATION

Torque: M7

17 Nm

Fig. 111: Guide Pins (9997273)


Courtesy of VOLVO CARS CORPORATION

see 9997273
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 112: Identifying Gasket Locations


Courtesy of VOLVO CARS CORPORATION

CAUTION: Make sure that the gaskets are correctly located.

Fig. 113: Cleaning Agent, 1161721 And (Applying liquid gasket)


Courtesy of VOLVO CARS CORPORATION

NOTE: Make sure that the component is clean, free of foreign material and lubricant.

Use: Cleaning agent, 1161721

see 9512767

Use: Chemical gasket, 1161059


2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 114: Identifying Oil Pan Bolts


Courtesy of VOLVO CARS CORPORATION

Torque: M7

17 Nm

Fig. 115: Identifying Oil Cooler Bolts


Courtesy of VOLVO CARS CORPORATION

Torque: M7

17 Nm
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 116: Axle Support Installed


Courtesy of VOLVO CARS CORPORATION

Torque: M10

50 Nm

Fig. 117: Identifying Rear Main Seal Tool 9997174


Courtesy of VOLVO CARS CORPORATION

see 9997174

MEASURING CRANKSHAFT ASSEMBLY (B5244S4, 2007-10; B5254T7, 2008-12)

NOTE: The graphics in this service information are used for different model years
and/or models. Therefore there may be some variation. However, the essential
information in the graphics is always correct.

MEASURING THE CRANKSHAFT


2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 118: Identifying Measurement Of Bearing Journal


Courtesy of VOLVO CARS CORPORATION

Use a micrometer.

Measure the out-of-round and taper of the bearing journal. Measure at a number of points laterally and
longitudinally.

Fig. 119: Checking Taper and Out-of-Round


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

For the correct values for the connecting rod bearing journals and main bearing journals, see ENGINE
(B5254T3; 2007-08, B5254T7; 2008-12) or ENGINE (B5244S4; 2007-10) .

CHECK THE OUT-OF-TRUE OF THE CRANKSHAFT

Fig. 120: Identifying Measurement Of Radial Runout Using A Dial Indicator And Magnetic Holder
Courtesy of VOLVO CARS CORPORATION

Use a dial indicator and magnetic holder.

Position the crankshaft with the two outer main bearings in the V block.

Turn the crankshaft and measure the radial runout on the other main bearing journals.

For the correct values, see ENGINE (B5254T3; 2007-08, B5254T7; 2008-12) or ENGINE (B5244S4; 2007-
10) .

REMOVING THE PISTON RINGS

Fig. 121: Identifying Piston Rings And Piston Ring Pliers


2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Courtesy of VOLVO CARS CORPORATION

Use piston ring pliers.

Remove coke deposits. Scrape the piston ring grooves clean with a groove cleaner or a broken and filed piston
ring.

Check for damage, wear and cracks.

CHECKING PISTON RING AXIAL CLEARANCE

Fig. 122: Checking Piston Ring Axial Clearance


Courtesy of VOLVO CARS CORPORATION

Use new piston rings.

For the correct values, see ENGINE (B5254T3; 2007-08, B5254T7; 2008-12) or ENGINE (B5244S4; 2007-
10) .

CHECKING THE PISTON DIAMETER


2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 123: Checking Piston Diameter


Courtesy of VOLVO CARS CORPORATION

Use a micrometer and vernier calliper.

For the correct values, see ENGINE (B5254T3; 2007-08, B5254T7; 2008-12) or ENGINE (B5244S4; 2007-
10) .

CALCULATING THE RUNNING CLEARANCE OF THE PISTON


2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 124: Calculating Running Clearance Of Piston


Courtesy of VOLVO CARS CORPORATION

For the correct values, see ENGINE (B5254T3; 2007-08, B5254T7; 2008-12) or ENGINE (B5244S4; 2007-
10) .

DISASSEMBLING CONNECTING RODS AND PISTONS

Fig. 125: Identifying Lock-Ring And Groove-Cut Chisel


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Check first that the piston and connecting rod are marked.

Piston marking: Scrape the piston pin clean. If the marking is unclear, mark the piston with the cylinder
number and an arrow pointing to the front of the engine. Use a marker pen.

Connecting rod marking: See ENGINE (B5254T3; 2007-08, B5254T7; 2008-12) or ENGINE (B5244S4;
2007-10) .

Carefully push out the lock-ring using a groove-cut chisel.

WARNING: The lock ring can easily fly off. Wear protective goggles

Press out the piston pin with your thumb.

Clean and check the connecting rods, caps and screws for damage, signs of wear or cracks.

CHECKING THE ALIGNMENT OF THE PISTON PINS IN THE PISTONS

Fig. 126: Checking Alignment Of Piston Pin With Piston


Courtesy of VOLVO CARS CORPORATION

The piston pin must not be loose. It should be possible to push it through the hole using thumb pressure.

Replace the piston if the play is too great.

CHECKING THE ALIGNMENT OF THE PISTON PINS IN THE CONNECTING RODS


2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

Fig. 127: Checking Alignment Of Piston Pin With Connecting Rod


Courtesy of VOLVO CARS CORPORATION

The piston pin should slide through the hole with light thumb pressure.

If the play is too great measure the piston pin.

Use a micrometer.

See ENGINE (B5244S4; 2007-10) or ENGINE (B5254T3; 2007-08, B5254T7; 2008-12) for the correct
diameter of the gudgeon pin.

NEW CONNECTING ROD

Fig. 128: Connecting Rod


Courtesy of VOLVO CARS CORPORATION

A new connecting rod has been introduced on certain engines.

The mating surface between the cap and the connecting rod is not machined. It is aligned through a dedicated
2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

fracture surface.

CAUTION: If the cap is turned the wrong way and tightened, the structure of the
fracture surface will be damaged and the connecting rod must be
discarded.

NOTE: Blow clean the fracture surfaces with compressed air before reinstalling caps.

CHECKING THE BEARING RECESS IN THE CONNECTING ROD BIG END

Fig. 129: Bearing Shells


Courtesy of VOLVO CARS CORPORATION

Visually check the bearing shells.


2012 Volvo C30 T-5
ENGINE Engine - Overhaul Instructions

If in doubt measure out-of-round. Use a bore gauge.

For the correct diameter of the bearing recess, see ENGINE (B5244S4; 2007-10) or ENGINE (B5254T3;
2007-08, B5254T7; 2008-12) .

CHECKING THE CONNECTING ROD IN A CONNECTING ROD ALIGNER

Check for out-of-true and twisting.

CAUTION: Check that the aligner fork is unburred and round at the handle. Loosen
and apply the expander at the big-end between each alignment operation.
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

ENGINE

Engine - Removal, replacement and installation

ACCESSORY DRIVE BELT AND VARIABLE VALVE TIMING (VVT)


ACCESSORY DRIVE BELT

REMOVAL

Remove right front wheel, see WHEELS

Fig. 1: Removing Fender Liner


Courtesy of VOLVO CARS CORPORATION

Fig. 2: Identifying Splash Panel Screws


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 3: Loosening Belt Tension


Courtesy of VOLVO CARS CORPORATION

Fig. 4: Removing Belt


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 5: Loosening Belt Tension


Courtesy of VOLVO CARS CORPORATION

Fig. 6: Removing Belt


Courtesy of VOLVO CARS CORPORATION

INSTALLATION

To install, reverse the removal procedure.

ACCESSORY DRIVE BELT TENSIONER

REMOVAL

Remove the auxiliaries belt, see ACCESSORY DRIVE BELT

Fig. 7: Removing/Installing Tensioner Bolt


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 8: Removing Tensioner Bolt


Courtesy of VOLVO CARS CORPORATION

INSTALLATION

Fig. 9: Removing Tensioner Bolt


Courtesy of VOLVO CARS CORPORATION

Torque: Belt tensioner accessory drive belt

42 Nm
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 10: Removing/Installing Tensioner Bolt


Courtesy of VOLVO CARS CORPORATION

NOTE: Only tighten the bolt finger tight at this stage.

Fig. 11: Installing Tensioner Bolt


Courtesy of VOLVO CARS CORPORATION

 Torque: Accessory drive belt tensioner

42 Nm
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 12: Identifying Gap at Tensioner


Courtesy of VOLVO CARS CORPORATION

Install the auxiliaries belt, see ACCESSORY DRIVE BELT

CAMSHAFT SEAL (TURBO)

Special tools
999 5651 Extractor (crankshaft rear seal)
D5252T
Tool number: 999 5651
Tool description: Extractor (crankshaft rear
seal) D5252T
Tool boards: 21

999 5718 Drift (installing/sealing camshaft


with VVT)
Tool number: 999 5718
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Tool description: Drift (installing/sealing


camshaft with VVT)
Tool boards: 21

REMOVAL

Remove the variable valve timing unit, see VVT UNIT (TURBO)

Fig. 13: Removing Cam Seal with Special Tool (9995651)


Courtesy of VOLVO CARS CORPORATION

see 9995651

INSTALLATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 14: Installing Cam Seal with VVT-Special Tool (9995718)


Courtesy of VOLVO CARS CORPORATION

see 9995718

Fig. 15: Installing Cam Seal with VVT-Special Tool (9995718)


Courtesy of VOLVO CARS CORPORATION

To install, reverse the removal procedure.

CAMSHAFT SEAL (NON-TURBO)

Special tools
999 5651 Extractor (crankshaft rear seal)
D5252T
Tool number: 999 5651
Tool description: Extractor (crankshaft rear
seal) D5252T
Tool boards: 21
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

999 7364 Drift


Tool number: 999 7364
Tool description: Drift
Tool boards: 21

999 5718 Drift (installing/sealing camshaft


with VVT)
Tool number: 999 5718
Tool description: Drift (installing/sealing
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

camshaft with VVT)


Tool boards: 21

REMOVAL

Remove the variable valve timing unit, see VVT UNIT (NON-TURBO).

Fig. 16: Removing Cam Seal with Special Tool (9995651)


Courtesy of VOLVO CARS CORPORATION

see 9995651

INSTALLATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 17: Installing Cam Seal without VVT using Special Tool (9997364)
Courtesy of VOLVO CARS CORPORATION

see 9997364

Fig. 18: Installing Cam Seal with VVT-Special Tool (9995718)


Courtesy of VOLVO CARS CORPORATION

see 9995718

To install, reverse the removal procedure.

CAMSHAFTS

Special tools
999 7107 Support
Tool number: 999 7107
Tool description: Support
Tool boards: 21
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

999 5454 PRESS TOOL (2) (CYLINDER


HEAD) B6304/B5254
Tool number: 999 5454
Tool description: PRESS TOOL (2)
(CYLINDER HEAD) B6304/B5254
Tool boards: 21

999 5670 Pliers (removing valve/camshaft


cover) B4184-B6304
Tool number: 999 5670
Tool description: Pliers (removing
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

valve/camshaft cover) B4184-B6304


Tool boards: 21

951 2767 Roller (Applying liquid gasket)


B234, 5234, 6304
Tool number: 951 2767
Tool description: Roller (Applying liquid
gasket) B234, 5234, 6304
Tool boards: 08

Materials
Designation Part number
Engine oil
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Gasket solution 1161847


Chemical gasket 1161059

REMOVAL

Fig. 19: Installation of Support Tool (9997107)


Courtesy of VOLVO CARS CORPORATION

see 9997107

Remove the following items:

 spark plugs, see SPARK PLUGS .


 camshaft seal, see CAMSHAFT SEAL (TURBO) or CAMSHAFT SEAL (NON-TURBO).

Fig. 20: Oil Filler Tube, Bolts


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 21: Special Tools (9995454)


Courtesy of VOLVO CARS CORPORATION

see 9995454

Fig. 22: Press Tools Installed


Courtesy of VOLVO CARS CORPORATION

see 9995454
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 23: Install 46 Bolts


Courtesy of VOLVO CARS CORPORATION

Fig. 24: Loosening Press Tools, Use Special Pliers (9995670) Remove Cam Cover Evenly
Courtesy of VOLVO CARS CORPORATION

CAUTION: Take extra care when handling the components.

see 9995670
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 25: Lifting Cam Cover, Tools Removed


Courtesy of VOLVO CARS CORPORATION

CAUTION: Take extra care when handling the components.

Fig. 26: Gently Lift Out Camshafts


Courtesy of VOLVO CARS CORPORATION

CAUTION: Note the position of the components before removal.

INSTALLATION

NOTE: This step is only necessary if adjustment is required

Perform valve clearance, see VALVE CLEARANCE .


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 27: Apply Engine Oil to Camshafts


Courtesy of VOLVO CARS CORPORATION

NOTE: Make sure that these components are installed to the noted removal position.

Use: Engine oil,

Fig. 28: Identifying Positions of Camshafts


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 29: Gasket Solution, 1161847


Courtesy of VOLVO CARS CORPORATION

CAUTION: Make sure that the mating faces are clean and free of foreign material.

Use: Gasket solution, 1161847

see 9512767

Use: Chemical gasket, 1161059

Fig. 30: Installing Press Tools (9995454)


Courtesy of VOLVO CARS CORPORATION

CAUTION: Take extra care when handling the components.


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 31: Install 46 Bolts


Courtesy of VOLVO CARS CORPORATION

Torque: M7

17 Nm

Fig. 32: Oil Filler Tube, Bolts


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm

Install the following items:

 camshaft seal, see CAMSHAFT SEAL (TURBO) or CAMSHAFT SEAL (NON-TURBO).


 VVT unit, see VVT UNIT (TURBO) or VVT UNIT (NON-TURBO)
 timing belt, see TIMING BELT
 spark plugs, see SPARK PLUGS
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

 ignition coil, see IGNITION COIL (TURBO) or IGNITION COIL (NON-TURBO) .

TIMING BELT

Special tools
999 5433 COUNTERHOLD (VIBRATION
DAMPENER)B6304 B5254
Tool number: 999 5433
Tool description: COUNTERHOLD
(VIBRATION DAMPENER)B6304 B5254
Tool boards: 21

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.

Remove the following items:

 the auxiliaries belt, see ACCESSORY DRIVE BELT TENSIONER


 Engine support insulator, right, see ENGINE SUPPORT INSULATOR, RIGHT
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 33: Hose and Bracket


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm

Fig. 34: Timing Belt Cover Bolt


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 35: Install Special Tool (9995433)


Courtesy of VOLVO CARS CORPORATION

see 9995433

Fig. 36: Remove/Install Crank Nut Using Special Tool (9995433)


Courtesy of VOLVO CARS CORPORATION

1. Torque: Center nut vibration damper (crankshaft)


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

180 Nm

2. Torque: Oscillation damper, flange screw

• Stage 1: 25 Nm

• Stage 2: 60 degree

Fig. 37: Remove Vibration Damper Pulley


Courtesy of VOLVO CARS CORPORATION

Fig. 38: Identifying Position of Crank Sprocket at TDC #1


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 39: Mark Position of Cam Sprockets at TDC #1


Courtesy of VOLVO CARS CORPORATION

Fig. 40: Loosening Tensioner


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 41: Idler Pulley Bolts


Courtesy of VOLVO CARS CORPORATION

Torque: M8

24 Nm

Fig. 42: Remove/Install Timing Belt


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Courtesy of VOLVO CARS CORPORATION

NOTE: The component can be reused unless it has been subjected to abnormal
mechanical stress, damage or oil contamination.

INSTALLATION

To install, reverse the removal procedure.

VVT SOLENOID

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.

Fig. 43: Identifying Engine Cover And Screws


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 44: Identifying Timing Case Cover


Courtesy of VOLVO CARS CORPORATION

Fig. 45: Bolts and Connectors


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm

INSTALLATION

To install, reverse the removal procedure.

VVT UNIT (TURBO)

Special tools
999 5452 CAMSHAFT ADJUSTMENT
TOOL(alignment-camshaft)B6304
Tool number: 999 5452
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Tool description: CAMSHAFT


ADJUSTMENT TOOL(alignment-camshaft)
B6304
Tool boards: 21

999 5451 ADJUSTMENT TOOL


(ALIGNMENT-CRANKSHAFT) B6304
B5254
Tool number: 999 5451
Tool description: ADJUSTMENT TOOL
(ALIGNMENT-CRANKSHAFT) B6304
B5254
Tool boards: 21

REMOVAL

Remove the following items:


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

 air cleaner (ACL) housing, see AIR CLEANER HOUSING


 timing belt, see TIMING BELT
 starter motor, see STARTER MOTOR

Fig. 46: Removing Turbocharger Inlet


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 47: Lift Hook Bolts


Courtesy of VOLVO CARS CORPORATION

Fig. 48: Cam Plugs


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 49: Cam Alignment Tool (9995452) Installed


Courtesy of VOLVO CARS CORPORATION

see 9995452

Fig. 50: Installing VVT Units


Courtesy of VOLVO CARS CORPORATION

INSTALLATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 51: Installing VVT Units


Courtesy of VOLVO CARS CORPORATION

NOTE: Only tighten the bolts finger tight at this stage.

Fig. 52: Crankshaft Holder Tool (9995451) Installed


Courtesy of VOLVO CARS CORPORATION

see 9995451

Install timing belt, see TIMING BELT


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 53: Torque VVT Unit Bolts to Specification


Courtesy of VOLVO CARS CORPORATION

Torque: VVT unit, center screw

120 Nm
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 54: Install Lift Hook, Bolts


Courtesy of VOLVO CARS CORPORATION

1. Torque: M10

50 Nm

2. Torque: M6

10 Nm

Install the following items:

 starter motor, see STARTER MOTOR


 timing belt, see TIMING BELT

Fig. 55: Removing Turbocharger Inlet


Courtesy of VOLVO CARS CORPORATION

CAUTION: Make sure that the inside of the pipe ends are clean and free of oil residue.

Torque: M6

10 Nm
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Install the air filter housing, see AIR CLEANER HOUSING

VVT UNIT (NON-TURBO)

Special tools
999 5452 CAMSHAFT ADJUSTMENT
TOOL(alignment-camshaft)B6304
Tool number: 999 5452
Tool description: CAMSHAFT
ADJUSTMENT TOOL(alignment-camshaft)
B6304
Tool boards: 21

999 5451 ADJUSTMENT TOOL


(ALIGNMENT-CRANKSHAFT) B6304
B5254
Tool number: 999 5451
Tool description: ADJUSTMENT TOOL
(ALIGNMENT-CRANKSHAFT) B6304
B5254
Tool boards: 21
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

REMOVAL

Remove the following items:

 air cleaner (ACL) housing, see AIR CLEANER HOUSING


 timing belt, see TIMING BELT
 starter motor, see STARTER MOTOR
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 56: Intake Plenum, Rear View


Courtesy of VOLVO CARS CORPORATION

Fig. 57: Intake Plenum, Front View


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 58: Lift Hook Bolts


Courtesy of VOLVO CARS CORPORATION

Fig. 59: Cam Plugs


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 60: Cam Alignment Tool (9995452) Installed


Courtesy of VOLVO CARS CORPORATION

see 9995452

Fig. 61: Remove/Install Sprocket Bolts


Courtesy of VOLVO CARS CORPORATION

INSTALLATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 62: Remove/Install Sprocket Bolts


Courtesy of VOLVO CARS CORPORATION

NOTE: Only tighten the bolts finger tight at this stage.

Fig. 63: Crankshaft Holder Tool (9995451) Installed


Courtesy of VOLVO CARS CORPORATION

see 9995451

Install timing belt, see TIMING BELT.


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 64: Torque Bolts to Specification


Courtesy of VOLVO CARS CORPORATION

1. Torque: M6

10 Nm

2. Torque: VVT unit, center screw

120 Nm

Fig. 65: Install Lift Hook, Bolts


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

1. Torque: M10

50 Nm

2. Torque: M6

10 Nm

Install the following items:

 starter motor, see STARTER MOTOR


 timing belt, see TIMING BELT

Fig. 66: Installing Intake Plenum, Front View


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 67: Installing Intake Plenum, Rear View


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm

Install the air filter housing, see AIR CLEANER HOUSING

COMPLETE ENGINE (TURBO)


ENGINE, REMOVAL (TURBO)

ENGINE, REMOVAL

Special tools
981 4123 Spanner
Tool number: 981 4123
Tool description: Spanner
Tool boards: 23
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

999 7077 Jimmy bar


Tool number: 999 7077
Tool description: Jimmy bar
Tool boards: 43

REMOVAL

Perform depressurizing fuel system, see FUEL SYSTEM PRESSURE RELEASE


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Drain cooling system, draining, filling, and bleeding, see COOLING SYSTEM - DRAINING, CHARGING
AND BLEEDING

Remove the following items:

 battery, see BATTERY


 air cleaner (ACL) housing, see AIR CLEANER HOUSING
 Tensioner accessory drive belt, see ACCESSORY DRIVE BELT TENSIONER
 Bracket lower torque rod, see BRACKET LOWER TORQUE ROD
 Front subframe
 the catalytic converter, see CATALYTIC CONVERTER
 Drive shaft right, see DRIVE SHAFT RIGHT
 Driveshaft left, see DRIVESHAFT LEFT
 right-hand side fog lamp front, see FRONT EXTERIOR LIGHTS .

Fig. 68: Removing Battery Box and Sensor


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 69: Removing Cover, Fuse Box


Courtesy of VOLVO CARS CORPORATION

Fig. 70: Removing Battery Cable to Fuse Box


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 71: Removing Grounding Cables


Courtesy of VOLVO CARS CORPORATION

Fig. 72: Battery Lead Terminal and Harness


Courtesy of VOLVO CARS CORPORATION

Fig. 73: Locating Wiring Harness Bracket Bolt


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 74: Removing Quick Release Connector With Tool (9814123)


Courtesy of VOLVO CARS CORPORATION

see 9814123

Fig. 75: Identifying Vacuum Connections


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 76: Viewing Dipstick Tube And Radiator Hose


Courtesy of VOLVO CARS CORPORATION

NOTE: Use suitable paper to absorb any escaping fluid.

Fig. 77: View Of Radiator Hose And Clamp, Lower


Courtesy of VOLVO CARS CORPORATION

NOTE: Use suitable paper to absorb any escaping fluid.


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 78: Identifying 9997077


Courtesy of VOLVO CARS CORPORATION

see 9997077

Fig. 79: Identifying Gear Selector Cable Clips


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 80: Identifying Switch Connector


Courtesy of VOLVO CARS CORPORATION

Fig. 81: Identifying Clutch Hydraulic Line and Clip


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 82: Removing Line


Courtesy of VOLVO CARS CORPORATION

Fig. 83: Identifying Air Tube And Attachments


Courtesy of VOLVO CARS CORPORATION

Fig. 84: Heater Hose Couplings


Courtesy of VOLVO CARS CORPORATION

NOTE: Use suitable paper to absorb any escaping fluid.


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 85: Pressure Sensor Connector


Courtesy of VOLVO CARS CORPORATION

Fig. 86: Locating Ground Wire


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 87: Coolant Hose at Reservoir


Courtesy of VOLVO CARS CORPORATION

Fig. 88: Coolant Reservoir


Courtesy of VOLVO CARS CORPORATION

Fig. 89: Identifying Bracket Bolts And Clip


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 90: Power Steering Lines and Bracket


Courtesy of VOLVO CARS CORPORATION

WARNING: Be prepared to collect escaping fluid.

Fig. 91: Identifying A/C Compressor Bolts


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 92: Removing/Installing Engine with Adaptable Lift Unit


Courtesy of VOLVO CARS CORPORATION

Remove the following items:

 Engine support insulator, right, see ENGINE SUPPORT INSULATOR, RIGHT


 Engine support insulator left, see ENGINE SUPPORT INSULATOR LEFT

Fig. 93: Removing/Installing Engine With Adaptable Lift Unit


Courtesy of VOLVO CARS CORPORATION

CAUTION: Take extra care when handling the components.

NOTE: Make sure that no components catch.

ENGINE, INSTALLATION (TURBO)


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

INSTALLATION

Fig. 94: Removing/Installing Engine With Adaptable Lift Unit


Courtesy of VOLVO CARS CORPORATION

CAUTION: Make sure that no components catch.

Install the following items:

 Engine support insulator left, see ENGINE SUPPORT INSULATOR LEFT


 Engine support insulator, right, see ENGINE SUPPORT INSULATOR, RIGHT

Fig. 95: Identifying A/C Compressor Bolts


Courtesy of VOLVO CARS CORPORATION

Torque: M8
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

24 Nm

Fig. 96: Identifying Power Steering Lines, Bolts and Clamps


Courtesy of VOLVO CARS CORPORATION

1. Torque: M10

50 Nm

2. Torque: Pressure line to power steering pump

30 Nm

Fig. 97: Identifying Bracket Bolts And Clip


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 98: Identifying Air Tube And Attachments


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm

Fig. 99: Pressure Sensor Connector


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 100: Remove/Install Coolant Reservoir


Courtesy of VOLVO CARS CORPORATION

Fig. 101: Remove/Install Coolant Hose


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 102: Locating Ground Wire


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm

Fig. 103: Installing Heater Hoses with Quick Connects


Courtesy of VOLVO CARS CORPORATION

Fig. 104: Installing Tubes With Quick Connects


Courtesy of VOLVO CARS CORPORATION

CAUTION: Make sure that the quick release couplings are correctly engaged.
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 105: Identifying Vacuum Connections


Courtesy of VOLVO CARS CORPORATION

Fig. 106: Installation of Gear Selector Cable


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 107: Cooler and Connections


Courtesy of VOLVO CARS CORPORATION

Fig. 108: Viewing Dipstick Tube And Radiator Hose


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm

Fig. 109: Locating Wiring Harness Bracket Bolt


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 110: Installing Battery Lead Terminal


Courtesy of VOLVO CARS CORPORATION

1. Torque: M8

24 Nm

2. Torque: M6

10 Nm

Fig. 111: View of Grounding Cables


Courtesy of VOLVO CARS CORPORATION

1. Torque: M8

24 Nm

2. Torque: M6
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

10 Nm

Fig. 112: View of Battery Cable to Fuse Box


Courtesy of VOLVO CARS CORPORATION

Fig. 113: Refitting Cover


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 114: Installing Battery Box and Sensor


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm

Assemble the following items:

 right-hand side fog lamp front, see FRONT EXTERIOR LIGHTS


 Driveshaft left, see DRIVESHAFT LEFT
 Drive shaft right, see DRIVE SHAFT RIGHT
 the catalytic converter, see CATALYTIC CONVERTER
 Front subframe
 Bracket lower torque rod, see BRACKET LOWER TORQUE ROD
 Tensioner accessory drive belt, see ACCESSORY DRIVE BELT TENSIONER
 air cleaner (ACL) housing, see AIR CLEANER HOUSING
 battery, see BATTERY

Fill cooling system, draining, filling, and bleeding, see COOLING SYSTEM - DRAINING, CHARGING
AND BLEEDING

Perform oil level power steering, check, see OIL LEVEL, POWER STEERING, CHECKING

Top up the engine oil, see ENGINE OIL

COMPLETE ENGINE (NON-TURBO)


ENGINE, REMOVAL (NON-TURBO)
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Special tools
999 7077 Jimmy bar
Tool number: 999 7077
Tool description: Jimmy bar
Tool boards: 43

981 4123 Spanner


Tool number: 981 4123
Tool description: Spanner
Tool boards: 23

REMOVAL
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Perform depressurizing fuel system, see FUEL SYSTEM PRESSURE RELEASE

Drain cooling system, draining, filling, and bleeding, see COOLING SYSTEM - DRAINING, CHARGING
AND BLEEDING

Remove the following items:

 battery, see BATTERY


 air cleaner (ACL) housing, see AIR CLEANER HOUSING
 Tensioner accessory drive belt, see ACCESSORY DRIVE BELT TENSIONER
 Bracket lower torque rod, see BRACKET LOWER TORQUE ROD
 Front subframe
 the catalytic converter, see CATALYTIC CONVERTER
 Drive shaft right, see DRIVE SHAFT RIGHT
 Driveshaft left, see DRIVESHAFT LEFT

Fig. 115: Removing Battery Box and Sensor


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 116: Removing Cover, Fuse Box


Courtesy of VOLVO CARS CORPORATION

Fig. 117: Removing Battery Cable to Fuse Box


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 118: Removing Grounding Cables


Courtesy of VOLVO CARS CORPORATION

Fig. 119: Battery Lead Terminal and Harness


Courtesy of VOLVO CARS CORPORATION

Fig. 120: Locating Wiring Harness Bracket Bolt


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 121: Identifying Vacuum Hose Connections


Courtesy of VOLVO CARS CORPORATION

Fig. 122: Viewing Dipstick Tube And Radiator Hose


Courtesy of VOLVO CARS CORPORATION

NOTE: Use suitable paper to absorb any escaping fluid.


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 123: View Of Radiator Hose And Clamp, Lower


Courtesy of VOLVO CARS CORPORATION

NOTE: Use suitable paper to absorb any escaping fluid.

Fig. 124: Identifying 9997077


Courtesy of VOLVO CARS CORPORATION

see 9997077
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 125: Identifying Gear Selector Cable Clips


Courtesy of VOLVO CARS CORPORATION

Fig. 126: Identifying Switch Connector


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 127: Identifying Clutch Hydraulic Line and Clip


Courtesy of VOLVO CARS CORPORATION

Fig. 128: Removing Line


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 129: Heater Hose Couplings


Courtesy of VOLVO CARS CORPORATION

NOTE: Use suitable paper to absorb any escaping fluid.

Fig. 130: Removing Quick Release Connector With Tool (9814123)


Courtesy of VOLVO CARS CORPORATION

NOTE: Use suitable paper to absorb any escaping fluid.

see 9814123

Fig. 131: Locating Ground Wire


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 132: Removing Coolant Hose at Reservoir


Courtesy of VOLVO CARS CORPORATION

Fig. 133: Removing Reservoir


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 134: Identifying Bracket Bolts And Clip


Courtesy of VOLVO CARS CORPORATION

Fig. 135: Power Steering Lines and Bracket


Courtesy of VOLVO CARS CORPORATION

WARNING: Be prepared to collect escaping fluid.

Fig. 136: Identifying A/C Compressor Bolts


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 137: Removing/Installing Engine with Adaptable Lift Unit


Courtesy of VOLVO CARS CORPORATION

Remove the following items:

 Engine support insulator, right, see ENGINE SUPPORT INSULATOR, RIGHT


 Engine support insulator left, see ENGINE SUPPORT INSULATOR LEFT

Fig. 138: Removing/Installing Engine With Adaptable Lift Unit


Courtesy of VOLVO CARS CORPORATION

CAUTION: Take extra care when handling the component.

NOTE: Make sure that no components catch.

ENGINE, INSTALLATION (NON-TURBO)


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

INSTALLATION

Fig. 139: Removing/Installing Engine With Adaptable Lift Unit


Courtesy of VOLVO CARS CORPORATION

CAUTION: Make sure that no components catch.

Install the following items:

 Engine support insulator left, see ENGINE SUPPORT INSULATOR LEFT


 Engine support insulator, right, see ENGINE SUPPORT INSULATOR, RIGHT

Fig. 140: Identifying A/C Compressor Bolts


Courtesy of VOLVO CARS CORPORATION

Torque: M8
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

24 Nm

Fig. 141: Identifying Power Steering Lines, Bolts and Clamps


Courtesy of VOLVO CARS CORPORATION

1. Torque: M10

50 Nm

2. Torque: Pressure line to power steering pump

30 Nm

Fig. 142: Identifying Bracket Bolts And Clip


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 143: Remove/Install Coolant Reservoir


Courtesy of VOLVO CARS CORPORATION

Fig. 144: Remove/Install Coolant Hose


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 145: Locating Ground Wire


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm

Fig. 146: Installing Tubes With Quick Connects


Courtesy of VOLVO CARS CORPORATION

CAUTION: Make sure that the quick release couplings are correctly engaged.

Fig. 147: Installing Heater Hoses with Quick Connects


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 148: Cooler and Connections


Courtesy of VOLVO CARS CORPORATION

Fig. 149: Installation of Gear Selector Cable


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 150: Viewing Dipstick Tube And Radiator Hose


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm

Fig. 151: Identifying Vacuum Hose Connections


Courtesy of VOLVO CARS CORPORATION

Fig. 152: Locating Wiring Harness Bracket Bolt


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 153: Installing Battery Lead Terminal


Courtesy of VOLVO CARS CORPORATION

1. Torque: M8

24 Nm

2. Torque: M6

10 Nm

Fig. 154: View of Grounding Cables


Courtesy of VOLVO CARS CORPORATION

1. Torque: M8

24 Nm

2. Torque: M6
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

10 Nm

Fig. 155: View of Battery Cable to Fuse Box


Courtesy of VOLVO CARS CORPORATION

Fig. 156: Refitting Cover


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 157: Installing Battery Box and Sensor


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm

Install the following items:

 Driveshaft left, see DRIVESHAFT LEFT


 Drive shaft right, see DRIVE SHAFT RIGHT
 the catalytic converter, see CATALYTIC CONVERTER
 Front subframe
 Bracket lower torque rod, see BRACKET LOWER TORQUE ROD
 Tensioner accessory drive belt, see ACCESSORY DRIVE BELT TENSIONER
 air cleaner (ACL) housing, see AIR CLEANER HOUSING
 battery, see BATTERY

Fill cooling system, draining, filling, and bleeding, see COOLING SYSTEM - DRAINING, CHARGING
AND BLEEDING

Perform oil level power steering, check, see OIL LEVEL, POWER STEERING, CHECKING

Top up the engine oil, see ENGINE OIL

CRANK MECHANISM
CARRIER PLATE

REPLACEMENT
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Special tools:

see 9995112

see 9995678

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.

PREPARATORY WORK

REMOVING THE TRANSMISSION

Remove the transmission according to: TRANSMISSION, REMOVING .

REMOVAL

REMOVING THE CARRIER PLATE

Remove the engine speed (RPM) sensor together with the bracket. Place the engine speed (RPM) sensor to one
side.

Fig. 158: Blocking Carrier Plate Using Gear Sector 999 5112
Courtesy of VOLVO CARS CORPORATION

Block the carrier plate using gear sector see 9995112 .

Remove:

 all screws
 the carrier plate
 gear sector see 9995112 .
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 159: Check Crankshaft Seal For Leakage


Courtesy of VOLVO CARS CORPORATION

Check the crankshaft seal for leakage.

To replace the crankshaft seal, refer to CRANKSHAFT SEAL, REAR.

INSTALLATION

NOTE: For tightening torques, see: TIGHTENING TORQUE .

INSTALLING THE CARRIER PLATE

Fig. 160: Carrier Plate, Studs And Gear Sector


Courtesy of VOLVO CARS CORPORATION

NOTE: Check that the contact surfaces on the crankshaft and drive flange plate are
completely clean.

Use: see 9995678 , which consists of 3 x clevis pins with nuts.


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Install:

 the 3 x clevis pins belonging to: see 9995678 distributed as shown in the illustration.
 the carrier plate.

NOTE: Check that the guide pin on the crankshaft is positioned directly opposite the
hole in the drive flange plate.

Locate the gear sector see 9995112 against the flexplate.

Pull the flexplate against the crankshaft using the 3 x nuts belonging to: see 9995678 .

CAUTION: The drive flange plate must have contact against the crankshaft flange
before the screws are installed. There is a risk that excess locking fluid on
the screws will end up between the contact surfaces.

Install 7 x new screws. Tighten. See: TIGHTENING TORQUE

Remove the 3 nuts and the studs.

Install:

 the remaining 3 x new screws. Tighten. See: TIGHTENING TORQUE


 the engine speed (RPM) sensor and bracket. Tighten.

FINISHING

INSTALLING THE TRANSMISSION

Install the gearbox. See: TRANSMISSION, INSTALLING .

CRANKSHAFT FRONT SEAL

Special tools
999 5304 SEPARATOR (DRIVE
FLANGE) M45-M47 II.
Tool number: 999 5304
Tool description: SEPARATOR (DRIVE
FLANGE) M45-M47 II.
Tool boards: 43
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

999 5919 PULLER (SEAL-PINION, CAM-


CRANKSHAFT)B200-6304
Tool number: 999 5919
Tool description: PULLER (SEAL-PINION,
CAM-CRANKSHAFT)B200-6304
Tool boards: 46

999 5747 Socket (remov./inst. oil


pump/crankshaft) B 4164-
Tool number: 999 5747
Tool description: Socket (remov./inst. oil
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

pump/crankshaft) B 4164-
Tool boards: 21

REMOVAL

Remove timing belt, see TIMING BELT.

Fig. 161: Identifying Special Tool (9995304)


Courtesy of VOLVO CARS CORPORATION

see 9995304
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 162: Removing Crankshaft Seal with Special Tool (9995919)


Courtesy of VOLVO CARS CORPORATION

see 9995919

INSTALLATION

Fig. 163: Identifying Special Tool (9995747)


Courtesy of VOLVO CARS CORPORATION

CAUTION: Take extra care not to damage the seal.

see 9995747
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 164: Identifying Crankshaft Sprocket


Courtesy of VOLVO CARS CORPORATION

NOTE: The component can only be installed in 1 position.

Install timing belt, see TIMING BELT.

CRANKSHAFT SEAL, REAR

Special tools
999 5651 Extractor (crankshaft rear seal)
D5252T
Tool number: 999 5651
Tool description: Extractor (crankshaft rear
seal) D5252T
Tool boards: 21

999 7174 Drift


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Tool number: 999 7174


Tool description: Drift
Tool boards: 23

REMOVAL

Remove flywheel, see FLYWHEEL.

Fig. 165: Identifying 9995651


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Courtesy of VOLVO CARS CORPORATION

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

see 9995651

INSTALLATION

Fig. 166: Identifying Rear Main Seal Tool 9997174


Courtesy of VOLVO CARS CORPORATION

CAUTION: Make sure that the mating faces are clean and free of foreign material.

see 9997174

Install flywheel, see FLYWHEEL.

FLYWHEEL

Special tools
999 5678 Special screw (flywheel) B4184-
B6304
Tool number: 999 5678
Tool description: Special screw (flywheel)
B4184-B6304
Tool boards: 21
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.

Remove clutch plate and pressure plate, see CLUTCH DISC AND PRESSURE PLATE

Fig. 167: Remove Crankshaft Position Sensor


Courtesy of VOLVO CARS CORPORATION

Torque: M7
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

17 Nm

Fig. 168: Flywheel Bolts (10)


Courtesy of VOLVO CARS CORPORATION

INSTALLATION

Fig. 169: Installing Locating Pins (9995678)


Courtesy of VOLVO CARS CORPORATION

CAUTION: Make sure that the flywheel is in full contact with the crankshaft flange
before installing the flywheel bolts.

NOTE: Make sure that the locating pin on the crankshaft is aligned with the guide hole
in the flywheel or flexplate.

see 9995678
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 170: Flywheel Bolt Torque Sequence


Courtesy of VOLVO CARS CORPORATION

Torque: Flywheel

• Stage 1: 45 Nm

• Stage 2: 65 degree

Fig. 171: Guide Pins Removed, Torque Remaining Bolts


Courtesy of VOLVO CARS CORPORATION

Torque: Flywheel

• Stage 1: 45 Nm

• Stage 2: 65 degree

To install, reverse the removal procedure.


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

CYLINDER HEAD
CYLINDER HEAD (TURBO)

Special tools
999 7107 Support
Tool number: 999 7107
Tool description: Support
Tool boards: 21

999 5454 PRESS TOOL (2) (CYLINDER


HEAD) B6304/B5254
Tool number: 999 5454
Tool description: PRESS TOOL (2)
(CYLINDER HEAD) B6304/B5254
Tool boards: 21
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

999 5670 Pliers (removing valve/camshaft


cover) B4184-B6304
Tool number: 999 5670
Tool description: Pliers (removing
valve/camshaft cover) B4184-B6304
Tool boards: 21

951 2050 BEVEL PROTRACTOR


Tool number: 951 2050
Tool description: BEVEL PROTRACTOR
Tool boards: 08
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

951 2767 Roller (Applying liquid gasket)


B234, 5234, 6304
Tool number: 951 2767
Tool description: Roller (Applying liquid
gasket) B234, 5234, 6304
Tool boards: 08

Materials
Designation Part number
Gasket solution 1161847
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Engine oil
Chemical gasket 1161059

REMOVAL

Drain cooling system, draining, filling, and bleeding, see COOLING SYSTEM - DRAINING, CHARGING
AND BLEEDING

Fig. 172: Installation of Support Tool (9997107)


Courtesy of VOLVO CARS CORPORATION

see 9997107

Remove the following items:

 air cleaner (ACL) housing, see AIR CLEANER HOUSING


 VVT unit, see VVT UNIT (TURBO)
 fuel injector, see FUEL INJECTOR
 exhaust manifold, see EXHAUST MANIFOLD
 the intake manifold, see INDUCTION PIPE
 VVT solenoid, see VVT SOLENOID
 spark plugs, see SPARK PLUGS
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 173: Quick Release Connector


Courtesy of VOLVO CARS CORPORATION

Fig. 174: Timing Belt Rear Cover Bolt


Courtesy of VOLVO CARS CORPORATION

Fig. 175: Engine Mount Bracket and Lift Hook


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 176: Oil Filler Tube, Bolts


Courtesy of VOLVO CARS CORPORATION

Fig. 177: Special Tools (9995454)


Courtesy of VOLVO CARS CORPORATION

see 9995454
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 178: Press Tools Installed


Courtesy of VOLVO CARS CORPORATION

see 9995454

Fig. 179: Install 46 Bolts


Courtesy of VOLVO CARS CORPORATION

Fig. 180: Loosening Press Tools, Use Special Pliers (9995670) Remove Cam Cover Evenly
Courtesy of VOLVO CARS CORPORATION

CAUTION: Take extra care when handling the component.

see 9995670
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 181: Lifting Cam Cover, Tools Removed


Courtesy of VOLVO CARS CORPORATION

CAUTION: Take extra care when handling the component.

Fig. 182: Gently Lift Out Camshafts


Courtesy of VOLVO CARS CORPORATION

NOTE: Note the position of each component before removal.


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 183: Identifying Camshaft Lifters


Courtesy of VOLVO CARS CORPORATION

NOTE: Note the position of each component before removal.

Fig. 184: Head Bolt Removal Sequence


Courtesy of VOLVO CARS CORPORATION

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

INSTALLATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 185: Gasket Solution, 1161847


Courtesy of VOLVO CARS CORPORATION

CAUTION: Take extra care when handling the component.

CAUTION: Make sure that the mating faces are clean and free of foreign material.

CAUTION: Make sure that no fluids are present in the cylinder head bolt threaded
bores.

Use: Gasket solution, 1161847

Fig. 186: Head Bolt Torque Sequence


Courtesy of VOLVO CARS CORPORATION

see 9512050
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Torque: Cylinder head

• Stage 1: 20 Nm

• Stage 2: 60 Nm

• Stage 3: 130 degree

Fig. 187: Apply Engine Oil to Cam Followers, Install at Original Location
Courtesy of VOLVO CARS CORPORATION

CAUTION: Only use the specified lubricant.

NOTE: Make sure that these components are installed to the noted removal position.

Use: Engine oil,

NOTE: This step is only necessary if adjustment is required

Perform valve clearance, see VALVE CLEARANCE


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 188: Apply Engine Oil to Camshafts


Courtesy of VOLVO CARS CORPORATION

CAUTION: Only use the specified lubricant.

NOTE: Make sure that these components are installed to the noted removal position.

Use: Engine oil,

Fig. 189: Identifying Positions of Camshafts


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 190: Gasket Solution, 1161847


Courtesy of VOLVO CARS CORPORATION

NOTE: Make sure that the mating faces are clean and free of foreign material.

Use: Gasket solution, 1161847

see 9512767

Use: Chemical gasket, 1161059

Fig. 191: Installing Press Tools (9995454)


Courtesy of VOLVO CARS CORPORATION

CAUTION: Take extra care when handling the component.


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 192: Install 46 Bolts


Courtesy of VOLVO CARS CORPORATION

Torque: M7

17 Nm

Fig. 193: Oil Filler Tube, Bolts


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 194: Remove Pipe


Courtesy of VOLVO CARS CORPORATION

Fig. 195: Engine Mounting Bracket and Lift Hooks


Courtesy of VOLVO CARS CORPORATION

1. Torque: M10

50 Nm

2. Torque: M8

24 Nm
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 196: Timing Belt Rear Cover Bolt


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm

Fig. 197: Quick Release Connector


Courtesy of VOLVO CARS CORPORATION

Install the following items:

 VVT unit, see VVT UNIT (TURBO)


 exhaust manifold, see EXHAUST MANIFOLD
 air cleaner (ACL) housing, see AIR CLEANER HOUSING
 fuel injector, see FUEL INJECTOR
 spark plugs, see SPARK PLUGS
 the intake manifold, see INDUCTION PIPE
 VVT solenoid, see VVT SOLENOID
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 198: Support Tool (9997107) Installed


Courtesy of VOLVO CARS CORPORATION

Torque: M10

50 Nm

Fill cooling system, draining, filling, and bleeding, see COOLING SYSTEM - DRAINING, CHARGING
AND BLEEDING

CYLINDER HEAD (NON-TURBO)

Special tools
999 7107 Support
Tool number: 999 7107
Tool description: Support
Tool boards: 21
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

999 5454 PRESS TOOL (2) (CYLINDER


HEAD) B6304/B5254
Tool number: 999 5454
Tool description: PRESS TOOL (2)
(CYLINDER HEAD) B6304/B5254
Tool boards: 21

999 5670 Pliers (removing valve/camshaft


cover) B4184-B6304
Tool number: 999 5670
Tool description: Pliers (removing
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

valve/camshaft cover) B4184-B6304


Tool boards: 21

951 2050 BEVEL PROTRACTOR


Tool number: 951 2050
Tool description: BEVEL PROTRACTOR
Tool boards: 08

951 2767 Roller (Applying liquid gasket)


B234, 5234, 6304
Tool number: 951 2767
Tool description: Roller (Applying liquid
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

gasket) B234, 5234, 6304


Tool boards: 08

Materials
Designation Part number
Gasket solution 1161847
Engine oil
Chemical gasket 1161059

REMOVAL

Perform cooling system draining, charging and bleeding, see COOLING SYSTEM - DRAINING,
CHARGING AND BLEEDING
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 199: Installation of Support Tool (9997107)


Courtesy of VOLVO CARS CORPORATION

see 9997107

Remove the following items:

 air cleaner (ACL) housing, see AIR CLEANER HOUSING


 spark plugs, see SPARK PLUGS
 VVT unit, see VVT UNIT (NON-TURBO)
 fuel injector, see FUEL INJECTOR
 exhaust manifold, see EXHAUST MANIFOLD
 the intake manifold, see INDUCTION PIPE
 VVT solenoid, see VVT SOLENOID

Fig. 200: Quick Release Connector


Courtesy of VOLVO CARS CORPORATION

Fig. 201: Timing Belt Rear Cover Bolt


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Courtesy of VOLVO CARS CORPORATION

Fig. 202: Engine Mount Bracket and Lift Hook


Courtesy of VOLVO CARS CORPORATION

Fig. 203: Remove Pipe


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 204: Oil Filler Tube, Bolts


Courtesy of VOLVO CARS CORPORATION

Fig. 205: Special Tools (9995454)


Courtesy of VOLVO CARS CORPORATION

see 9995454

Fig. 206: Press Tools Installed


Courtesy of VOLVO CARS CORPORATION

see 9995454
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 207: Install 46 Bolts


Courtesy of VOLVO CARS CORPORATION

Fig. 208: Loosening Press Tools, Use Special Pliers (9995670) Remove Cam Cover Evenly
Courtesy of VOLVO CARS CORPORATION

CAUTION: Take extra care when handling the component.

see 9995670
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 209: Lifting Cam Cover, Tools Removed


Courtesy of VOLVO CARS CORPORATION

CAUTION: Take extra care when handling the component.

Fig. 210: Gently Lift Out Camshafts


Courtesy of VOLVO CARS CORPORATION

NOTE: Note the position of each component before removal.


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 211: Identifying Camshaft Lifters


Courtesy of VOLVO CARS CORPORATION

NOTE: Note the position of the component before removal.

Fig. 212: Head Bolt Removal Sequence


Courtesy of VOLVO CARS CORPORATION

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

INSTALLATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 213: Gasket Solution, 1161847


Courtesy of VOLVO CARS CORPORATION

CAUTION: Take extra care when handling the component.

CAUTION: Make sure that the mating faces are clean and free of foreign material.

CAUTION: Make sure that no fluids are present in the cylinder head bolt threaded
bores.

Use: Gasket solution, 1161847

Fig. 214: Head Bolt Torque Sequence


Courtesy of VOLVO CARS CORPORATION

Torque: Cylinder head


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

• Stage 1: 20 Nm

• Stage 2: 60 Nm

• Stage 3: 130 degree

see 9512050

Fig. 215: Apply Engine Oil to Cam Followers, Install at Original Location
Courtesy of VOLVO CARS CORPORATION

CAUTION: Only use the specified lubricant.

NOTE: Make sure that this component is installed to the noted removal position.

Use: Engine oil,

NOTE: This step is only necessary if adjustment is required

Perform valve clearance, see VALVE CLEARANCE


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 216: Apply Engine Oil to Camshafts


Courtesy of VOLVO CARS CORPORATION

CAUTION: Only use the specified lubricant.

NOTE: Make sure that this component is installed to the noted removal position.

Use: Engine oil,

Fig. 217: Identifying Positions of Camshafts


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 218: Gasket Solution, 1161847


Courtesy of VOLVO CARS CORPORATION

NOTE: Make sure that the mating faces are clean and free of foreign material.

Use: Gasket solution, 1161847

see 9512767

Use: Chemical gasket, 1161059

Fig. 219: Installing Press Tools (9995454)


Courtesy of VOLVO CARS CORPORATION

CAUTION: Take extra care when handling the component.


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 220: Install 46 Bolts


Courtesy of VOLVO CARS CORPORATION

Torque: M7

17 Nm

Fig. 221: Oil Filler Tube, Bolts


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 222: Remove Pipe


Courtesy of VOLVO CARS CORPORATION

Fig. 223: Engine Mounting Bracket and Lift Hooks


Courtesy of VOLVO CARS CORPORATION

1. Torque: M10

50 Nm

2. Torque: M8

24 Nm
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 224: Timing Belt Rear Cover Bolt


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm

Fig. 225: Quick Release Connector


Courtesy of VOLVO CARS CORPORATION

Install the following items:

 VVT unit, see VVT UNIT (NON-TURBO)


 exhaust manifold, see EXHAUST MANIFOLD
 air cleaner (ACL) housing, see AIR CLEANER HOUSING
 fuel injector, see FUEL INJECTOR
 spark plugs, see SPARK PLUGS
 the intake manifold, see INDUCTION PIPE
 VVT solenoid, see VVT SOLENOID
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 226: Support Tool (9997107) Installed


Courtesy of VOLVO CARS CORPORATION

Torque: M10

50 Nm

Perform cooling system draining, charging and bleeding, see COOLING SYSTEM - DRAINING,
CHARGING AND BLEEDING .

ENGINE OIL PAN


OIL PAN (TURBO)

Special tools
999 7273 Guide pin
Tool number: 999 7273
Tool description: Guide pin
Tool boards: 21
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

951 2767 Roller (Applying liquid gasket)


B234, 5234, 6304
Tool number: 951 2767
Tool description: Roller (Applying liquid
gasket) B234, 5234, 6304
Tool boards: 08

Materials
Designation Part number
Cleaning agent 1161721
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Chemical gasket 1161059

REMOVAL

Remove the auxiliaries belt, see ACCESSORY DRIVE BELT.

Fig. 227: A/C Compressor Bolts


Courtesy of VOLVO CARS CORPORATION

Fig. 228: Air Tube, Turbocharger


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 229: Remove/Install Bolt


Courtesy of VOLVO CARS CORPORATION

Fig. 230: Remove/Install Bolt


Courtesy of VOLVO CARS CORPORATION

Fig. 231: Dipstick Tube Bolt


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 232: Oil Cooler Bolts


Courtesy of VOLVO CARS CORPORATION

Fig. 233: 29 Oil Pan Bolts


Courtesy of VOLVO CARS CORPORATION

INSTALLATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 234: Guide Pins (9997273)


Courtesy of VOLVO CARS CORPORATION

see 9997273

Fig. 235: Identifying Gasket Locations


Courtesy of VOLVO CARS CORPORATION

CAUTION: Make sure that the gaskets are correctly located.

Fig. 236: Cleaning Agent, 1161721 And (Applying liquid gasket)


Courtesy of VOLVO CARS CORPORATION

CAUTION: Make sure that the mating faces are clean and free of foreign material.

Use: Cleaning agent, 1161721


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

see 9512767

Use: Chemical gasket, 1161059

Fig. 237: Identifying Oil Pan Bolts


Courtesy of VOLVO CARS CORPORATION

Torque: M7

17 Nm

To install, reverse the removal procedure.

OIL PAN (NON-TURBO)

Special tools
999 7273 Guide pin
Tool number: 999 7273
Tool description: Guide pin
Tool boards: 21
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

951 2767 Roller (Applying liquid gasket)


B234, 5234, 6304
Tool number: 951 2767
Tool description: Roller (Applying liquid
gasket) B234, 5234, 6304
Tool boards: 08

Materials
Designation Part number
Cleaning agent 1161721
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Chemical gasket 1161059

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.

Remove the auxiliaries belt, see ACCESSORY DRIVE BELT.

Fig. 238: Remove/Install A/C Compressor Bolts


Courtesy of VOLVO CARS CORPORATION

Torque: M8

24 Nm

Fig. 239: Remove/Install Bolt


Courtesy of VOLVO CARS CORPORATION

Torque: M10
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

50 Nm

Fig. 240: Remove/Install Bolt


Courtesy of VOLVO CARS CORPORATION

Torque: M10

50 Nm

Fig. 241: Dipstick Tube Bolt


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 242: Oil Cooler Bolts


Courtesy of VOLVO CARS CORPORATION

Torque: M7

17 Nm

Fig. 243: 29 Oil Pan Bolts


Courtesy of VOLVO CARS CORPORATION

INSTALLATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 244: Guide Pins (9997273)


Courtesy of VOLVO CARS CORPORATION

see 9997273

Fig. 245: Identifying Gasket Locations


Courtesy of VOLVO CARS CORPORATION

CAUTION: Make sure that the gaskets are correctly located.


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 246: Cleaning Agent, 1161721 And (Applying liquid gasket)


Courtesy of VOLVO CARS CORPORATION

CAUTION: Make sure that the mating faces are clean and free of foreign material.

Use: Cleaning agent, 1161721

see 9512767

Use: Chemical gasket, 1161059

Fig. 247: Identifying Oil Pan Bolts


Courtesy of VOLVO CARS CORPORATION

Torque: M7

17 Nm
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

To install, reverse the removal procedure.

ENGINE MOUNTING
ENGINE SUPPORT INSULATOR, RIGHT

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.

Fig. 248: Installing Engine Support Beam and Hook (9995185, 997103)
Courtesy of VOLVO CARS CORPORATION

Fig. 249: Removing Coolant Reservoir


Courtesy of VOLVO CARS CORPORATION

WARNING: Be prepared to collect escaping fluid.


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 250: Remove/Install Engine Pad, Right


Courtesy of VOLVO CARS CORPORATION

Torque: Engine pad to frame member

90 Nm

Fig. 251: Engine Pad Bolts to Engine


Courtesy of VOLVO CARS CORPORATION

Torque: Engine pad to engine, screw

133 Nm

INSTALLATION

To install, reverse the removal procedure.

ENGINE SUPPORT INSULATOR LEFT


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

REPLACEMENT

Special tools
999 7103 Lifting beam
Tool number: 999 7103
Tool description: Lifting beam
Tool boards: 21

999 5185 HOOK (LIFTING OUT


ENGINE-TO 2810)
Tool number: 999 5185
Tool description: HOOK (LIFTING OUT
ENGINE-TO 2810)
Tool boards: 21

999 7102 Lifting yoke


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Tool number: 999 7102


Tool description: Lifting yoke
Tool boards: 21

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.

Remove the air filter housing, see AIR CLEANER HOUSING

Remove battery, see BATTERY

Fig. 252: Installing Engine Support Beam and Hook (9995185, 997103)
Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

see 9997103 see 9995185

Fig. 253: Lifting Yoke (9997102) Installed


Courtesy of VOLVO CARS CORPORATION

see 9997102

Fig. 254: Removing/Installing Engine Pad, Left


Courtesy of VOLVO CARS CORPORATION

Remove the following items:

1. Torque: Engine pad, left side (4 nuts M10)

• Stage 1: 34 Nm

• Stage 2: 60 degree

2. Torque: M8
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

24 Nm

3. Torque: M6

10 Nm

Fig. 255: Removing/Installing Engine Pad, Left


Courtesy of VOLVO CARS CORPORATION

Fig. 256: Removing/Installing Engine Pad, Left


Courtesy of VOLVO CARS CORPORATION

Torque: Engine pad, left side (screw M12)

80 Nm

INSTALLATION

To install, reverse the removal procedure.


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

FRONT BUSHING, SUBFRAME FRONT

Special tools:

see 9997054

see 9997034

see 9997132

see 9997131

see 9997130

see 9997134

see 9997133

see 9997138

see 9997137

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

Remove the wheel.

Remove the sub-frame.

REMOVAL

REMOVING FRONT SUB-FRAME BUSHING


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 257: Identifying Tools 9997054, 9997034, 9997132, 9997131 And 9997130
Courtesy of VOLVO CARS CORPORATION

Press the control arm into place.

Install the hydraulic cylinder.

Use: see 9997054 with: see 9997034 , nut M12: see 9997132 , socket: see 9997131 and drift: see 9997130 .

Pull the bushing out.

REMOVING REAR SUB-FRAME BUSHING


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 258: Identifying Hydraulic Cylinder


Courtesy of VOLVO CARS CORPORATION

Press the control arm into place.

Install the hydraulic cylinder.

Use: see 9997054 with: see 9997034 , nut M12: see 9997132 , socket: see 9997136 and drift: see 9997135 .

Pull the bushing out.

INSTALLATION

INSTALLING THE FRONT SUB-FRAME BUSHING


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 259: Identifying Hydraulic Cylinder


Courtesy of VOLVO CARS CORPORATION

Install the hydraulic cylinder.

Use: see 9997054 with: see 9997034 , nut: see 9997132 , socket: see 9997134 , lock ring: see 9997134 and ring:
see 9997133 .

Pull in the bushing until it is centered in the link arm. Pull the bushing in approximately half-way and then
remove: see 9997134 .

Then pull the bushing in so that it bottoms out against the flange

INSTALLING REAR SUB-FRAME BUSHING


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

Fig. 260: Identifying Control Arm


Courtesy of VOLVO CARS CORPORATION

Install the control arm.

Use: see 9997054 with: see 9997034 , nut: see 9997132 , socket: see 9997138 , drift: see 9997135 lock ring: see
9997138 and ring: see 9997137 .

NOTE: The bushings shall be installed with the markings in line across the length of
the car.

Pull the bushing in approximately half-way and then remove: see 9997138 .

Then pull the bushing in so that it bottoms out against the flange.

FINISHING

INSTALLING THE SUB-FRAME

Install the sub-frame.

Install the wheel according to: WHEELS .


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

LOWER TORQUE ROD

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.

Fig. 261: Identifying Splash Panel Screws


Courtesy of VOLVO CARS CORPORATION

Fig. 262: Removing/Installing Torque Rod


Courtesy of VOLVO CARS CORPORATION

Remove the following items:

1. Torque: M12

80 Nm

2. Torque: M12
2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

80 Nm

INSTALLATION

To install, reverse the removal procedure.

LOWER TORQUE ROD BRACKET

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.

Fig. 263: Identifying Splash Panel Screws


Courtesy of VOLVO CARS CORPORATION

Fig. 264: Bracket Bolts


Courtesy of VOLVO CARS CORPORATION

Remove the following items:


2012 Volvo C30 T-5
ENGINE Engine - Removal, replacement and installation

1. Torque: M12

80 Nm

2. Torque: Bottom torque rod (screw M10)

60 Nm

INSTALLATION

To install, reverse the removal procedure.


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Installation Instructions, Accessories

ACCESSORIES AND BODY, CAB

Exterior Trim, Glass, Weatherstrips - Installation Instructions, Accessories

MIRROR, COVER
MIRROR, COVER (STYLE 1)

REMOVE

Fig. 1: Identifying Removal Of Mirror Cover


Courtesy of VOLVO CARS CORPORATION

 Pry/twist off the mirror cover using a weatherstrip tool (1). Fold it forward (2) and unhook it at the front
edge.

Fig. 2: Pressing The Cover Down


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Installation Instructions, Accessories

Fig. 3: Aligning The Cover


Courtesy of VOLVO CARS CORPORATION

 Take a new cover from the kit, push it down towards the mirror housing and align the covers three lugs in
the corresponding recesses in the housing.
 Align the covers inner end in the housing.

Fig. 4: Identifying Alignment Of Mirror Cover


Courtesy of VOLVO CARS CORPORATION

 Check that the cover is parallel to the housing.

INSTALL
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Installation Instructions, Accessories

Fig. 5: Installation Of Mirror Cover


Courtesy of VOLVO CARS CORPORATION

 First press the cover on the inside and then on the outside.
 Check that the cover is secured correctly.
 Repeat the steps for the other mirror.

MIRROR, COVER (STYLE 2)

REMOVE

Fig. 6: Identifying Pry Tool To Remove Mirror Glass


Courtesy of VOLVO CARS CORPORATION

 Carefully pry off the mirror glass.


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Installation Instructions, Accessories

Fig. 7: Identifying Removal Of Mirror Cover


Courtesy of VOLVO CARS CORPORATION

 Press out the mirror's cover using a small screwdriver.


 Remove the cover. New cover is included in the kit.

INSTALLING

Fig. 8: Identifying Mirror Glass


Courtesy of VOLVO CARS CORPORATION

 Make sure that the damper blades end up in their grooves.


 Carefully press the mirror glass into place.
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Installation Instructions, Accessories

Fig. 9: Pressing In Cover


Courtesy of VOLVO CARS CORPORATION

 Press the new cover on the mirror. Press all the way around so that all catches engage.
 Repeat on the car's other side.

Fig. 10: Identifying Catches


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Installation Instructions, Accessories

Fig. 11: Installation Of Mirror Cover


Courtesy of VOLVO CARS CORPORATION

SILL MOULDING, DECOR PROTECTION (2010-2011)


SILL MOULDING, DECOR PROTECTION

NOTE: Do not carry out the work at temperatures below 20 °C (68°F).

Do not use the car within two hours after carrying out the work.

Do not wash the car within 48 hours.

PREPARATION

Fig. 12: Clean The Dirt From Sill


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Installation Instructions, Accessories

 Clean the sill from dirt and wipe dry.

Fig. 13: Clean The Sill Using Isopropanol


Courtesy of VOLVO CARS CORPORATION

 Clean the sill using isopropanol and wipe dry.

INSTALLATION

Fig. 14: Identifying Decor Tape


Courtesy of VOLVO CARS CORPORATION

 Carefully attach the decor tape's long straight side approximately in the center (1) of the radius for the
longer part of the sill, at the same time as the cutout in the decor tape is opposite the joint on the sill
panel.
 Attach tape at the sides and in the center of the decor strip.
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Installation Instructions, Accessories

Fig. 15: Attach Tape At Sides And In Center Of Decor Strip


Courtesy of VOLVO CARS CORPORATION

Fig. 16: Remove Protective Tape From Center Of Decor Tape


Courtesy of VOLVO CARS CORPORATION

 Remove the protective tape from the center of the decor tape.
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Installation Instructions, Accessories

Fig. 17: Check For Air Bubbles


Courtesy of VOLVO CARS CORPORATION

 Apply the decor tape starting from the middle, first the flat part of the sill, then inwards towards the
embossing in the sill and then along the sill.
 Check for air bubbles. If there are any, carefully prick them using a pin and rub along the decor tape using
the plastic scraper.

Fig. 18: Remove Protective Tape


Courtesy of VOLVO CARS CORPORATION

 Remove the protective tape from the outer part of the decor tape.
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Installation Instructions, Accessories

Fig. 19: Check For Air Bubbles


Courtesy of VOLVO CARS CORPORATION

 Apply the decor tape to the outer part starting from the middle and working outwards, and then along.
 Check for air bubbles. If there are any, carefully prick them using a pin and rub along the decor tape using
the plastic scraper.

Fig. 20: Remove Protective Tape From Inner Part


Courtesy of VOLVO CARS CORPORATION

 Remove the protective tape from the inner part of the decor tape.
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Installation Instructions, Accessories

Fig. 21: Check For Air Bubbles


Courtesy of VOLVO CARS CORPORATION

 Apply the decor tape to the inner part, working inwards towards the flat part of the sill, then the vertical
part of the sill and then along the sill.
 Check for air bubbles. If there are any, carefully prick them using a pin and rub along the decor tape using
the plastic scraper.
 Repeat the above steps for the other side.
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

ACCESSORIES AND BODY, CAB

Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

OUTSIDE TRIM PARTS, EMBLEM, REFLECTOR


EMBLEM FRONT FENDER (2009-2012)

REMOVAL

Fig. 1: Identifying Front Fender Emblem And Removal/Installation Tools


Courtesy of VOLVO CARS CORPORATION

INSTALLATION

Follow the instructions regarding components with double-sided adhesive tape, see COMPONENTS WITH
DOUBLE-SIDED TAPE
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 2: Identifying Front Fender Emblem Area (Left Fender)


Courtesy of VOLVO CARS CORPORATION

Fig. 3: Identifying Front Fender Emblem Area (Right Fender)


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

EMBLEM RADIATOR MASKING (2009-2012)

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.

Remove the bumper. See COVER BUMPER FRONT (2007-2011 EARLY) or COVER BUMPER FRONT
(2011 LATE -2012) .

Fig. 4: Identifying Removal Of Radiator Grill Emblem (1 Of 2)


Courtesy of VOLVO CARS CORPORATION

Fig. 5: Identifying Removal Of Radiator Grill Emblem (2 Of 2)


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

INSTALLATION

To install, reverse the removal procedure.

FRONT FENDER WIDENER

Fig. 6: Wheel Arch Lining Retainers


Courtesy of VOLVO CARS CORPORATION

Fig. 7: Identifying Fender Panel Retainers


Courtesy of VOLVO CARS CORPORATION

LOWER TRIM STRIP, FRONT DOOR

NOTE: The illustrations in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the illustrations is always correct.

REMOVAL
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 8: Identifying Lower Trim Strip, Front Door


Courtesy of VOLVO CARS CORPORATION

Remove the 2 screws (1).

Remove the 2 hidden clips (4).

HINT: Use a weatherstrip tool to disconnect the trim and the clips.

INSTALLATION

INSTALLING THE LOWER FRONT DOOR TRIM


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 9: Identifying Installation Of Lower Front Door Trim


Courtesy of VOLVO CARS CORPORATION

Guide the door trim into place using the locating pin in the center and the 4 clips. Press into place.

Install the 2 screws (1). Tighten.

LOWER TRIM STRIP, REAR DOOR

NOTE: The illustrations in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the illustrations is always correct.

REMOVAL

REMOVING THE LOWER REAR DOOR TRIM


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 10: Identifying Removal Of Lower Rear Door Trim


Courtesy of VOLVO CARS CORPORATION

Remove the 2 screws (1).

Remove the 2 hidden clips (2).

HINT: Use a weatherstrip tool to disconnect the trim and the clips.

INSTALLATION

INSTALLING THE LOWER REAR DOOR TRIM


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 11: Identifying Installation Of Lower Front Door Trim


Courtesy of VOLVO CARS CORPORATION

Guide the door trim into place using the locating pin in the center and the 2 clips. Press into place.

Install the 2 screws (1). Tighten.

LUGGAGE COMPARTMENT LID BADGES (2007-08)

Materials:
Designation Part number
Cleaning agent 9192678-2

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 12: Removing Emblem With Heat Gun


Courtesy of VOLVO CARS CORPORATION

CAUTION: Do not damage the vehicle paintwork.

INSTALLATION

CAUTION: Make sure that the mating faces are at a minimum temperature of +20 °C.

CAUTION: Make sure that the mating faces are clean and free of foreign material.

Use: Cleaning agent, 9192678-2

CAUTION: Make sure that the mating surfaces are dry.

CAUTION: Apply even pressure along the entire component.


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 13: Aligning Rear Emblem (1 Of 4)


Courtesy of VOLVO CARS CORPORATION

Fig. 14: Aligning Rear Emblem (2 Of 4)


Courtesy of VOLVO CARS CORPORATION

Fig. 15: Aligning Rear Emblem (3 Of 4)


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 16: Aligning Rear Emblem (4 Of 4)


Courtesy of VOLVO CARS CORPORATION

CAUTION: Make sure that the tape has not detached from the edges of the
component.

CAUTION: Make sure that the customer is advised not to wash the vehicle within the
next 72 hours.

LUGGAGE COMPARTMENT LID BADGES (2009-2011 EARLY)

REMOVAL
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 17: Removing Emblem With Heat Gun


Courtesy of VOLVO CARS CORPORATION

INSTALLATION

Follow the instructions regarding components with double-sided adhesive tape, see COMPONENTS WITH
DOUBLE-SIDED TAPE

Fig. 18: Aligning Rear Emblem (1 Of 4)


Courtesy of VOLVO CARS CORPORATION

Fig. 19: Aligning Rear Emblem (2 Of 4)


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 20: Aligning Rear Emblem (3 Of 4)


Courtesy of VOLVO CARS CORPORATION

Fig. 21: Aligning Rear Emblem (4 Of 4)


Courtesy of VOLVO CARS CORPORATION

LUGGAGE COMPARTMENT LID BADGES (2011 LATE -2012)

REMOVAL
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 22: Removing Emblem With Heat Gun


Courtesy of VOLVO CARS CORPORATION

INSTALLATION

Follow the instructions regarding components with double-sided adhesive tape, see COMPONENTS WITH
DOUBLE-SIDED TAPE

Fig. 23: Aligning Rear Emblem (1 Of 4)


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Courtesy of VOLVO CARS CORPORATION

Fig. 24: Aligning Rear Emblem (2 Of 4)


Courtesy of VOLVO CARS CORPORATION

Fig. 25: Aligning Rear Emblem (3 Of 4)


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 26: Aligning Rear Emblem (4 Of 4)


Courtesy of VOLVO CARS CORPORATION

REAR FENDER WIDENER

Fig. 27: Identifying Fender Fastener


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 28: Locating Fender Widener Fasteners (5)


Courtesy of VOLVO CARS CORPORATION

SILL PANEL

Fig. 29: Sill Panel Removal And Installation Procedure (1 Of 6)


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 30: Sill Panel Removal And Installation Procedure (2 Of 6)


Courtesy of VOLVO CARS CORPORATION

Fig. 31: Sill Panel Removal And Installation Procedure (3 Of 6)


Courtesy of VOLVO CARS CORPORATION

Fig. 32: Sill Panel Removal And Installation Procedure (4 Of 6)


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 33: Sill Panel Removal And Installation Procedure (5 Of 6)


Courtesy of VOLVO CARS CORPORATION

Fig. 34: Sill Panel Removal And Installation Procedure (6 Of 6)


Courtesy of VOLVO CARS CORPORATION

GLASS AND SEALING MOLDING FOR WINDSHIELD


WINDSHIELD

Special tools
951 2925 Rollout 2000 (For window removal)
Tool number: 951 2925
Tool description: Rollout 2000 (For window
removal)
Tool boards: 80

951 2335 Window lifter 2 pieces (replaces


9986030)
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Tool description: Window lifter 2 pieces (replaces


9986030)
Tool boards:

981 4022 Oven 220V SHUKO


Tool number: 981 4022
Tool description: Oven 220V SHUKO
Tool boards: US99

981 4023 Oven 220V UK


Tool number: 981 4023
Tool description: Oven 220V UK
Tool boards: US99

981 4024 Oven 110V US


Tool number: 981 4024
Tool description: Oven 110V US
Tool boards: US99

981 4019 Glue gun 220V SHUKO


Tool number: 981 4019
Tool description: Glue gun 220V SHUKO
Tool boards: US99

981 4020 Glue gun 220V UK


Tool number: 981 4020
Tool description: Glue gun 220V UK
Tool boards: US99

981 4021 Glue gun 110V US


Tool number: 981 4021
Tool description: Glue gun 110V US
Tool boards: US99

Materials
Designation Part number
H Cleaner 1161436-9
Adhesive kit 31299177
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

REMOVAL

NOTE: Make sure that the vehicle is standing on a level surface.

See information about bonded windows, general information, see BONDED WINDOW GENERAL,
INFORMATION

Remove the following items:

 Plenum chamber, see PLENUM CHAMBER


 Rain sensor, see RAIN SENSOR
 inner rear view mirror, see INNER REAR VIEW MIRROR

WARNING: Wear safety goggles.

Fig. 35: Cutting Cable


Courtesy of VOLVO CARS CORPORATION

see 9512925
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 36: Inserting Cable with Special Tool


Courtesy of VOLVO CARS CORPORATION

Fig. 37: Identifying Cable Pulled Through Gap Under Windshield


Courtesy of VOLVO CARS CORPORATION

Fig. 38: Identifying Cable Taped On Surface Of Windshield


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 39: Identifying Excess Cable Pulled Through Gap Under Windshield
Courtesy of VOLVO CARS CORPORATION

Fig. 40: Identifying Placement Of Cable Under Windshield


Courtesy of VOLVO CARS CORPORATION

Fig. 41: Identifying Cable Placed Under Windshield


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 42: Identifying Application Of #1 Suction Cup Glass Lifter / Roll Out Tool 9512925
Courtesy of VOLVO CARS CORPORATION

Fig. 43: Ensuring Components Are Protected


Courtesy of VOLVO CARS CORPORATION

CAUTION: Make sure that the components are protected.


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 44: Identifying Cable End Pulled Under Weatherstrip And Around Windshield With Roll Out Tool
9512925
Courtesy of VOLVO CARS CORPORATION

WARNING: Wear safety goggles.

Fig. 45: Applying Roll Out Tool 9512925


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 46: Identifying Repositioned #1 Roll Out Tool 9512925 Around Windshield
Courtesy of VOLVO CARS CORPORATION

Fig. 47: Identifying Application Of Second Roll Out Tool 9512925


Courtesy of VOLVO CARS CORPORATION

Fig. 48: Identifying Repositioned #2 Roll Out Tool 9512925 Around Windshield
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 49: Identifying Repositioned #1 Roll Out Tool 9512925 Around Windshield
Courtesy of VOLVO CARS CORPORATION

Fig. 50: Lifting Glass with Assistant


Courtesy of VOLVO CARS CORPORATION

see 9512335

INSTALLATION

See information about bonded windows, general safety information, see BONDED WINDOW, GENERAL
SAFETY INFORMATION

See information about bonded windows, general information, see BONDED WINDOW GENERAL,
INFORMATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 51: Applying H Cleaner, 1161436-9 (1 Of 4)


Courtesy of VOLVO CARS CORPORATION

Use: H Cleaner, 1161436-9

Fig. 52: Applying H Cleaner, 1161436-9 (2 Of 4)


Courtesy of VOLVO CARS CORPORATION

Use: H Cleaner, 1161436-9


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 53: Applying H Cleaner, 1161436-9 (3 Of 4)


Courtesy of VOLVO CARS CORPORATION

Fig. 54: Applying H Cleaner, 1161436-9 (4 Of 4)


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 55: Drying Time 10 Min.


Courtesy of VOLVO CARS CORPORATION

Fig. 56: Applying Adhesive (Kit, 31299177)


Courtesy of VOLVO CARS CORPORATION

see 9814022 see 9814023 see 9814024 see 9814019 see 9814020 see 9814021

Use: Adhesive kit, 31299177

Fig. 57: Identifying Ten Minute Requirement To Allow Cleaner To Evaporate


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 58: Lifting Out Windshield With Roll Out Tools 9512925
Courtesy of VOLVO CARS CORPORATION

Fig. 59: Identifying Time And Temperature Requirements For Adhesive To Dry
Courtesy of VOLVO CARS CORPORATION

WARNING: Wait for the specified time at the specified temperature before moving the
car.

Install the following items:

 Plenum chamber, see PLENUM CHAMBER


 Rain sensor, see RAIN SENSOR
 inner rear view mirror, see INNER REAR VIEW MIRROR

GLASS FOR SIDE DOORS AND WINDOW


FIXED SIDE WINDOW
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Special tools
951 2925 Rollout 2000 (For window removal)
Tool number: 951 2925
Tool description: Rollout 2000 (For window
removal)
Tool boards: 80
951 2335 Window lifter 2 pieces (replaces
9986030)
Tool number: 951 2335
Tool description: Window lifter 2 pieces (replaces
9986030)
Tool boards:

981 4022 Oven 220V SHUKO


Tool number: 981 4022
Tool description: Oven 220V SHUKO
Tool boards: US99

981 4023 Oven 220V UK


Tool number: 981 4023
Tool description: Oven 220V UK
Tool boards: US99

981 4024 Oven 110V US


Tool number: 981 4024
Tool description: Oven 110V US
Tool boards: US99

981 4019 Glue gun 220V SHUKO


Tool number: 981 4019
Tool description: Glue gun 220V SHUKO
Tool boards: US99

981 4020 Glue gun 220V UK


Tool number: 981 4020
Tool description: Glue gun 220V UK
Tool boards: US99

981 4021 Glue gun 110V US


Tool number: 981 4021
Tool description: Glue gun 110V US
Tool boards: US99
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Materials
Designation Part number
H Cleaner 1161436-9
Adhesive kit 31299177

REMOVAL

Remove the following items:

 B-pillar trim panel, see B-PILLAR TRIM PANEL


 C-pillar trim panel, see C-PILLAR TRIM PANEL

WARNING: Wear safety goggles.

Fig. 60: Identifying Length Of Roll Out Cable


Courtesy of VOLVO CARS CORPORATION

see 9512925
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 61: Applying Tape and Threading Cable In Window Seal Area
Courtesy of VOLVO CARS CORPORATION

Fig. 62: Cable In Window Seal Area


Courtesy of VOLVO CARS CORPORATION

Fig. 63: Cable In Window Seal Area Removal Direction (1 Of 2)


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 64: Cable In Window Seal Area Removal Direction (2 Of 2)


Courtesy of VOLVO CARS CORPORATION

Fig. 65: Applying Roll Out Tool 9512925


Courtesy of VOLVO CARS CORPORATION

Fig. 66: Using Roll Out Tool On Rear Part Of Side Window
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 67: Applying Roll Out Tool 9512925


Courtesy of VOLVO CARS CORPORATION

Fig. 68: Using Roll Out Tool On Front Part Of Side Window
Courtesy of VOLVO CARS CORPORATION

Fig. 69: Lifting Glass With Assistant


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

see 9512335

INSTALLATION

Fig. 70: H Cleaner, 1161436-9


Courtesy of VOLVO CARS CORPORATION

Use: H Cleaner, 1161436-9

Fig. 71: H Cleaner, 1161436-9


Courtesy of VOLVO CARS CORPORATION

Use: H Cleaner, 1161436-9


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 72: Applying H Cleaner, 1161436-9 (1 Of 2)


Courtesy of VOLVO CARS CORPORATION

Fig. 73: Applying H Cleaner, 1161436-9 (2 Of 2)


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 74: Drying Time 10 Min.


Courtesy of VOLVO CARS CORPORATION

Fig. 75: Applying Adhesive (Kit, 31299177)


Courtesy of VOLVO CARS CORPORATION

see 9814022 see 9814023 see 9814024 see 9814019 see 9814020 see 9814021

Use: Adhesive kit, 31299177

Fig. 76: Identifying Ten Minute Requirement To Allow Cleaner To Evaporate


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 77: Identifying Time And Temperature Requirements For Adhesive To Dry
Courtesy of VOLVO CARS CORPORATION

WARNING: Wait for the specified time at the specified temperature before moving the
car.

Assemble the following items:

 B-pillar trim panel, see B-PILLAR TRIM PANEL


 C-pillar trim panel, see C-PILLAR TRIM PANEL

RUBBER PROTECTION GLASS CLAMP

Special tools:

see 9995723

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.

REMOVAL

REMOVING THE RUBBER LIP


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 78: Identifying Removal Of Rubber Lip


Courtesy of VOLVO CARS CORPORATION

Remove the rubber lip located in the glass clamp. Use a pair of bent pliers and pull it out through the rear hole
of the door module.

INSTALLATION

INSTALLING THE RUBBER LIP

Fig. 79: Identifying Installation Of Rubber Lip


Courtesy of VOLVO CARS CORPORATION

Install the new rubber lip through the hole in the door module and hold in place using the pliers.

Use see 9995723 or a similar long flat tool to insert between the inner and outer door panel.

Then press the rubber lip into position in the glass clamp.
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 80: Identifying Clamp Centered


Courtesy of VOLVO CARS CORPORATION

NOTE: Ensure that the glass is centered in the clamp.

WINDOW, FRONT DOOR.

Operation Number(s): 84406-2

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.

Fig. 81: Roll Window Up 160 mm


Courtesy of VOLVO CARS CORPORATION

Remove door panel. See PANEL FRONT DOOR


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 82: Do Not Loosen Bolts More Than 2 Turns


Courtesy of VOLVO CARS CORPORATION

NOTE: Do not loosen the bolts more than 2 turns.

Torque: Window to power window mechanism (front side door)

8 Nm

Fig. 83: Identifying Rotation Arrows


Courtesy of VOLVO CARS CORPORATION

INSTALLATION

Install in reverse order.

Initiate window lift. See VIDA car communication. VIDA is Volvo-specific scan tool.

SILL TRIM PANEL


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

FRONT SILL TRIM PANEL

Fig. 84: Identifying Front Sill Trim Panel


Courtesy of VOLVO CARS CORPORATION

REAR SILL TRIM PANEL

Fig. 85: Identifying Rear Sill Trim Panel


Courtesy of VOLVO CARS CORPORATION

OUTSIDE MIRRORS
COVER, EXTERNAL MIRROR

REMOVAL

Remove mirror rear-view mirror external, see MIRROR, REAR VIEW MIRROR
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 86: Identifying Rear View Mirror Cover Removal


Courtesy of VOLVO CARS CORPORATION

INSTALLATION

Fig. 87: Identifying Rear View Mirror Cover Installation


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 88: Identifying Rear View Mirror Cover Installation (1 Of 2)


Courtesy of VOLVO CARS CORPORATION

Fig. 89: Identifying Rear View Mirror Cover Installation (2 Of 2)


Courtesy of VOLVO CARS CORPORATION

Install external rearview mirror, see MIRROR, REAR VIEW MIRROR

MIRROR, REAR VIEW MIRROR


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 90: Identifying Removal Of Rear View Mirror Glass (1 Of 2)


Courtesy of VOLVO CARS CORPORATION

Fig. 91: Identifying Removal Of Rear View Mirror Glass (2 Of 2)


Courtesy of VOLVO CARS CORPORATION

MOTOR, EXTERNAL MIRROR

REMOVAL

Remove the mirror glass. See MIRROR, REAR VIEW MIRROR.


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Fig. 92: Identifying Rear View Mirror Motor


Courtesy of VOLVO CARS CORPORATION

REAR VIEW MIRROR EXTERNAL

Operation Number(s): 84622-2

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.

Remove the panel. See PANEL FRONT DOOR

Fig. 93: Removing External Rear View Mirror (1 Of 2)


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Exterior Trim, Glass, Weatherstrips - Removal, replacement and installation

Courtesy of VOLVO CARS CORPORATION

Fig. 94: Removing External Rear View Mirror (2 Of 2)


Courtesy of VOLVO CARS CORPORATION

Torque: Rear view mirror to front door

8 Nm

NOTE: Use a new seal.

INSTALLATION

To install, reverse the removal procedure


2012 Volvo C30 T-5
ELECTRICAL Body Electrical

ELECTRICAL

Body Electrical

BODY ELECTRICAL
FIBER OPTIC CABLE HARNESS, REPAIRING

NOTE: As the illustrations in this service information are used for different model years
and / or models, some variation may occur. However, the essential information
in the illustrations is always correct.

Fig. 1: MOST Bus (Media Oriented System Transportation) Communication Diagram


Courtesy of VOLVO CARS CORPORATION

The components in the infotainment system are part of an optical network, known as the MOST bus. (Media
Oriented System Transportation). The network consists of fiber optics (POF = Polymer Optical Fibers), special
connectors for fiber optics and MOST nodes, i. e. control modules which are connected to the MOST bus.

Data is transmitted via the fiber optics, for example music, in the form of light signals. The MOST bus is a ring
which must be unbroken for it to work. None of the infotainment system will work if an optical fiber breaks or
if a connector is disconnected. The ends of the fibers must also be clean to allow the light to pass.
2012 Volvo C30 T-5
ELECTRICAL Body Electrical

Fig. 2: Identifying Maximum Bend Radius Of Optic Cable


Courtesy of VOLVO CARS CORPORATION

A fiber requires a larger bend radius than a copper cable. The bend radius must not be less than 25 mm . If the
fiber bends too much, not enough light will be let through.

NOTE: Fiber optics must not be spliced.

Damaged fiber optics can be repaired if there is sufficient length remaining to


install a new ferrule (4). If the remaining fiber is not long enough, a new fiber
optic must be routed parallel to the damaged fiber.

NOTE: Fiber optics are sensitive to bending and pinching. Be careful when routing and
securing.

DISASSEMBLING THE CONNECTOR


2012 Volvo C30 T-5
ELECTRICAL Body Electrical

Fig. 3: Identifying Catch Pressed Out With Screwdriver


Courtesy of VOLVO CARS CORPORATION

NOTE: There is one fiber for the input and one for the output signal. The system will
not work if the are interchanged.

Press out the catch (1) using a screwdriver.


2012 Volvo C30 T-5
ELECTRICAL Body Electrical

Fig. 4: Identifying Catches Opened With Screwdriver To Pull Out Ferrule


Courtesy of VOLVO CARS CORPORATION

Open the catches (3) using a screwdriver.

Pull out the ferrule (1). Make a note of its location.

DISASSEMBLING THE COMBINED CONNECTOR (OPTIC AND ELECTRICAL CONDUCTOR) (1)


2012 Volvo C30 T-5
ELECTRICAL Body Electrical

Fig. 5: Disassembling Combined Connector


Courtesy of VOLVO CARS CORPORATION

Release the lock using a screwdriver. Remove the inner section (2).

Remove the ferrule. See DISASSEMBLING THE CONNECTOR

INSTALLING THE FERRULE


2012 Volvo C30 T-5
ELECTRICAL Body Electrical

Fig. 6: Identifying Fiber Optic Cable Stripped With Tool 9512868 (1 Of 2)


Courtesy of VOLVO CARS CORPORATION

Cut the required length (+10 mm) of fiber optic.

Strip the fiber optic. Use tool see 9512868 as shown in the illustration
2012 Volvo C30 T-5
ELECTRICAL Body Electrical

Fig. 7: Identifying Fiber Optic Cable Stripped With Tool 9512868 (2 Of 2)


Courtesy of VOLVO CARS CORPORATION

Strip the fiber optic. Use tool see 9512868 as shown in the illustration.
2012 Volvo C30 T-5
ELECTRICAL Body Electrical

Fig. 8: Aligning Ferrule Using Tool 9512869


Courtesy of VOLVO CARS CORPORATION

Align the ferrule. Use tool see 9512869 as shown in the illustration.
2012 Volvo C30 T-5
ELECTRICAL Body Electrical

Fig. 9: Ensuring Ferrule Is Edge To Edge With Fiber


Courtesy of VOLVO CARS CORPORATION

Check that the ferrule is secure and is edge to edge with the fiber.

ASSEMBLING THE CONNECTOR


2012 Volvo C30 T-5
ELECTRICAL Body Electrical

Fig. 10: Identifying Ferrule Pressed Into Place In Connector


Courtesy of VOLVO CARS CORPORATION

NOTE: There is one fiber for the input and one for the output signal. If they are mixed
up the system will not work.

Press the ferrule (1) into place in the connector (2).


2012 Volvo C30 T-5
ELECTRICAL Body Electrical

Fig. 11: Identifying Installation Of Catch


Courtesy of VOLVO CARS CORPORATION

Install the catch (1).

ASSEMBLING THE COMBINED CONNECTOR (2 OPTIC AND 4 ELECTRICAL CONDUCTORS)

Install the ferrule. See ASSEMBLING THE CONNECTOR.


2012 Volvo C30 T-5
ELECTRICAL Body Electrical

Fig. 12: Identifying Inner Section Pressed Into Place In Combined Connector
Courtesy of VOLVO CARS CORPORATION

Press the inner section into place in the combined connector.

FINISHING WORK

Check the repair. See DIAGNOSTIC INSTRUCTIONS - FIBRE OPTIC CABLE .


2012 Volvo C30 T-5
ACCESSORIES & EQUIPMENT Seats

ACCESSORIES & EQUIPMENT

Seats

SEATS
SIDE PANEL FRONT SEAT

Fig. 1: Removing Front Seat Side Panel - Vehicle With Manual Seat (1 Of 2)
Courtesy of VOLVO CARS CORPORATION

Vehicle with manual seat.

Fig. 2: Removing Front Seat Side Panel - Vehicle With Manual Seat (2 Of 2)
Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES & EQUIPMENT Seats

Fig. 3: Removing Front Seat Side Panel - Vehicle With Electric Seat (1 Of 2)
Courtesy of VOLVO CARS CORPORATION

Vehicle with electric seat.

Fig. 4: Removing Front Seat Side Panel - Vehicle With Electric Seat (2 Of 2)
Courtesy of VOLVO CARS CORPORATION

Remove the control module in the front seat. See CONTROL MODULE FRONT SEAT .

To install, reverse the removal procedure


2012 Volvo C30 T-5
ENGINE PERFORMANCE Ignition And Control Systems - Removal, replacement and installation

ENGINE PERFORMANCE

Ignition And Control Systems - Removal, replacement and installation

IGNITION COIL AND SPARK PLUG


IGNITION COIL (TURBO)

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.

Fig. 1: Identifying Air Intake Hose And Fasteners


Courtesy of VOLVO CARS CORPORATION

Torque: M7

17 Nm

Fig. 2: Identifying Engine Cover And Screws


2012 Volvo C30 T-5
ENGINE PERFORMANCE Ignition And Control Systems - Removal, replacement and installation

Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm

Fig. 3: Identifying Timing Case Cover


Courtesy of VOLVO CARS CORPORATION

Fig. 4: Identifying Ignition Coils, Connectors And Screws


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm

INSTALLATION

To install, reverse the removal procedure.

IGNITION COIL (NON-TURBO)


2012 Volvo C30 T-5
ENGINE PERFORMANCE Ignition And Control Systems - Removal, replacement and installation

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.

Fig. 5: Identifying Air Intake Hose Clamp And Electrical Connector With Cable Clamp
Courtesy of VOLVO CARS CORPORATION

Fig. 6: Identifying Intake Plenum and Bolts


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm
2012 Volvo C30 T-5
ENGINE PERFORMANCE Ignition And Control Systems - Removal, replacement and installation

Fig. 7: Moving Plenum Out of the Way


Courtesy of VOLVO CARS CORPORATION

Fig. 8: Sealing Off Openings


Courtesy of VOLVO CARS CORPORATION

CAUTION: Make sure that all openings are sealed. Use new blanking caps.
2012 Volvo C30 T-5
ENGINE PERFORMANCE Ignition And Control Systems - Removal, replacement and installation

Fig. 9: Identifying Engine Cover End Piece And Screws


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm

Fig. 10: Identifying Ignition Coil Connectors


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE PERFORMANCE Ignition And Control Systems - Removal, replacement and installation

Fig. 11: Identifying Ignition Coil Screws


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm

INSTALLATION

To install, reverse the removal procedure.

SPARK PLUGS

REPLACEMENT

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.

Remove ignition coil, see IGNITION COIL


2012 Volvo C30 T-5
ENGINE PERFORMANCE Ignition And Control Systems - Removal, replacement and installation

Fig. 12: Identifying Spark Plug Locations


Courtesy of VOLVO CARS CORPORATION

Torque: Spark plug

25 Nm

INSTALLATION

To install, reverse the removal procedure.

ENGINE CONTROL SYSTEM


CRANKSHAFT POSITION SENSOR (CKP)

REPLACEMENT

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.

Remove the air filter housing, see AIR CLEANER HOUSING


2012 Volvo C30 T-5
ENGINE PERFORMANCE Ignition And Control Systems - Removal, replacement and installation

Fig. 13: Identifying Pipe


Courtesy of VOLVO CARS CORPORATION

Fig. 14: Identifying Crankshaft Position Sensor


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm

INSTALLATION

To install, reverse the removal procedure.

CAMSHAFT POSITION SENSOR (CMP) (TURBO)

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.


2012 Volvo C30 T-5
ENGINE PERFORMANCE Ignition And Control Systems - Removal, replacement and installation

Fig. 15: Identifying Air Intake Hoses And Fasteners


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm

Fig. 16: Identifying Engine Cover And Screws


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm
2012 Volvo C30 T-5
ENGINE PERFORMANCE Ignition And Control Systems - Removal, replacement and installation

Fig. 17: Identifying Camshaft Position Sensor Connector And Screw


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm

INSTALLATION

To install, reverse the removal procedure.

CAMSHAFT POSITION SENSOR (CMP) (NON-TURBO)

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.

REMOVAL

REMOVING UPPER INTAKE MANIFOLD


2012 Volvo C30 T-5
ENGINE PERFORMANCE Ignition And Control Systems - Removal, replacement and installation

Fig. 18: Identifying Upper Intake Manifold And Screws


Courtesy of VOLVO CARS CORPORATION

CAUTION: Seal the openings in the lower part of the intake manifold. Use tape or
similar.

Remove/slacken off:

 the hose clamp for the hose between the intake manifold and the mass air flow (MAF) sensor
 the 6 screws for the upper intake manifold closest to the front cover plate. Remove/slacken off the 2
screws against the firewall. Lift up the intake manifold and place to one side. Disconnect the connector
for the pressure sensor on the intake manifold. Cut the tie strap.

REMOVING THE CAMSHAFT POSITION (CMP) SENSOR


2012 Volvo C30 T-5
ENGINE PERFORMANCE Ignition And Control Systems - Removal, replacement and installation

Fig. 19: Identifying Camshaft Position Sensors And Screws


Courtesy of VOLVO CARS CORPORATION

Disconnect the connector for the position sensor on the camshaft.

Remove:

 the screw for the position sensor


 the position sensor on the camshaft.

INSTALLATION

NOTE: For tightening torques, see: TIGHTENING TORQUE .

INSTALLING THE CAMSHAFT POSITION (CMP) SENSOR

Install:

 the position sensor on the camshaft


 the screw for the position sensor. Tighten.

Connect the connector for the position sensor on the camshaft.


2012 Volvo C30 T-5
ENGINE PERFORMANCE Ignition And Control Systems - Removal, replacement and installation

INSTALLING UPPER INTAKE MANIFOLD

Fig. 20: Identifying Upper Intake Manifold And Screws


Courtesy of VOLVO CARS CORPORATION

CAUTION: Make sure that the guides for the lower section are in the correct position.

Install:

 a new gasket for the upper section of the intake manifold


 the upper intake manifold. Tighten the screws alternately. Tighten. See: TIGHTENING TORQUE .
Tighten the hose clamp to the mass air flow (MAF) sensor. Connect the connector for the pressure sensor
on the intake manifold
 new tie strap for the cable harness.

FINISHING

CHECKING INJECTORS AND PULSATION DAMPERS

Start the engine. Check the function of the engine. Check for leakage.
2012 Volvo C30 T-5
ENGINE PERFORMANCE Ignition And Control Systems - Removal, replacement and installation

ENGINE CONTROL MODULE (ECM)

REMOVAL

Fig. 21: Identifying Ignition In OFF Position


Courtesy of VOLVO CARS CORPORATION

Fig. 22: Removing Engine Control Module Cover


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE PERFORMANCE Ignition And Control Systems - Removal, replacement and installation

Fig. 23: Removing Engine Control Module


Courtesy of VOLVO CARS CORPORATION

NOTE: Make sure that the component terminals are not bent or damaged.

NOTE: Make sure that the seal is correctly located.

INSTALLATION

To install, reverse the removal procedure.

Order and download software according to: 30668285

Reset according to "Adapting throttle unit" using VIDA (Volvo scan tool).

ENGINE COOLANT TEMPERATURE SENSOR (ECT)

REPLACEMENT

REMOVAL

Drain cooling system, draining, filling, and bleeding, see COOLING SYSTEM - DRAINING, CHARGING
AND BLEEDING

Remove the air filter housing, see AIR CLEANER HOUSING


2012 Volvo C30 T-5
ENGINE PERFORMANCE Ignition And Control Systems - Removal, replacement and installation

Fig. 24: Identifying Engine Coolant Temperature Sensor Connector


Courtesy of VOLVO CARS CORPORATION

Fig. 25: Removing Engine Coolant Temperature Sensor


Courtesy of VOLVO CARS CORPORATION

INSTALLATION

To install, reverse the removal procedure.

FUEL PUMP DRIVER MODULE

REMOVAL AND INSTALLATION

Remove the seat cushion, rear seat, see SEAT CUSHION, REAR SEAT .
2012 Volvo C30 T-5
ENGINE PERFORMANCE Ignition And Control Systems - Removal, replacement and installation

Fig. 26: Identifying Clip


Courtesy of VOLVO CARS CORPORATION

Fig. 27: Identifying Fuel Pump Driver Module, Connector, And Metal Tabs
Courtesy of VOLVO CARS CORPORATION

KNOCK SENSOR (KS)

REPLACEMENT

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.

Remove the air filter housing, see AIR CLEANER HOUSING


2012 Volvo C30 T-5
ENGINE PERFORMANCE Ignition And Control Systems - Removal, replacement and installation

Fig. 28: Identifying Knock Sensor Connector


Courtesy of VOLVO CARS CORPORATION

Fig. 29: Identifying Body Ground Cables


Courtesy of VOLVO CARS CORPORATION

CAUTION: Note the position of the components before removal.

Torque: Knock sensor

20 Nm

INSTALLATION

To install, reverse the removal procedure.

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR


2012 Volvo C30 T-5
ENGINE PERFORMANCE Ignition And Control Systems - Removal, replacement and installation

REMOVAL

Fig. 30: Identifying Manifold Absolute Pressure Sensor Connector And Screws
Courtesy of VOLVO CARS CORPORATION

INSTALLATION

To install, reverse the removal procedure.

PRESSURE SENSOR, FUEL RAIL (FRP)

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

DRAINING THE FUEL SYSTEM

Remove:

 the screws for the upper timing cover


 the upper timing cover.

Drain the fuel system. See: FUEL SYSTEM PRESSURE RELEASE .

REMOVAL

REMOVING THE FUEL PRESSURE SENSOR


2012 Volvo C30 T-5
ENGINE PERFORMANCE Ignition And Control Systems - Removal, replacement and installation

Fig. 31: Identifying Fuel Pressure Sensor Connector And Screw


Courtesy of VOLVO CARS CORPORATION

CAUTION: Place paper on top of the generator.

Disconnect the connector for the sensor.

Remove:

 the screw for the fuel pressure sensor


 the sensor.

INSTALLATION

NOTE: For tightening torque, see: TIGHTENING TORQUE .

INSTALLING THE FUEL PRESSURE SENSOR


2012 Volvo C30 T-5
ENGINE PERFORMANCE Ignition And Control Systems - Removal, replacement and installation

Fig. 32: Identifying Fuel Pressure Sensor Connector And Screw


Courtesy of VOLVO CARS CORPORATION

Install:

 the sensor
 the screw for the sensor. Tighten. Connect the connector for the sensor
 the upper timing cover
 the screws for the cover. Tighten.

FINISHING

CHECKS

Start the engine. Check for leakage. Check the engine function.

TEMPERATURE AND MANIFOLD ABSOLUTE PRESSURE SENSOR (MAPT)

REMOVAL

Remove right-hand cover, see FRONT EXTERIOR LIGHTS .


2012 Volvo C30 T-5
ENGINE PERFORMANCE Ignition And Control Systems - Removal, replacement and installation

Fig. 33: Identifying Temperature And Manifold Absolute Pressure Sensor Connector And Screw
Courtesy of VOLVO CARS CORPORATION

INSTALLATION

To install, reverse the removal procedure.


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

ENGINE

Fuel System - Removal, Replacement And Installation

FUEL PUMP AND STRAINER


LEVEL SENSOR FUEL TANK

Special tools:

see 9997093

NOTE: The graphics in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the graphics is always correct.

PREPARATORY WORK

Remove the fuel tank. See FUEL TANK.

REMOVAL

REMOVING THE LEVEL SENSOR


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 1: Removing Threaded Ring with Tool (9997093)


Courtesy of VOLVO CARS CORPORATION

Remove:

 the large plastic nut. Use tool see 9997093


 the level sensor.

CAUTION: Ensure that the lever on the level sensor is not damaged when removing
the pump.

TRANSFERRING COMPONENTS

TRANSFERRING SUCTION LINE


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 2: Transferring Suction Line


Courtesy of VOLVO CARS CORPORATION

NOTE: Applies to vehicles equipped with auxiliary heater.

Remove the plug for the suction line from the underside of the level sensor, use a 9 mm socket.

Transfer the suction line to the new fuel pump.

INSTALLATION

NOTE: For tightening torques, see TIGHTENING TORQUE .

INSTALLING THE LEVEL SENSOR


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 3: Lining Up The Match Marks


Courtesy of VOLVO CARS CORPORATION

Install the level sensor.

CAUTION: Ensure that the lever on the level sensor is not damaged when removing
the pump.

Install the large plastic nut. Use tool see 9997093 . Tighten acc. to TIGHTENING TORQUE .

NOTE: Ensure that the level sensor marking is opposite the marking on the tank.

FINISHING

Install the fuel tank. See FUEL TANK.

FUEL FILTER (B5254T7; 2008-12)

Special tools

981 4098 Spanner


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Tool description: Spanner


Tool boards: 23

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.

Fig. 4: Verify Less Than 3/4 Full


Courtesy of VOLVO CARS CORPORATION

WARNING: Make sure that the fuel tank is no more than 3/4 full.
2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 5: Identifying Fuel Filter Drain


Courtesy of VOLVO CARS CORPORATION

WARNING: Be prepared to collect escaping fluid.

NOTE: Do not loosen the bolt more than 4 turns.

Torque: Draining screw to fuel filter

2 Nm

Fig. 6: Using Special Tool (9814098)


Courtesy of VOLVO CARS CORPORATION

see 9814098

Torque: Fuel filter


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

INSTALLATION

To install, reverse the removal procedure.

EXTRA FUEL FILTER

NOTE: The graphics in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the graphics is always correct.

PREPARATORY WORK

Drain the fuel injection system. See FUEL SYSTEM PRESSURE RELEASE .

HINT: Place a tray or similar under the filter to capture any spillage.

REMOVAL

REMOVING THE FUEL FILTER

Fig. 7: Fuel Filter Retaining Bolt And Quick-Release Connector


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

CAUTION: Extreme cleanliness must be exercised when handling these components.

Remove:

 the screw for the clamp around the filter


 the quick-release connectors for the pipes
 the filter.

INSTALLATION

NOTE: For tightening torques, see TIGHTENING TORQUE .

INSTALLING THE FUEL FILTER

Install:

 the filter
 the pipes
 the M8 screw for the clamp around the filter (M8)
 the fuel pump fuse. See FUEL SYSTEM PRESSURE RELEASE .

FUEL FILTER IN TANK

REMOVAL AND INSTALLATION

Remove fuel filter. See FUEL PUMP AND LEVEL SENSOR UNIT

FUEL PUMP (B5254T7; 2008-12)

Special tools:

see 9997111

NOTE: The graphics in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the graphics is always correct.

PREPARATORY WORK

Remove:

 the fuel tank. See FUEL TANK.


 the level sensor on the left-hand side. See LEVEL SENSOR FUEL TANK .
2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

REMOVAL

REMOVING THE FUEL PUMP (FP)

Fig. 8: Removing Ring with Special Tool 9997111


Courtesy of VOLVO CARS CORPORATION

CAUTION: Do not damage the lever on the level sensor during removal.

CAUTION: When removing the plastic nut ensure that the level sensor is not turned
with it.

Release the 2 catches. Remove the plastic nut. Use see 9997111 .

Remove the pump.

TRANSFERRING PARTS

TRANSFERRING SUCTION LINE


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 9: Transferring Suction Line


Courtesy of VOLVO CARS CORPORATION

NOTE: Applies to vehicles equipped with auxiliary heater.

Remove the plug for the suction line from the underside of the level sensor, use a 9 mm socket.

Transfer the suction line to the new fuel pump.

INSTALLATION

NOTE: For tightening torques, see TIGHTENING TORQUE .

INSTALLING THE FUEL PUMP (FP)


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 10: Image of Pump Module


Courtesy of VOLVO CARS CORPORATION

CAUTION: Do not damage the lever on the level sensor during installation.

CAUTION: When installing the plastic nut ensure that the level sensor is not turned
with it.

Install a new O-ring.

Insert the hose for the fuel pump (FP) from the right-hand to the left-hand side of the tank.

Install the fuel pump (FP).


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 11: Keep Aware of Alignment Marks


Courtesy of VOLVO CARS CORPORATION

Tighten the plastic nut. See TIGHTENING TORQUE . Use see 9997111

NOTE: The marking on the fuel pump (FP) must be opposite the marking on the fuel
tank.

FINISHING

Install:

 the level sensor on the left-hand side. See LEVEL SENSOR FUEL TANK
 the fuel tank, USA. See FUEL TANK

FUEL PUMP AND LEVEL SENSOR UNIT

NOTE: Some variation may occur. However, the essential information in the graphics is
always correct.

REMOVING
2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Remove the fuel tank. See FUEL TANK.

Fig. 12: Removing the Threaded Ring With Tool (9997111)


Courtesy of VOLVO CARS CORPORATION

NOTE: Ensure that the lever on the level sensor is not damaged when removing the
pump.

Remove:

 the large plastic nut, 1 pc. Use 9997111


 the pump.

TRANSFER OF SUCTION LINE (FOR VEHICLES EQUIPPED WITH AUXILIARY HEATER)

Fig. 13: Transferring Suction Line


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Remove the plug for the suction line from the underside of the level sensor, use a 9 mm socket.

Transfer the suction line to the new fuel pump.

INSTALLING

NOTE: For tightening torques, see TIGHTENING TORQUE .

Fig. 14: Aligning The Match Marks


Courtesy of VOLVO CARS CORPORATION

NOTE: Ensure that the lever on the level sensor is not damaged when installing the
pump.

Install:

 new O-ring
 the level sensor

NOTE: The marking on the level sensor must be aligned with the marking on the
fuel tank.

 the 1 large plastic nut. Use see 9997111 .

Install the fuel tank. See FUEL TANK.

FUEL TANK, FUEL LINES, EVAPORATOR SYSTEM


EVAPORATIVE EMISSION

NOTE: See EVAPORATION SYSTEM AND FUEL SYSTEM PRESSURE - INSPECTION


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

article.

CHARCOAL FILTER

Special tools:

see 9985972

see 9995972

NOTE: The graphics in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the graphics is always correct.

PREPARATORY WORK

REMOVING THE SHOCK ABSORBER

Fig. 15: Identifying Lower Shock Mounting


Courtesy of VOLVO CARS CORPORATION

Remove the following on both sides:


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

 1 screw
 the shock absorber from the lateral link.

REMOVAL

REMOVING THE EXHAUST

Fig. 16: Installing The Exhaust Bracket


Courtesy of VOLVO CARS CORPORATION

Remove the rubber mounting from the center muffler.


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 17: Identifying Rear Muffler And Rubber Mountings


Courtesy of VOLVO CARS CORPORATION

Remove the 2 rubber mountings from the rear muffler.

LOWERING THE SUB-FRAME


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 18: Supporting Subframe With Mobile Jack (9985972)


Courtesy of VOLVO CARS CORPORATION

NOTE: Make sure that no cables/hoses are loaded or trapped when lowering the sub-
frame.

Use mobile jack: see 9985972 and see 9995972 .

Position the mobile jack against the sub-frame.

Pull the brake hose out of its bracket on both sides.

Remove the screws on both sides.


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 19: Locating Subframe Bolts


Courtesy of VOLVO CARS CORPORATION

Remove the 2 screws on both sides. Lower the sub-frame approximately 4 cm. Ensure that no cables/hoses are
loaded or trapped when lowering the sub-frame.

REMOVING THE CARBON FILTER CONTAINER


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 20: Removing Carbon Canister


Courtesy of VOLVO CARS CORPORATION

NOTE: When removing the carbon filter canister, make sure that the pipe sleeve (2) is
not loaded.

Remove:

 the 2 M5 screws securing the carbon filter container to the sub-frame


 the 2 pipes, secured using quick-release connectors (1)
 the hose (2).

Pull the carbon filter container out of the mounting. Take out the carbon filter container over the rear muffler.
Remove the container.

INSTALLATION

NOTE: For tightening torques, see TIGHTENING TORQUE .

INSTALLING THE CARBON FILTER CONTAINER


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 21: Removing Carbon Canister


Courtesy of VOLVO CARS CORPORATION

NOTE: When installing the carbon filter canister, make sure that the pipe sleeve (2) is
not loaded.

Position the carbon filter container on the sub-frame. Insert the carbon filter container over the rear muffler.

Install:

 the 2 pipes, secured using quick-release connectors (1)


 the hose (2)
 the 2 M5 screws securing the carbon filter container to the sub-frame.

FINISHING

INSTALLING THE SUB-FRAME


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 22: Locating Subframe Bolts


Courtesy of VOLVO CARS CORPORATION

Lift up the sub-frame. Ensure that the locating pins engage in their holes in the bodywork.

NOTE: Make sure that no cables/hoses are loaded or trapped when installing the sub-
frame. Install the 2 screws on both sides. Tighten, see TIGHTENING TORQUE .
2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 23: Supporting Subframe With Mobile Jack (9985972)


Courtesy of VOLVO CARS CORPORATION

Install the screw on both sides.

Tighten, see TIGHTENING TORQUE .

Remove the lifting table.

INSTALLING THE SHOCK ABSORBER


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 24: Identifying Lower Shock Mounting


Courtesy of VOLVO CARS CORPORATION

Install on both sides:

 the shock absorber


 the screw. Tighten. See TIGHTENING TORQUE
 the brake hose in its bracket on both sides.

INSTALLING THE EXHAUST BRACKET


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 25: Installing The Exhaust Bracket


Courtesy of VOLVO CARS CORPORATION

Install the rubber mounting.


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 26: Identifying Rear Muffler And Rubber Mountings


Courtesy of VOLVO CARS CORPORATION

Install the 2 rubber mountings for the rear muffler.

FUEL TANK

Special tools:

see 9995972

NOTE: The graphics in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the graphics is always correct.

PREPARATORY WORK

Drain the fuel system. See FUEL SYSTEM PRESSURE RELEASE .

Drain the fuel tank. See FUEL TANK DRAINING .

REMOVAL
2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

REMOVING THE EXHAUST SYSTEM

Detach the exhaust system at the three-way catalytic converter (TWC) and at the rubber mountings.

Hang the exhaust system to one side.

NOTE: Support the front section of the exhaust pipe so as not to put strain on the
exhaust manifold.

REMOVING THE HEAT DEFLECTOR PLATE

Fig. 27: Removing/Installing Heat Deflector Plate


Courtesy of VOLVO CARS CORPORATION

Remove:

 the 7 plastic nuts


 the heat deflector plate.

DETACHING THE HOSE CONNECTIONS


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 28: Removing Hoses


Courtesy of VOLVO CARS CORPORATION

Remove:

 the hose clamp for the evacuation pipe at the fuel tank
 the hose clamp for the hose to the fuel filler pipe.

NOTE: Carefully detach the hose from the fuel filler pipe, there may be fuel left in the
tank.

REMOVING THE CARBON FILTER CONTAINER


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 29: Removing Carbon Canister


Courtesy of VOLVO CARS CORPORATION

Remove:

 the hose (1)


 the 2 pipes, secured using quick-release connectors (2).

REMOVING THE FUEL TANK


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 30: Supporting Fuel Tank With Mobile Jack


Courtesy of VOLVO CARS CORPORATION

Install a mobile jack with fixture see 9995972 under the fuel tank.

Disconnect the fuel connection (1).

Remove the screws for the fuel tank straps, x 3.

Remove the tank retaining straps. Lower the tank slightly.

Disconnect the level sensor connector.

Lower the tank.

REMOVING THE FUEL PUMP (FP)

Remove:

 the fuel connection for the fuel pump (FP)


 the fuel pump (FP). See FUEL PUMP AND LEVEL SENSOR UNIT.

INSTALLATION
2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

INSTALLING THE FUEL PUMP (FP)

Install:

 the fuel pump (FP). See FUEL PUMP AND LEVEL SENSOR UNIT.
 the fuel connection for the fuel pump (FP).

INSTALLING THE FUEL TANK

Place the tank on the mobile jack together with fixture: see 9995972 .

Raise the tank so that it is 30 cm from the top.

Connect the connector for the level sensor.

Lift up the fuel tank.

Install:

 the tank retaining straps. Use the 3 x M8 screws


 the fuel connection.

INSTALLING THE HOSE CONNECTORS

Install:

 the hose clamp for the evacuation pipe at the fuel tank
 the hose clamp on the hose for the fuel filler pipe.

INSTALLING THE CARBON FILTER CONTAINER


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 31: Removing Carbon Canister


Courtesy of VOLVO CARS CORPORATION

Install:

 the hose
 the 2 pipes, secured using quick-release connectors.

INSTALLING THE HEAT DEFLECTOR PLATE

Install:

 the 7 plastic nuts


 the heat deflector plate.

INSTALLING THE EXHAUST SYSTEM

NOTE: To ensure that there is no exhaust leakage, see FLANGED JOINT,


ASSEMBLING .

Install:
2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

 the rubber mountings.

FINISHING

Top up the fuel.

Install the fuse for the fuel pump (FP).

LEAK DIAGNOSTIC PUMP (B5244S4; 2007-10, B5254T7; 2008-12)

Special tools:

see 9985972

see 9995972

NOTE: As the graphics in this service information are used for different model years
and / or models, some variation may occur. However, the essential information
in the graphics is always correct.

PREPARATORY WORK

REMOVING THE SHOCK ABSORBER


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 32: Identifying Lower Shock Mounting


Courtesy of VOLVO CARS CORPORATION

Remove the following on both sides:

 1 screw
 the shock absorber from the lateral link.

LOWERING THE SUB-FRAME


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 33: Supporting Subframe With Mobile Jack (9985972)


Courtesy of VOLVO CARS CORPORATION

NOTE: Ensure that no cables/hoses are loaded or trapped when lowering the sub-
frame.

Use mobile jack: see 9985972 and see 9995972 . Position the mobile jack against the sub-frame.

Pull the brake hose out of its bracket on both sides

Remove the screw on both sides


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 34: Locating Subframe Bolts


Courtesy of VOLVO CARS CORPORATION

Remove the 2 screws on both sides.

Carefully lower the sub-frame. Ensure that no cables / hoses are loaded or trapped when lowering the sub-
frame.

REMOVAL

REMOVING THE PUMP FOR LEAK DIAGNOSTICS


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 35: View Of Leak Detection Pump


Courtesy of VOLVO CARS CORPORATION

Remove:

 the M6 screw securing the pump mounting to the sub-frame


 the connector (1) from the pump
 the hose from the carbon filter container
 the pump for leak diagnostics.

TRANSFERRING THE BRACKET


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 36: Transferring Bracket


Courtesy of VOLVO CARS CORPORATION

Remove:

 the hose
 the 3 screws
 the bracket.

INSTALLATION

NOTE: For tightening torques, see TIGHTENING TORQUE .

INSTALLING THE PUMP FOR LEAK DIAGNOSTICS


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 37: View Of Leak Detection Pump


Courtesy of VOLVO CARS CORPORATION

Install:

 the hose to the carbon filter container


 the connector (1)
 the M6 screw.

FINISHING

INSTALLING THE SUB-FRAME


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 38: Locating Subframe Bolts


Courtesy of VOLVO CARS CORPORATION

Lift up the sub-frame. Ensure that the locating pins engage in their holes in the bodywork.

NOTE: Ensure that no cables/hoses are loaded or trapped when installing the sub-
frame.

Install the 2 screws on both sides. Tighten. See TIGHTENING TORQUE .


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 39: Supporting Subframe With Mobile Jack (9985972)


Courtesy of VOLVO CARS CORPORATION

Install the screw on both sides. Tighten. See TIGHTENING TORQUE .

Remove the lifting table.

INSTALLING THE SHOCK ABSORBER


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 40: Identifying Lower Shock Mounting


Courtesy of VOLVO CARS CORPORATION

Install on both sides:

 the shock absorber


 the screw. Tighten. See TIGHTENING TORQUE .
 the brake hose in its bracket on both sides.

INJECTOR AND DELIVERY PIPE


FUEL INJECTOR (B5244S4; 2007-10)

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.

Drain depressurizing fuel system. See FUEL SYSTEM PRESSURE RELEASE


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 41: Identifying Air Intake Hose Clamp And Electrical Connector With Cable Clamp
Courtesy of VOLVO CARS CORPORATION

Fig. 42: Identifying Intake Plenum and Bolts


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm
2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 43: Moving Plenum Out Of Way


Courtesy of VOLVO CARS CORPORATION

Fig. 44: Sealing Off Openings


Courtesy of VOLVO CARS CORPORATION

CAUTION: Make sure that all openings are sealed. Use new blanking caps.
2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 45: Identifying Engine Cover End Piece And Screws


Courtesy of VOLVO CARS CORPORATION

Torque: M7

17 Nm

Fig. 46: Removing/Installing Injector Connectors


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 47: Remove/Install Injector Rail Bolts


Courtesy of VOLVO CARS CORPORATION

NOTE: Use suitable paper to absorb any escaping fluid.

Torque: M6

10 Nm

Fig. 48: Clear Away Dirt and Remove Injector Assembly


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 49: Identifying Bolts and Retaining Plate


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm

INSTALLATION

To install, reverse the removal procedure.

FUEL INJECTOR (B5254T3; 2007-08, B5254T7; 2008-12)

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.

Drain depressurising fuel system. See FUEL SYSTEM PRESSURE RELEASE

Remove the air filter housing. See AIR CLEANER HOUSING


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 50: Identifying Engine Cover And Screws


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm

Fig. 51: Removing/Installing Timing Belt Cover


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm
2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 52: Remove/Install Inlet Tube


Courtesy of VOLVO CARS CORPORATION

Fig. 53: View Of Fuel Delivery Pipe


Courtesy of VOLVO CARS CORPORATION

Fig. 54: View Of Throttle Control Harness Connector


2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

NOTE: Make sure that the mating faces are clean and free of foreign material.

Fig. 55: View of Intake Plenum, Underside


Courtesy of VOLVO CARS CORPORATION

Torque: M7

17 Nm

Fig. 56: View Of Injector Harness And Fuel Rail Bolts


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 57: Identifying Bolts And Retaining Plate


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm

INSTALLATION

To install, reverse the removal procedure.

CONTROL SYSTEM
MASS AIR FLOW (MAF) SENSOR (B5244S4; 2007-10)

REMOVAL AND INSTALLATION

Fig. 58: Viewing Mass Air Flow (MAF) Sensor and Connector
Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

MASS AIR FLOW (MAF) SENSOR (B5254T3; 2007-08, B5254T7; 2008-12)

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.

Fig. 59: Identifying Air Intake Hoses And Fasteners


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm

Fig. 60: Remove/Install Vent Tube


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ENGINE Fuel System - Removal, Replacement And Installation

Fig. 61: Viewing Mass Air Flow Sensor


Courtesy of VOLVO CARS CORPORATION

INSTALLATION

To install, reverse the removal procedure.


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Lighting - Component Location

ACCESSORIES AND BODY, CAB

Lighting - Component Location

COMPONENT LOCATION, HEADLAMP CONTROL MODULE (HCM)


LOCATION OF COMPONENTS

Fig. 1: Locating Headlamp Control Module Components


Courtesy of VOLVO CARS CORPORATION

Overview

1. Headlamp Control Module (HCM)


2. Left headlamp control unit (LHCU)
3. Right headlamp control unit (RHCU)
4. Front position sensor
5. Rear position sensor

COMPONENT POSITION, HEADLIGHT


COMPONENT POSITION

POSITION OF BULBS
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Lighting - Component Location

Fig. 2: Locating Bulbs


Courtesy of VOLVO CARS CORPORATION

1. Low beam
2. High beam
3. Parking lights
4. Direction indicators.
5. Side marker lights

LIGHTING, FRONT
COMPONENT POSITION HEADLIGHTS (2007)

LOCATION OF COMPONENTS
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Lighting - Component Location

Fig. 3: Locating Headlight Components


Courtesy of VOLVO CARS CORPORATION

1. side running lights


2. direction indicator
3. Dipped beam
4. Parking lights
5. High beam.

COMPONENT POSITION HEADLIGHTS (2008-2009)

LOCATION OF COMPONENTS
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Lighting - Component Location

Fig. 4: Identifying Early Version Headlight Components


Courtesy of VOLVO CARS CORPORATION

1. Dipped beam
2. High beam.
3. Parking lights
4. direction indicator
5. direction indicator

COMPONENT POSITION HEADLIGHTS (2010-2012)

LOCATION OF COMPONENTS

VEHICLES EARLY VERSION

Fig. 5: Identifying Early Version Headlight Components


Courtesy of VOLVO CARS CORPORATION

1. Dipped beam
2. High beam.
3. Parking lights
4. direction indicator
5. direction indicator

VEHICLES LATE VERSION


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Lighting - Component Location

Fig. 6: Identifying Late Version Headlight Components


Courtesy of VOLVO CARS CORPORATION

1. side running lights


2. direction indicator
3. Dipped beam
4. High beam.
5. Parking lights

LOCATION OF COMPONENTS, HEADLIGHTS (BI-XENON) (2010-2012)

LOCATION OF COMPONENTS

VEHICLES EARLY VERSION


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Lighting - Component Location

Fig. 7: Identifying Early Version Headlight Components


Courtesy of VOLVO CARS CORPORATION

1. Dipped beam
2. High beam.
3. Parking lights
4. direction indicator
5. direction indicator

VEHICLES LATE VERSION


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Lighting - Component Location

Fig. 8: Identifying Headlights (Bi-Xenon) Components


Courtesy of VOLVO CARS CORPORATION

1. side running lights


2. direction indicator
3. Dipped beam
4. High beam.
5. Parking lights

LIGHTING, REAR
LOCATION OF COMPONENTS, TAIL LAMP.

LOCATION OF COMPONENTS
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Lighting - Component Location

Fig. 9: Identifying Tail Lamp Component Location


Courtesy of VOLVO CARS CORPORATION

1. brake light
2. back-up light
3. fog lights
4. direction indicator
5. back-up light

LOCATION OF COMPONENTS, TAIL LAMP


COMPONENT POSITION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Lighting - Component Location

Fig. 10: Identifying Tail Lamp Component Location


Courtesy of VOLVO CARS CORPORATION

1. Brake light
2. Tail lamps
3. Rear fog light
4. Turn signal lamps
5. Back-up (reversing) lamps

NOTE: A fog tail lamp bulb is only used in the left tail lamp.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Exterior Trim, Glass, Weatherstrips - Overhaul Instructions

ACCESSORIES AND EQUIPMENT

Exterior Trim, Glass, Weatherstrips - Overhaul Instructions

HEATED WINDOW GRID WIRE

Materials
Designation Part Number
Window cleaner -
Conductive paint 1161441

RECONDITIONING

Fig. 1: Identifying Heated Window Grid Wire Measurements


Courtesy of VOLVO CARS CORPORATION

NOTE: If the specified value is exceeded, a new component must be installed.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Exterior Trim, Glass, Weatherstrips - Overhaul Instructions

Fig. 2: Cleaning Heated Window Grid Wire


Courtesy of VOLVO CARS CORPORATION

Use: Window cleaner,

Fig. 3: Identifying Repair Tape


Courtesy of VOLVO CARS CORPORATION

Use: Conductive paint, 1161441


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Exterior Trim, Glass, Weatherstrips - Overhaul Instructions

Fig. 4: Shake Conductive Paint At Least One Minute


Courtesy of VOLVO CARS CORPORATION

Fig. 5: Reconditioning Heated Window Grid Wire


Courtesy of VOLVO CARS CORPORATION

Use: Conductive paint, 1161441


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Exterior Trim, Glass, Weatherstrips - Overhaul Instructions

Fig. 6: Identifying Repair Tape Removal


Courtesy of VOLVO CARS CORPORATION

Fig. 7: Identifying Wire Repair Precaution


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

ACCESSORIES AND BODY, CAB

Roof Panel, Replacing - Removal, Replacement And Installation

HOOD, COVER WITH ASSEMBLY PARTS


CONTROL LOCK ENGINE HOOD

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.

REMOVAL

REMOVING THE HOOD LOCK CONTROL

Fig. 1: Identifying Hood Lock Control


Courtesy of VOLVO CARS CORPORATION

Fold back the insulation panel by the hood lock control.

Remove:
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

 the 2 nuts
 the mechanical cable from the control
 control.

INSTALLATION

NOTE: For tightening torques, see: TIGHTENING TORQUE .

INSTALLING THE HOOD LOCK CONTROL

Install:

 the control
 the cable
 2 M6 nuts. Tighten.

Ensure that the insulation panel is in the correct position.

Check the function of the control.

DOOR LATCH HOOD

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

REMOVAL

REMOVING HOOD CATCH


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Fig. 2: Identifying Air Intake Screws


Courtesy of VOLVO CARS CORPORATION

Open the hood.

Remove:

 the bumper cover. See: BUMPERS AND MUDFLAPS


 the 2 screws on the air intake
 the air intake. Pull the air intake away from the upper mounting. Then bend the air intake upwards.
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Fig. 3: Identifying Engine Compartment Panel Screws


Courtesy of VOLVO CARS CORPORATION

Remove:

 the 2 screws holding the engine compartment panel


 the engine compartment panel.
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Fig. 4: Identifying Airtight Seal Nuts


Courtesy of VOLVO CARS CORPORATION

Remove the 3 nuts holding the airtight seal.

Fold the airtight seal down.


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Fig. 5: Identifying Hood Catch Screws


Courtesy of VOLVO CARS CORPORATION

Remove the 2 screws holding the hood catch.


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Fig. 6: View Of Hood Catch And Cable


Courtesy of VOLVO CARS CORPORATION

Disconnect the connector.

Unhook the cable and remove the hood catch.

INSTALLATION

INSTALLING HOOD CATCH

NOTE: For tightening torques, see TIGHTENING TORQUE

Install:

 the hood catch and the 2 M8 screws. Tighten


 the connector
 the cable on the hood catch
 the airtight seal and the 3 plastic nuts. Tighten
 the engine compartment panel together with the 2 M6 screws. Tighten
 the air intake together with the 2 M6 screws. Tighten
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

 the bumper cover. See: BUMPERS AND MUDFLAPS

HOOD HINGE

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.

REMOVAL

REMOVING HINGES HOOD

Fig. 7: Identifying Front Fender Screws


Courtesy of VOLVO CARS CORPORATION

Remove:

 the hood
 the 4 M6 screws at the top edge of the front fender.

Carefully bend in the fender to access the 2 hinge screws.


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Remove the 2 M8 screws and remove the hinge.

INSTALLATION

NOTE: For tightening torques, see: TIGHTENING TORQUE

INSTALLING HINGES HOOD

Fig. 8: Identifying Hood Hinges


Courtesy of VOLVO CARS CORPORATION

Install:

 the hinge together with the 2 M8 screws. Tighten


 the front fender using the 4 M6 screws. Tighten
 the hood.

HOOD INSULATION

REMOVAL AND INSTALLATION


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Fig. 9: Identifying Hood Insulation


Courtesy of VOLVO CARS CORPORATION

WIRE LOCK ENGINE HOOD

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.

REMOVAL

REMOVING THE MECHANICAL CABLE


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Fig. 10: Removing Mechanical Cable


Courtesy of VOLVO CARS CORPORATION

Remove:

 the 2 screws for the cover above the hood latch


 the cover.

Unhook the mechanical cable at the hood catch.


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Fig. 11: Identifying Mechanical Cable At The Hood Catch


Courtesy of VOLVO CARS CORPORATION

Remove the soundproofing panel on the driver's side in accordance with: INSTRUMENT PANEL LOWER .

Unhook the cable from the hood catch mechanism.


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Fig. 12: Identifying Brake Fluid Reservoir Protective Cover


Courtesy of VOLVO CARS CORPORATION

Remove:

 the battery. See: BATTERY


 the 3 M6 screws for the bottom of the battery box. Remove the battery box
 the connector
 the 2 clips securing the plastic cover in front of the power brake booster. Carefully fold the plastic cover
forwards.

NOTE: Note the routing of the wire.

Remove the cable.

INSTALLATION

NOTE: For tightening torques, see: TIGHTENING TORQUE .

INSTALLING THE MECHANICAL CABLE

Insert the mechanical cable as noted previously.


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Hook the mechanical cable into the hood catch and the hood catch control.

Install:

 the soundproofing panel on the driver's side. See: INSTRUMENT PANEL LOWER
 the 2 clips
 the bottom of the battery box
 the connector
 the 3 M6 screws. Tighten
 the battery. See: BATTERY
 the cover over the hood catch using the 2 screws.

HINT: Test the function before closing the hood.

RADIATOR GRILLE
PLENUM CHAMBER

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.

REMOVAL

REMOVING THE PLENUM CHAMBER

Fig. 13: Identifying Cowl Clips


Courtesy of VOLVO CARS CORPORATION

Remove:
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

 the windshield wipers. See WIPER ARM


 the 4 clips

Press the center pin down onto the clips.

Turn the 2 catches (1) anti-clockwise 1/4 turn.

Lift out the cowl.

REMOVING THE SPLASH GUARD

Fig. 14: Remove Old Protective Cover Under Cowl


Courtesy of VOLVO CARS CORPORATION

Remove the old protective cover from under the cowl using a screwdriver or similar.

Fig. 15: Identifying Protective Cover's Plastic Welds


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Remove the remains from the protective covers plastic welds using a small chisel.

INSTALLATION

INSTALLING BUTYL TAPE

Fig. 16: Installing Butyl Tape


Courtesy of VOLVO CARS CORPORATION

Apply butyl tape to the protective cover. Press the tape out slightly before securing to the vehicle.

INSTALLING PROTECTIVE COVER

Fig. 17: Installing Protective Cover


Courtesy of VOLVO CARS CORPORATION

Install the protective cover by sliding it towards and under the windshield (1).

Press the front edge of the protective cover firmly so that the butyl tape adheres to the plate (2).
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

INSTALLING THE PLENUM CHAMBER

Install the cowl in the correct position. Ensure that the rubber seals against the fenders and the windshield are
correctly located. Check that the guide clips underneath the cowl are in the correct position in relation to the
windshield.

Turn the 2 catches clockwise 1/4 turn. Check that the marking on the relevant catch is turned toward the
windshield.

Install the 4 clips.

NOTE: Start with the outer clips.

Fig. 18: Correctly Checking Cowl Position


Courtesy of VOLVO CARS CORPORATION

Use a thin plastic film (transparent). Check that the cowl is correctly positioned against the windshield.

CAUTION: To prevent water leaks, the corners of the plastic film must not be between
the cowl and the windshield.

Install the windshield wipers. See WIPER ARM.

WIPER ARM

Special tools

981 4088 Puller


Tool number: 981 4088
Tool description: Puller
Tool boards: 80
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

REMOVAL

Fig. 19: Identifying Ignition In OFF Position


Courtesy of VOLVO CARS CORPORATION

CAUTION: Make sure that the motor is in the park position.

Fig. 20: Identifying Windshield Wiper Arm Screws


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Fig. 21: View Of Special Tool 9814088


Courtesy of VOLVO CARS CORPORATION

see 9814088

Fig. 22: View Of Windshield Wiper Arm Removal


Courtesy of VOLVO CARS CORPORATION

INSTALLATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Fig. 23: View Of Windshield Wiper Arm Position


Courtesy of VOLVO CARS CORPORATION

Torque: Windshield wiper arm

30 Nm

RADIATOR GRILLE (2007-2009)

Special tools

999 7390 Key


Tool number: 999 7390
Tool description: Key
Tool boards: 80

REMOVAL
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Fig. 24: Locating Radiator Grille Fasteners


Courtesy of VOLVO CARS CORPORATION

Fig. 25: Identifying Location Of Radiator Grill Clip Under Grille


Courtesy of VOLVO CARS CORPORATION

see 9997390
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Fig. 26: Locating Radiator Grille Clip Area


Courtesy of VOLVO CARS CORPORATION

CAUTION: Make sure that the components are protected.


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Fig. 27: Removing Radiator Grill - 1 Of 8


Courtesy of VOLVO CARS CORPORATION

Fig. 28: Removing Radiator Grill - 2 Of 8


Courtesy of VOLVO CARS CORPORATION

Fig. 29: Removing Radiator Grill - 3 Of 8


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Courtesy of VOLVO CARS CORPORATION

Fig. 30: Removing Radiator Grille - 4 Of 8


Courtesy of VOLVO CARS CORPORATION

Fig. 31: Removing Radiator Grille - 5 Of 8


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Fig. 32: Removing Radiator Grille - 6 Of 8


Courtesy of VOLVO CARS CORPORATION

Fig. 33: Removing Radiator Grille - 7 Of 8


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Fig. 34: Removing Radiator Grille - 8 Of 8


Courtesy of VOLVO CARS CORPORATION

INSTALLATION

Fig. 35: Installation Of Radiator Grille


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

RADIATOR GRILLE (2010-2011 EARLY)

Special tools

999 7390 Key


Tool number: 999 7390
Tool description: Key
Tool boards: 80

REMOVAL

Fig. 36: Locating Radiator Grille Fasteners


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Fig. 37: Removing Radiator Grille (1 Of 9)


Courtesy of VOLVO CARS CORPORATION

CAUTION: Make sure that the components are protected.


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Fig. 38: Removing Radiator Grille (2 Of 9)


Courtesy of VOLVO CARS CORPORATION

see 9997390

Fig. 39: Removing Radiator Grille (3 Of 9)


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Fig. 40: Removing Radiator Grille (4 Of 9)


Courtesy of VOLVO CARS CORPORATION

Fig. 41: Removing Radiator Grille (5 Of 9)


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Fig. 42: Removing Radiator Grille (6 Of 9)


Courtesy of VOLVO CARS CORPORATION

Fig. 43: Removing Radiator Grille (7 Of 9)


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Fig. 44: Removing Radiator Grille (8 Of 9)


Courtesy of VOLVO CARS CORPORATION

Fig. 45: Removing Radiator Grille (9 Of 9)


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Fig. 46: Removing Radiator Grille Emblem


Courtesy of VOLVO CARS CORPORATION

INSTALLATION

To install, reverse the removal procedure.

RADIATOR GRILLE (2011 LATE-2012)

REMOVAL

Remove casing bumper front, see COVER BUMPER FRONT


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Fig. 47: Identifying Radiator Grille Clips


Courtesy of VOLVO CARS CORPORATION

Fig. 48: Identifying Direction To Remove Radiator Grille


Courtesy of VOLVO CARS CORPORATION

Fig. 49: Identifying Emblem Interlocking Clips


Courtesy of VOLVO CARS CORPORATION

INSTALLATION

To install, reverse the removal procedure.

FRONT SECTION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

FRONT END

FRONT END

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.

REMOVAL

REMOVING THE FRONT SECTION

Fig. 50: Identifying Front Section Screws


Courtesy of VOLVO CARS CORPORATION

Remove:

 the headlights
 the bumper. See: COVER BUMPER FRONT (2011 LATE - 2012)
 the washer jets on the left and right side
 the cover plate
 the air guides
 hood catch cable
 hood catch
 radiator mounting
 power steering fluid reservoir

Disconnect:

 2 impact sensors
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

 the cable harness and radiator hoses from the front plate.

Remove:

 the front edge of the fender


 the 3 screws in the top edge of the fender
 the fender and 5 M6 screws.

Pull the front edge of the fender outward slightly so that the screws are accessible. See the illustration.

Fig. 51: View Of Front Edge Of The Fender Screws


Courtesy of VOLVO CARS CORPORATION

Remove the 8 M8 screws of the front plate and remove the plate.

INSTALLATION

INSTALLING THE FRONT SECTION

NOTE: For tightening torques, see: TIGHTENING TORQUE .

Install:

 the front plate with 8 M8 screws


 the cable harness and radiator hoses
 the power steering fluid reservoir
 radiator mounting
 hood catch
 the hood catch cable
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Check that the hood catch engages and disengages.

Install:

 2 impact sensors
 the air guides
 the cover plate
 2 washer jets.

Adjust the front fenders and screw them into place.

Install:

 the headlights
 the bumper. See COVER BUMPER FRONT (2007 - 2011 EARLY) or COVER BUMPER FRONT
(2011 LATE - 2012) .

BRACKET FRONT PIECE (2012)

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.

REMOVAL

REMOVING FRONT SIDE PANEL


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Fig. 52: Removing Front Side Panel


Courtesy of VOLVO CARS CORPORATION

Remove components. See: FRONT SECTION, EXPOSING .

Remove the welds using a drill.

Grind clean.

Apply welding primer.

INSTALLATION

INSTALLING FRONT SIDE PANEL

Spot-weld the front side panel. Tip diameter: 4.5 mm.

When welding body components, see: WELDING, GENERAL (2007-2011) or WELDING, GENERAL
(2012) .

Rust-proof. See: RUSTPROOFING .

Install components. See: FRONT SECTION, EXPOSING .


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

FRONT MUDGUARD
FENDER (2007-2011 EARLY)

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.

Remove fender widener front, see FRONT FENDER WIDENER

Fig. 53: Identifying Wheel Arch Lining Retaining Clips


Courtesy of VOLVO CARS CORPORATION

Fig. 54: Identifying M10 Bolts


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Fig. 55: Removing Bumper And Rocker


Courtesy of VOLVO CARS CORPORATION

Fig. 56: View Of Wheel Arc Screws


Courtesy of VOLVO CARS CORPORATION

Fig. 57: Locating Fender Screws


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Torque: M6

10 Nm

INSTALLATION

To install, reverse the removal procedure.

Follow the instructions regarding corrosion protection, see RUSTPROOFING

FENDER (2011 LATE - 2012)

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.

Remove fender widener front, see FRONT FENDER WIDENER

Fig. 58: Identifying Wheel Arch Lining Retaining Clips (1 of 2)


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Fig. 59: Identifying Wheel Arch Lining Retaining Clips (2 of 2)


Courtesy of VOLVO CARS CORPORATION

Fig. 60: Identifying Removal Of Panels (1 Of 2)


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Fig. 61: Identifying Removal Of Panels (2 Of 2)


Courtesy of VOLVO CARS CORPORATION

Fig. 62: Identifying Fender Panel Screws


Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm

INSTALLATION

To install, reverse the removal procedure.

Follow the instructions regarding corrosion protection, see RUSTPROOFING

REAR MUDGUARD
FENDER

Materials:
Designation Part number
2-component foam 3M 08463

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.

Welding body components. See WELDING, GENERAL (2007-2011) or WELDING, GENERAL (2011-
2012)

Remove the following items:


2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

 side section. See SIDE SECTION, EXPOSING


 rear section. See REAR SECTION, EXPOSING (2007-2009) or REAR SECTION, EXPOSING
(2010-2012)

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 .

Fig. 63: 2-Component Foam, 3M 08463


Courtesy of VOLVO CARS CORPORATION

Attach the following items:

1. Use: 2-component foam, 3M 08463


2. Use: 2-component foam, 3M 08463
2012 Volvo C30 T-5
ACCESSORIES AND BODY, CAB Roof Panel, Replacing - Removal, Replacement And Installation

Fig. 64: Identifying Fender Cut Points


Courtesy of VOLVO CARS CORPORATION

Seal fender. See BODY SEAL, SEALING DIAGRAM .

Rustproof fender. See RUSTPROOFING .

INSTALL

Install in reverse order.


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

BRAKES

Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

BRAKE PIPES AND CONNECTIONS (2007-09)


BRAKE LINES ABS UNIT/PIPE COUPLING REAR, REPLACING

NOTE: The graphics in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the graphics is always correct.

PREPARATORY WORK

Fig. 1: Bleeding Brakes


Courtesy of VOLVO CARS CORPORATION

Remove the wheel.

Secure the pedal in the depressed position. Use a pedal jack.

Remove the protective cap from the bleed nipple at the left front wheel.
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Install a plastic hose on the nipple. Open the bleed nipple.

Collect the brake fluid in a container.

Shut the bleed nipple.

REMOVAL

REMOVING THE BATTERY BOX

Fig. 2: Identifying Battery Box


Courtesy of VOLVO CARS CORPORATION

Ignition off.

Remove:

 the battery. See BATTERY


 the 3 screws (1)
 the battery box (2).

REMOVING SPLASH GUARDS


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 3: Identifying Cowl Fasteners


Courtesy of VOLVO CARS CORPORATION

Remove the 3 clips holding the cowl.


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 4: Identifying Brake Fluid Reservoir Protective Cover


Courtesy of VOLVO CARS CORPORATION

Carefully lift up the cowl. Remove the 2 clips for the protective cover.

Remove the protective cover over the brake fluid reservoir.


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 5: Identifying Firewall Upper Protective Cover Nut


Courtesy of VOLVO CARS CORPORATION

Remove:

 the plastic nut, x 1


 the protective cover for the firewall.

REMOVING THE BRAKE PIPE


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 6: Identifying Protective Cover


Courtesy of VOLVO CARS CORPORATION

NOTE: Clean the brake pipe terminals. Place paper under the hydraulic modulator to
avoid brake fluid spillage.

Remove:

 the two brake pipes from the ABS unit (1)


 the two brake pipes from the front-rear brake pipe (2)
 the brake pipe from the clips.

INSTALLATION

NOTE: For tightening torques, see TIGHTENING TORQUE .

INSTALLING THE BRAKE PIPES


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 7: Identifying Protective Cover


Courtesy of VOLVO CARS CORPORATION

Install:

 the brake pipe (1). Tighten. See TIGHTENING TORQUE


 the brake pipe (2). Tighten. See TIGHTENING TORQUE
 the brake pipe in the clips.

BLEEDING BRAKE SYSTEMS

Remove the pedal jack.

Bleed the brake system. See BRAKE SYSTEM BLEEDING .

Check that the brake pipe connections are sealed.

Check the brake fluid level.

INSTALLING THE PROTECTIVE COVERS


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 8: Identifying Firewall Upper Protective Cover Nut


Courtesy of VOLVO CARS CORPORATION

Install:

 the upper protective cover for the firewall


 the plastic nut, x 1.
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 9: Identifying Brake Fluid Reservoir Protective Cover


Courtesy of VOLVO CARS CORPORATION

Install the protective cover over the brake fluid reservoir. Carefully lift up the cowl. Install the 2 clips for the
protective cover.
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 10: Identifying Cowl Fasteners


Courtesy of VOLVO CARS CORPORATION

Install the 3 clips holding the cowl.

FINISHING

INSTALLING THE BATTERY BOX


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 11: Identifying Battery Box


Courtesy of VOLVO CARS CORPORATION

Install:

 the battery box (2)


 the 1 M6 screws (3)
 the battery. See BATTERY .

BRAKE LINES ABS UNIT/PIPE COUPLING RIGHT FRONT WHEEL, REPLACING

NOTE: The graphics in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the graphics is always correct.

PREPARATORY WORK
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 12: Bleeding Brakes


Courtesy of VOLVO CARS CORPORATION

Remove the wheel.

Secure the pedal in the depressed position. Use a pedal jack.

Remove the protective cap from the bleed nipple at the left front wheel.

Install a plastic hose on the nipple. Open the bleed nipple.

Collect the brake fluid in a container.

Shut the bleed nipple.

REMOVAL

REMOVING THE BATTERY BOX


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 13: Identifying Battery Box


Courtesy of VOLVO CARS CORPORATION

Ignition off.

Remove:

 the battery. See BATTERY


 the 3 screws (1)
 the battery box (2).

REMOVING SPLASH GUARDS


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 14: Identifying Cowl Fasteners


Courtesy of VOLVO CARS CORPORATION

Remove the 3 clips holding the cowl.


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 15: Identifying Brake Fluid Reservoir Protective Cover


Courtesy of VOLVO CARS CORPORATION

Carefully lift up the cowl. Remove the 2 clips for the protective cover.

Remove the protective cover over the brake fluid reservoir.


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 16: Identifying Firewall Upper Protective Cover Nut


Courtesy of VOLVO CARS CORPORATION

Remove:

 the plastic nut, x 1


 the protective cover for the firewall.

REMOVING THE HEAT DEFLECTOR PLATE


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 17: Identifying Heat Deflector Plate


Courtesy of VOLVO CARS CORPORATION

Remove:

 the heat deflector plate. Pull straight out


 the hoses from the clip.

REMOVING THE BRAKE PIPE


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 18: Brake Lines ABS Unit/Pipe Coupling Rear


Courtesy of VOLVO CARS CORPORATION

NOTE: Clean the brake pipe terminals. Place paper under the hydraulic modulator to
avoid brake fluid spillage.

Remove:

 the two brake pipes (1). See BRAKE LINES ABS UNIT/PIPE COUPLING REAR, REPLACING
 the 3 nuts (2)
 the lower protective cover for the firewall.
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 19: Brake Pipe


Courtesy of VOLVO CARS CORPORATION

Remove:

 the brake pipe (3) from the ABS unit. Install the plug
 the brake pipe (4)
 the brake pipe from the clips.

INSTALLATION

NOTE: For tightening torques, see TIGHTENING TORQUE .

INSTALLING THE BRAKE PIPES


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 20: Brake Pipe


Courtesy of VOLVO CARS CORPORATION

Install:

 the brake pipe (3). Tighten. See TIGHTENING TORQUE


 the brake pipe (4). Tighten. See TIGHTENING TORQUE
 the brake pipe in the clips.
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 21: Brake Lines ABS Unit/Pipe Coupling Rear


Courtesy of VOLVO CARS CORPORATION

Install:

 the lower protective cover for the firewall


 the 3 nuts (2)
 the two brake pipes (1). See BRAKE LINES ABS UNIT/PIPE COUPLING REAR, REPLACING.

BLEEDING BRAKE SYSTEMS

Remove the pedal jack.

Bleed the brake system. See BRAKE SYSTEM BLEEDING .

Check that the brake pipe connections are sealed.

Check the brake fluid level.

INSTALLING THE HEAT DEFLECTOR PLATE


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 22: Identifying Heat Deflector Plate


Courtesy of VOLVO CARS CORPORATION

Install:

 the heat deflector plate


 the hoses
 the 1 clip.

INSTALLING THE PROTECTIVE COVERS


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 23: Identifying Firewall Upper Protective Cover Nut


Courtesy of VOLVO CARS CORPORATION

Install:

 the upper protective cover for the firewall


 the plastic nut, x1.
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 24: Identifying Brake Fluid Reservoir Protective Cover


Courtesy of VOLVO CARS CORPORATION

Install the protective cover over the brake fluid reservoir. Carefully lift up the cowl. Install the 2 clips for the
protective cover.
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 25: Identifying Cowl Fasteners


Courtesy of VOLVO CARS CORPORATION

Install the 3 clips holding the cowl.

FINISHING

INSTALLING THE BATTERY BOX


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 26: Identifying Battery Box


Courtesy of VOLVO CARS CORPORATION

Install:

 the battery box (2)


 the 1 M6 screws (3)
 the battery. See BATTERY .

BRAKE PIPE LEFT-HAND FRONT WHEEL, REPLACING

NOTE: The graphics in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the graphics is always correct.

PREPARATORY WORK
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 27: Bleeding Brakes


Courtesy of VOLVO CARS CORPORATION

Remove the wheel.

Secure the pedal in the depressed position. Use a pedal jack.

Remove the protective cap from the bleed nipple at the left front wheel.

Install a plastic hose on the nipple. Open the bleed nipple.

Collect the brake fluid in a container.

Shut the bleed nipple.

REMOVAL

REMOVING THE BATTERY BOX


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 28: Identifying Battery Box


Courtesy of VOLVO CARS CORPORATION

Ignition off.

Remove:

 the battery. See BATTERY


 the 3 screws (1)
 the battery box (2).

REMOVING SPLASH GUARDS


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 29: Identifying Cowl Fasteners


Courtesy of VOLVO CARS CORPORATION

Remove the 3 clips holding the cowl.


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 30: Identifying Brake Fluid Reservoir Protective Cover


Courtesy of VOLVO CARS CORPORATION

Carefully lift up the cowl. Remove the 2 clips for the protective cover.

Remove the protective cover over the brake fluid reservoir.


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 31: Identifying Firewall Upper Protective Cover Nut


Courtesy of VOLVO CARS CORPORATION

Remove:

 the plastic nut


 the protective cover for the firewall.

REMOVING THE BRAKE PIPE


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 32: Identifying Protective Cover


Courtesy of VOLVO CARS CORPORATION

Remove the nut for the lower protective cover for the firewall.

NOTE: Clean the brake pipe terminals. Place paper under the hydraulic modulator to
avoid brake fluid spillage.

Remove the brake pipe from the ABS unit. Install the plug.
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 33: Identifying Brake Hose/Pipe And Clip


Courtesy of VOLVO CARS CORPORATION

Remove:

 the brake pipe from the brake hose


 the brake pipe from the clips.

INSTALLATION

NOTE: For tightening torques, see TIGHTENING TORQUE .

INSTALLING THE BRAKE PIPES

Install:

 the brake pipe on the ABS unit. Tighten. See TIGHTENING TORQUE
 the brake pipe on the brake hose. Tighten. See TIGHTENING TORQUE
 the brake pipe in the clips.

BLEEDING BRAKE SYSTEMS


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Remove the pedal jack.

Bleed the brake system. See BRAKE SYSTEM BLEEDING .

Check that the brake pipe connections are sealed.

Check the brake fluid level.

INSTALLING THE PROTECTIVE COVERS

Fig. 34: Identifying Firewall Upper Protective Cover Nut


Courtesy of VOLVO CARS CORPORATION

Install:

 the nut for the lower protective cover for the firewall. Tighten. See TIGHTENING TORQUE
 the upper protective cover for the firewall
 the plastic nut, x 1.
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 35: Identifying Brake Fluid Reservoir Protective Cover


Courtesy of VOLVO CARS CORPORATION

Install the protective cover over the brake fluid reservoir. Carefully lift up the cowl. Install the 2 clips for the
protective cover.
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 36: Identifying Cowl Fasteners


Courtesy of VOLVO CARS CORPORATION

Install the 3 clips holding the cowl.

INSTALLING THE BATTERY BOX


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 37: Identifying Battery Box


Courtesy of VOLVO CARS CORPORATION

Install:

 the battery box (2)


 the 1 M6 screws (3)
 the battery. See BATTERY .

FINISHING

Install the wheel. See WHEELS .

BRAKE PIPE MASTER CYLINDER/ABS UNIT, REPLACING

NOTE: The graphics in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the graphics is always correct.

PREPARATORY WORK
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 38: Identifying Battery Box


Courtesy of VOLVO CARS CORPORATION

Switch off the ignition.

Remove:

 the battery. See BATTERY


 the 3x screws (1)
 the battery box (2).

REMOVAL

REMOVING SPLASH GUARDS


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 39: Identifying Cowl Fasteners


Courtesy of VOLVO CARS CORPORATION

Remove the 3 clips holding the cowl.


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 40: Identifying Brake Fluid Reservoir Protective Cover


Courtesy of VOLVO CARS CORPORATION

Carefully lift up the cowl. Remove the 2 clips for the protective cover. Remove the protective cover over the
brake fluid reservoir.
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 41: Identifying Firewall Upper Protective Cover Nut


Courtesy of VOLVO CARS CORPORATION

Remove:

 the plastic nut, x1


 the upper protective cover for the firewall.

REMOVING THE BRAKE PIPES BETWEEN THE MASTER CYLINDER AND ABS UNIT
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 42: Brake Piping/ABS Unit


Courtesy of VOLVO CARS CORPORATION

Clean the brake pipes terminals at the master cylinder and ABS unit.

Place paper under the master cylinder to avoid brake fluid spillage.

Remove the brake pipes between the master cylinder and the ABS unit.

INSTALLATION

INSTALLING THE BRAKE PIPES

NOTE: For tightening torques, see TIGHTENING TORQUE .

Install the brake pipes between the master cylinder and the ABS unit. Tighten. See TIGHTENING TORQUE .

BLEEDING BRAKE SYSTEMS

Bleed the brake system. See BRAKE SYSTEM BLEEDING .

Check that the brake pipe connections are sealed.


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Check the brake fluid level.

INSTALLING THE PROTECTIVE COVERS

Fig. 43: Identifying Firewall Upper Protective Cover Nut


Courtesy of VOLVO CARS CORPORATION

Install:

 the protective cover for the firewall


 the plastic nut.
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 44: Identifying Brake Fluid Reservoir Protective Cover


Courtesy of VOLVO CARS CORPORATION

Install the protective cover over the brake fluid reservoir.

Carefully lift up the cowl. Install the 2 clips for the protective cover.
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 45: Identifying Cowl Fasteners


Courtesy of VOLVO CARS CORPORATION

Install the 3x clips holding the cowl.

FINISHING
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 46: Identifying Battery Box


Courtesy of VOLVO CARS CORPORATION

Install:

 the battery box (2)


 the 1 M6 screws (3)
 the battery. See BATTERY .

BRAKE PIPE RIGHT FRONT WHEEL, REPLACING

NOTE: The graphics in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the graphics is always correct.

PREPARATORY WORK
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 47: Bleeding Brakes


Courtesy of VOLVO CARS CORPORATION

Remove the wheel.

Secure the pedal in the depressed position. Use a pedal jack.

Remove the protective cap from the bleed nipple at the left front wheel.

Install a plastic hose on the nipple. Open the bleed nipple.

Collect the brake fluid in a container.

Shut the bleed nipple.

REMOVAL

REMOVING THE BATTERY BOX


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 48: Identifying Battery Box


Courtesy of VOLVO CARS CORPORATION

Ignition off.

Remove:

 the battery. See BATTERY


 the 3 screws (1)
 the battery box (2).

REMOVING SPLASH GUARDS


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 49: Identifying Cowl Fasteners


Courtesy of VOLVO CARS CORPORATION

Remove the 3 clips holding the cowl.


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 50: Identifying Brake Fluid Reservoir Protective Cover


Courtesy of VOLVO CARS CORPORATION

Carefully lift up the cowl. Remove the 2 clips for the protective cover.

Remove the protective cover over the brake fluid reservoir.


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 51: Identifying Firewall Upper Protective Cover Nut


Courtesy of VOLVO CARS CORPORATION

Remove:

 the plastic nut, x1


 the protective cover for the firewall.

REMOVING THE HEAT DEFLECTOR PLATE


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 52: Identifying Heat Deflector Plate


Courtesy of VOLVO CARS CORPORATION

Remove:

 the heat deflector plate. Pull straight out


 the hoses from the clip.

REMOVING THE BRAKE PIPE


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 53: Brake Lines ABS Unit/Pipe Coupling Rear


Courtesy of VOLVO CARS CORPORATION

NOTE: Clean the brake pipe terminals. Place paper under the hydraulic modulator to
avoid brake fluid spillage.

Remove:

 the two brake pipes (1). See BRAKE LINES ABS UNIT/PIPE COUPLING REAR, REPLACING
 the 3 nuts (2)
 the lower protective cover for the firewall.
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 54: Identifying Brake Pipe


Courtesy of VOLVO CARS CORPORATION

Remove:

 the brake pipe (3) and install the plug


 the brake pipe (4) from the brake hose
 the brake pipe from the clips.

INSTALLATION

NOTE: For tightening torques, see TIGHTENING TORQUE .

INSTALLING THE BRAKE PIPES


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 55: Identifying Brake Pipe


Courtesy of VOLVO CARS CORPORATION

Install:

 the brake pipe (3). Tighten. See TIGHTENING TORQUE


 the brake pipe (4). Tighten. See TIGHTENING TORQUE
 the brake pipe in the clips.
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 56: Brake Lines ABS Unit/Pipe Coupling Rear


Courtesy of VOLVO CARS CORPORATION

Install:

 the lower protective cover for the firewall


 the 3 nuts (2)
 the two brake pipes (1): BRAKE LINES ABS UNIT/PIPE COUPLING REAR, REPLACING.

BLEEDING BRAKE SYSTEMS

Remove the pedal jack.

Bleed the brake system. See BRAKE SYSTEM BLEEDING .

Check that the brake pipe connections are sealed.

Check the brake fluid level.

INSTALLING THE HEAT DEFLECTOR PLATE


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 57: Identifying Heat Deflector Plate


Courtesy of VOLVO CARS CORPORATION

Install:

 the heat deflector plate


 the hoses
 the 1 clip.

INSTALLING THE PROTECTIVE COVERS


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 58: Identifying Firewall Upper Protective Cover Nut


Courtesy of VOLVO CARS CORPORATION

Install:

 the upper protective cover for the firewall


 the plastic nut, x1.
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 59: Identifying Brake Fluid Reservoir Protective Cover


Courtesy of VOLVO CARS CORPORATION

Install the protective cover over the brake fluid reservoir. Carefully lift up the cowl. Install the 2 clips for the
protective cover.
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 60: Identifying Cowl Fasteners


Courtesy of VOLVO CARS CORPORATION

Install the 3 clips holding the cowl.

INSTALLING THE BATTERY BOX


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 61: Identifying Battery Box


Courtesy of VOLVO CARS CORPORATION

Install:

 the battery box (2)


 the 1 M6 screws (3)
 the battery. See BATTERY .

FINISHING

Install the wheel. See WHEELS .

BRAKE PIPES LONGITUDINAL, REPLACING

NOTE: The graphics in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the graphics is always correct.

PREPARATORY WORK
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 62: Bleeding Brakes


Courtesy of VOLVO CARS CORPORATION

Secure the pedal in the depressed position. Use a pedal jack.

Remove the protective cap from the bleed nipple.

Install a plastic hose on the nipple.

Open the bleed nipple. Collect the brake fluid in a container (bottle). Shut the bleed nipple

REMOVAL

REMOVING THE SIPS MEMBER


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 63: Identifying SIPS Member


Courtesy of VOLVO CARS CORPORATION

Remove:

 the clips for the heated oxygen sensor (HO2S) wiring (1)
 the plastic nut (2)
 the two screws (3)
 the SIPS member.

REMOVING THE HEAT DEFLECTOR PLATE FOR THE COWL PANEL


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 64: Identifying Heat Deflector Plate


Courtesy of VOLVO CARS CORPORATION

Remove the heat deflector plate by pulling it out.

REMOVING THE FRONT-REAR BRAKE PIPE


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 65: Brake Lines ABS Unit/Pipe Coupling Rear


Courtesy of VOLVO CARS CORPORATION

Detach the two brake pipes (4).


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 66: Identifying Brake Pipes And Clips


Courtesy of VOLVO CARS CORPORATION

Detach the two brake pipes (5).

Remove all six clips (6).

INSTALLATION

INSTALLING THE FRONT-REAR BRAKE PIPE

NOTE: For tightening torques, see TIGHTENING TORQUE .


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 67: Brake Lines ABS Unit/Pipe Coupling Rear


Courtesy of VOLVO CARS CORPORATION

Install the two brake pipes (4).


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 68: Identifying Brake Pipes And Clips


Courtesy of VOLVO CARS CORPORATION

Install:

 the two brake pipes (5)


 the six clips.

BLEEDING BRAKE SYSTEMS

Remove the pedal jack.

Bleed the brake system. See BRAKE SYSTEM BLEEDING

Check that the brake pipe connections are sealed.

Check the brake fluid level

INSTALLING THE SIPS MEMBER


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 69: Identifying SIPS Member


Courtesy of VOLVO CARS CORPORATION

Install:

 the SIPS member


 the two M10 screws (3)
 the plastic nut (2)
 the clips for the heated oxygen sensor (HO2S) wiring (1).

INSTALLING THE HEAT DEFLECTOR PLATE FOR THE COWL PANEL

Install the heat deflector plate

BRAKE PIPES REAR WHEEL, REPLACING

NOTE: The graphics in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the graphics is always correct.

PREPARATORY WORK
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 70: Bleeding Brakes


Courtesy of VOLVO CARS CORPORATION

Remove the wheel.

Secure the pedal in the depressed position. Use a pedal jack.

Remove the protective cap from the bleed nipple.

Install a plastic hose on the nipple. Open the bleed nipple.

Collect the brake fluid in a container.

Shut the bleed nipple.

REMOVAL

REMOVING THE AIR BAFFLE


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 71: Identifying Air Baffle


Courtesy of VOLVO CARS CORPORATION

Applies to the left-hand side.

Remove:

 the 2 plastic nuts (1)


 the 1 screw (2)
 the air baffle.

REMOVING THE HEAT DEFLECTOR PLATE


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 72: Identifying Heat Deflector Plate


Courtesy of VOLVO CARS CORPORATION

Applies to the left-hand side.

Remove:

 the 5 plastic nuts


 the heat deflector plate. Hang the heat deflector plate on the exhaust system.

REMOVING THE LEFT REAR BRAKE PIPE


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 73: Identifying Brake Hose/Pipe And Clip


Courtesy of VOLVO CARS CORPORATION

Remove the brake pipe from the brake hose.


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 74: Identifying Brake Pipe Coupling


Courtesy of VOLVO CARS CORPORATION

Remove:

 the brake pipe from the front-rear pipe


 the brake pipe from the clips.

REMOVING THE RIGHT REAR BRAKE PIPE


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 75: Identifying Brake Pipe And Connector


Courtesy of VOLVO CARS CORPORATION

Remove:

 the connector (1)


 the brake pipe from the brake hose (2).
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 76: Identifying Brake Pipe And Clips


Courtesy of VOLVO CARS CORPORATION

Remove:

 the brake pipe from the front-rear pipe


 the brake pipe from the clips.

INSTALLATION

NOTE: For tightening torques, see TIGHTENING TORQUE .

INSTALLING THE LEFT REAR BRAKE PIPE


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 77: Identifying Brake Pipe Coupling


Courtesy of VOLVO CARS CORPORATION

Install the brake pipe in the front-rear pipe. Tighten. See TIGHTENING TORQUE .
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 78: Identifying Brake Hose/Pipe And Clip


Courtesy of VOLVO CARS CORPORATION

Install:

 the brake pipe in the brake hose. Tighten. See TIGHTENING TORQUE
 the brake pipe in the clips.

INSTALLING THE RIGHT REAR BRAKE PIPE


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 79: Identifying Brake Pipe And Clips


Courtesy of VOLVO CARS CORPORATION

Install the brake pipe in the front-rear brake pipe. Tighten. See TIGHTENING TORQUE .
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 80: Identifying Brake Pipe And Connector


Courtesy of VOLVO CARS CORPORATION

Install:

 the brake pipe in the brake hose (2). Tighten. See TIGHTENING TORQUE
 the connector (1)
 the brake pipe in the clips.

BLEEDING BRAKE SYSTEMS

Remove the pedal jack.

Bleed the brake system. See BRAKE SYSTEM BLEEDING .

Check that the brake pipe connections are sealed.

Check the brake fluid level.

INSTALLING THE HEAT DEFLECTOR PLATE


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 81: Identifying Heat Deflector Plate


Courtesy of VOLVO CARS CORPORATION

Applies to the left-hand side.

Install:

 the heat deflector plate


 the 5 plastic nuts.

INSTALLING THE AIR BAFFLE


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 82: Identifying Air Baffle


Courtesy of VOLVO CARS CORPORATION

Applies to the left-hand side.

Install:

 the air baffle


 the 2 plastic nuts (1)
 1 screw (2).

FINISHING

Install the wheel. See WHEELS .

MASTER CYLINDER, BRAKE SERVO


BRAKE FLUID

NOTE: The graphics in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the graphics is always correct.
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

GUIDELINES AND BACKGROUND

GUIDELINES FOR BRAKE FLUID REPLACEMENT

It is recommended that brake fluid is changed every other year. On cars that are exposed to heavy and frequent
braking, for example, mountain driving or driving in tropical climates with high humidity, the brake fluid must
be changed every year.

BACKGROUND

Fig. 83: Brake Fluid And Reservoir


Courtesy of VOLVO CARS CORPORATION

The oil must be replaced because it is hygroscopic (the fluid absorbs water molecules from the air). This
absorption of water occurs through the brake hoses and brake fluid reservoir. These components are rubber and
plastic respectively and are not completely sealed against water molecules. An increased water content in the
brake fluid dramatically reduces its boiling point and causes corrosion in the brake system components. This
results in damage to the brake system. Braking performance deteriorates markedly.

NOTE: Use only Volvo Genuine Parts brake fluid designated DOT 4+. Never reuse
brake fluid. Always keep the brake fluid sealed in the original packaging.

NOTE: Continually check that there is sufficient brake fluid in the brake fluid reservoir
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

when changing brake fluid.

PREPARATORY WORK

Switch off the ignition.

Remove all four wheels.

REPLACEMENT

CHANGING THE BRAKE FLUID, FRONT

Fig. 84: Collecting Bottle, Hose And G-Clamp


Courtesy of VOLVO CARS CORPORATION

Remove the protective cap from the bleed nipple.

Install a plastic hose on the nipple.

Open the bleed nipple.

Collect the brake fluid in a container.


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Press the brake caliper piston to the bottom of the caliper.

Use G-clamp as shown.

Leave the G-clamp in pushed in position.

Fig. 85: Bleeding Brake System


Courtesy of VOLVO CARS CORPORATION

Alternative 1:

Connect the bleeding unit. See BRAKE SYSTEM BLEEDING .

Open the bleed nipple on the caliper. Wait until there is new oil in the plastic hose.

Close the bleed nipple

Alternative 2:

Press down the brake pedal to the limit position.

Keep it pressed down for approximately 2 seconds before releasing it.


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Repeat until there is new brake fluid in the plastic hose.

Close the bleed nipple when the brake pedal is fully depressed.

Remove the hose. Install the protective cap.

Remove the G-clamp from the brake caliper.

Repeat the process on the other front wheel. Install the wheel. See WHEELS .

REPLACING BRAKE FLUID, REAR

Fig. 86: Identifying Special Tool 9995782


Courtesy of VOLVO CARS CORPORATION

Remove the brake caliper. See BRAKE PADS REAR .

Press the piston into the brake caliper. Use: see 9995782 replace 5782-1 with: see 9997091 .

Remove the protective cap from the bleed nipple.

Install the plastic hose on the nipple. Open the bleed nipple.
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Collect the brake fluid in a container.

Alternative 1:

Connect the bleeding unit. See BRAKE SYSTEM BLEEDING .

Open the bleed nipple on the caliper. Wait until there is new oil in the plastic hose.

Close the bleed nipple.

Alternative 2:

Press down the brake pedal to the limit position. Keep it pressed down for approximately 2 seconds before
releasing it.

Repeat until there is new brake fluid in the plastic hose.

Close the bleed nipple when the brake pedal is fully depressed.

Remove the hose and install the protective cap.

Remove the tool.

Install the brake caliper. See BRAKE PADS REAR . Repeat the process on the other rear wheel.

Install the wheel. See WHEELS .

BRAKE BOOSTER

NOTE: The graphics in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the graphics is always correct.

PREPARATORY WORK
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 87: Identifying Battery Box


Courtesy of VOLVO CARS CORPORATION

Ignition off.

Remove:

 the battery. See BATTERY


 the 3 screws
 the battery box.

Remove the windshield wiper motor. See WIPER MECHANISM, WINDSHIELD

REMOVAL

REMOVING SPLASH GUARDS


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 88: Identifying Protective Cover


Courtesy of VOLVO CARS CORPORATION

Remove:

 the 2 clips
 the protective cover over the brake fluid reservoir.
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 89: Identifying Protective Cover


Courtesy of VOLVO CARS CORPORATION

Remove:

 the plastic nut


 the protective cover for the firewall.

REMOVING THE PEDAL SENSOR


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 90: Identifying Pedal Sensor Connector


Courtesy of VOLVO CARS CORPORATION

Remove:

 the pressure sensor (1)


 the connector (2).
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 91: Identifying Pedal Sensor


Courtesy of VOLVO CARS CORPORATION

Remove the pedal sensor. Widen the snap ring and pull out the pedal sensor.

HINT: The opening on the snap ring points straight down. The snap ring does not need to be completely
removed, just opened.

NOTE: Ensure that the O-ring is also removed.

REMOVING THE HEAT DEFLECTOR PLATE


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 92: Identifying Heat Deflector Plate


Courtesy of VOLVO CARS CORPORATION

Remove:

 the heat deflector plate. Pull straight out


 the hoses from the clip.

REMOVING THE BRAKE PIPE


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 93: Brake Lines ABS Unit/Pipe Coupling Rear


Courtesy of VOLVO CARS CORPORATION

Remove:

 the two brake tubes (3) between the master cylinder and the control module.
 the two brake tubes (4)
 the 3 nuts (5)
 the lower protective cover for the firewall.

REMOVING THE MASTER CYLINDER

Remove the master cylinder. See MASTER CYLINDER, BRAKE.

REMOVING SOUNDPROOFING PANELS

Remove the soundproofing panel. See INSTRUMENT PANEL LOWER .

REMOVING THE POWER BRAKE BOOSTER


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 94: Identifying Brake Booster Push Rod


Courtesy of VOLVO CARS CORPORATION

Remove the pin for the power brake booster.

NOTE: The pin cannot be entirely removed. It must be replaced with a new pin on
installation.
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 95: 4 Nuts Holding Power Brake Booster


Courtesy of VOLVO CARS CORPORATION

Remove:

 the 4 nuts
 the power brake booster.

INSTALLATION

INSTALLING THE POWER BRAKE BOOSTER

NOTE: For tightening torques, see TIGHTENING TORQUE .

Install:

 the new power brake booster


 the 4 M8 nuts
 the new pin for the push rod.

INSTALLING THE PEDAL SENSOR


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 96: Identifying Pedal Sensor Connector


Courtesy of VOLVO CARS CORPORATION

Press in the new pedal sensor.

NOTE: Use a new O-ring. The pedal sensor can only be installed in one position, i. e.
with the locating pin pointing straight up.

Lubricate with soap solution and install the pressure sensor (1).

Connect the electrical connector (2).

INSTALLING MASTER CYLINDER

Install the master cylinder. See MASTER CYLINDER, BRAKE

INSTALLING THE BRAKE PIPES


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 97: Brake Lines ABS Unit/Pipe Coupling Rear


Courtesy of VOLVO CARS CORPORATION

Install:

 the two brake tubes (3)


 the lower protective cover for the firewall
 the 3 nuts (5)
 the two brake tubes (4).

BLEEDING BRAKE SYSTEMS

Bleed the brake system. See BRAKE SYSTEM BLEEDING .

Check that the brake pipe connections are sealed.

Check the brake fluid level.

INSTALLING THE HEAT DEFLECTOR PLATE


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 98: Identifying Heat Deflector Plate


Courtesy of VOLVO CARS CORPORATION

Install:

 the heat deflector plate


 the hoses
 the clip.

INSTALLING THE SOUNDPROOFING PANEL

Install the soundproofing panel. See INSTRUMENT PANEL LOWER .

INSTALLING THE PROTECTIVE COVERS


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 99: Identifying Protective Cover


Courtesy of VOLVO CARS CORPORATION

install:

 the protective cover for the firewall


 the plastic nut.
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 100: Identifying Protective Cover


Courtesy of VOLVO CARS CORPORATION

Install:

 the protective cover over the brake fluid reservoir


 the 2 clips.

FINISHING

Install:

 the windshield wiper motor. See WIPER MECHANISM, WINDSHIELD .


 the battery box
 the 3 M6 screws
 the battery as shown: BATTERY .

MASTER CYLINDER, BRAKE

NOTE: The graphics in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the graphics is always correct.
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

PREPARATORY WORK

Fig. 101: Identifying Battery Box


Courtesy of VOLVO CARS CORPORATION

Ignition off.

Remove:

 the battery. See BATTERY


 the 3 screws (1)
 the battery box (2).

REMOVAL

REMOVING SPLASH GUARDS


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 102: Identifying Cowl Fasteners


Courtesy of VOLVO CARS CORPORATION

Remove the 3 clips holding the cowl.


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 103: Identifying Brake Fluid Reservoir Protective Cover


Courtesy of VOLVO CARS CORPORATION

Carefully lift up the cowl. Remove the 2 clips for the protective cover. Remove the protective cover over the
brake fluid reservoir.
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 104: Identifying Firewall Upper Protective Cover Nut


Courtesy of VOLVO CARS CORPORATION

Remove:

 the plastic nut, x 1


 the upper protective cover for the firewall.

REMOVING THE MASTER CYLINDER


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 105: Identifying Brake Master Cylinder Connections


Courtesy of VOLVO CARS CORPORATION

NOTE: Clean the brake tube terminals at the master cylinder and anti-lock brake
system unit. Place paper under the master cylinder. This is to protect the
paintwork from damage if brake fluid is spilled.

Remove:

 the connector on the brake fluid reservoir


 the 2 nuts
 the 2 brake pipes from the master cylinder. Install the sealing plugs
 the feeder hose for the clutch cylinder. Install the sealing plugs
 the master cylinder.

TRANSFERRING COMPONENTS

Transfer the brake fluid reservoir to the new master cylinder. See RESERVOIR, BRAKE FLUID.

NOTE: Only use brake fluid to lubricate the O-rings in the brake system.
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

INSTALLING MASTER CYLINDER

NOTE: For tightening torques, see TIGHTENING TORQUE .

Install:

 the 2 brake pipes. Tighten. See TIGHTENING TORQUE


 the 2 M8 nuts
 the connector on the brake fluid reservoir
 the feeder hose for the clutch cylinder.

BLEEDING BRAKE SYSTEMS

Bleed the brake system. See BRAKE SYSTEM BLEEDING .

Check that the brake pipe connections are sealed.

Check the brake fluid level.

INSTALLING THE PROTECTIVE COVERS

Fig. 106: Identifying Firewall Upper Protective Cover Nut


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Courtesy of VOLVO CARS CORPORATION

Install:

 the protective cover for the firewall


 the plastic nut, x 1.

Fig. 107: Identifying Brake Fluid Reservoir Protective Cover


Courtesy of VOLVO CARS CORPORATION

Install the protective cover over the brake fluid reservoir. Carefully lift up the cowl. Install the 2 clips for the
protective cover.
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 108: Identifying Cowl Fasteners


Courtesy of VOLVO CARS CORPORATION

Install the 3 clips holding the cowl.

FINISHING
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 109: Identifying Battery Box


Courtesy of VOLVO CARS CORPORATION

Install:

 the battery box (2)


 the 1 M6 screws (3)
 the battery as shown: BATTERY .

RESERVOIR, BRAKE FLUID

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 110: Locating Brake Master Cylinder Reservoir


Courtesy of VOLVO CARS CORPORATION

Remove master cylinder brake. See MASTER CYLINDER, BRAKE

Fig. 111: Identifying Brake Master Cylinder Reservoir Retaining Bolt


Courtesy of VOLVO CARS CORPORATION

Torque: Brake fluid reservoir in master cylinder

3.5 Nm
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 112: Identifying Mating Surfaces


Courtesy of VOLVO CARS CORPORATION

CAUTION: Make sure that the mating faces are clean and free of foreign material.

INSTALLATION

To install, reverse the removal procedure.

BRAKE LINE WITH CONNECTIONS


FRONT BRAKE FLEXIBLE HOSE

NOTE: The graphics in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the graphics is always correct.

PREPARATORY WORK
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 113: Bleeding Brakes


Courtesy of VOLVO CARS CORPORATION

Remove the wheel.

Secure the pedal in the depressed position. Use a pedal jack.

Remove the protective cap from the bleed nipple.

Install a plastic hose on the nipple.

Open the bleed nipple. Collect the brake fluid in a container.

Shut the bleed nipple.

REMOVAL

REMOVING THE BRAKE HOSE


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 114: Identifying Brake Hose/Pipe And Clip


Courtesy of VOLVO CARS CORPORATION

Remove:

 the brake pipe from the brake hose (1)


 the retaining clip (2).

Pull the brake hose out of the mounting (3).

Remove the brake hose from the brake caliper (4).

INSTALLATION

INSTALLING THE BRAKE HOSE

NOTE: For tightening torques, see TIGHTENING TORQUE .


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 115: Identifying Brake Hose/Pipe And Clip


Courtesy of VOLVO CARS CORPORATION

Install:

 the brake hose (4) to the caliper. Tighten. See TIGHTENING TORQUE
 the brake hose (3) in the mounting
 the retaining clip (2).
 brake pipe in the hose (1). Tighten. See TIGHTENING TORQUE .

NOTE: Ensure that the brake hose is not twisted. If the brake hose is twisted, there is a
risk of circuit failure.

FINISHING

Remove the pedal jack.

Fill and bleed the brake system. To bleed the brake system, see BRAKE SYSTEM BLEEDING .

NOTE: Use only Volvo Genuine parts brake fluid (Volvo DOT 4+).

Check:
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

 the function of the brakes after bleeding


 that there is no leakage
 brake fluid level.

Depress the brake pedal a few times. Check the level of the brake fluid reservoir. Top up if necessary.

Install the wheel. See WHEELS .

REAR BRAKE FLEXIBLE HOSE

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.

Remove the wheel. See WHEELS

Fig. 116: Bleeding Brake Fluid


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 117: Removing/Installing Clip


Courtesy of VOLVO CARS CORPORATION

Fig. 118: Removing/Installing Pipe to Hose with Clip


Courtesy of VOLVO CARS CORPORATION

Torque: Ø6 mm diameter brake line

14 Nm
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 119: Removing/Installing Rear Brake Flexible Hose


Courtesy of VOLVO CARS CORPORATION

Torque: Rear Brake Flexible Hose

23 Nm

INSTALLATION

To install, reverse the removal procedure.

Perform bleeding air brake system. See BRAKE SYSTEM BLEEDING

BRAKE CONTROL
BUSHING PUSH ROD

NOTE: The graphics in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the graphics is always correct.

PREPARATORY WORK

Remove the soundproofing panel. See INSTRUMENT PANEL LOWER .

REMOVAL

REMOVING THE BUSHING


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 120: Identifying Brake Booster Push Rod


Courtesy of VOLVO CARS CORPORATION

Break off the bushing together with the pin from the push rod.

NOTE: The pin cannot be separated entirely. It must be replaced with a new pin on
installation.

INSTALLATION

INSTALLING THE BUSHING

Press in the bushing together with the pin into the push rod.

NOTE: The pin cannot be separated entirely. It must be replaced with a new pin on
installation.

PEDAL BOX, BRAKE

REMOVAL

Remove the following items:


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

 See STEERING COLUMN


 See ACCELERATOR PEDAL

Fig. 121: Locating Brake Pedal Pin


Courtesy of VOLVO CARS CORPORATION

Fig. 122: Identifying Brake Pedal Switch Connector


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 123: Identifying Brake Pedal Switch


Courtesy of VOLVO CARS CORPORATION

Fig. 124: Identifying Brake Pedal Assembly Nuts


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

INSTALLATION

To install, reverse the removal procedure.

VACUUM PUMP, TANK, LINE AND VALVE


BRAKE BOOSTER VACUUM HOSE

NOTE: The graphics in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the graphics is always correct.

PREPARATORY WORK

Fig. 125: Identifying Battery Box


Courtesy of VOLVO CARS CORPORATION

Ignition off.

Remove:

 the battery. See BATTERY


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

 the 3 screws
 the battery box.

REMOVAL

REMOVING SPLASH GUARDS

Fig. 126: Identifying Cowl Fasteners


Courtesy of VOLVO CARS CORPORATION

Remove the 3 clips holding the cowl.


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 127: Identifying Brake Fluid Reservoir Protective Cover


Courtesy of VOLVO CARS CORPORATION

Carefully lift up the cowl. Remove the 2 clips for the protective cover.

Remove the protective cover over the brake fluid reservoir.


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 128: Identifying Firewall Upper Protective Cover Nut


Courtesy of VOLVO CARS CORPORATION

Remove:

 the plastic nut


 the upper protective cover for the firewall.

REMOVING THE MASTER CYLINDER


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 129: Identifying Brake Master Cylinder Fasteners


Courtesy of VOLVO CARS CORPORATION

Remove the 2 nuts. Pull the master cylinder out from the studs. Allow the master cylinder to hang from the
brake pipes.

NOTE: Do not damage the brake pipes when removing the master cylinder.

REMOVING THE VACUUM HOSE


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 130: Identifying Brake Booster Vacuum Valve and Connector


Courtesy of VOLVO CARS CORPORATION

Remove:

 the connector (1)


 the control valve (2).
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 131: Identifying Brake Booster Vacuum Hose


Courtesy of VOLVO CARS CORPORATION

Remove:

 the clamp (1)


 the vacuum hose from the hose for the intake manifold
 the vacuum hose from the pump (2)
 the vacuum hose.

INSTALLATION

INSTALLING THE VACUUM HOSE

NOTE: For tightening torques, see TIGHTENING TORQUE .


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 132: Identifying Brake Booster Vacuum Hose


Courtesy of VOLVO CARS CORPORATION

Install:

 the vacuum hose


 the vacuum hose on the pump (2)
 the vacuum hose on the hose for the intake manifold
 the clamp (1).
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 133: Identifying Brake Booster Vacuum Valve and Connector


Courtesy of VOLVO CARS CORPORATION

Install:

 the connector (1)


 the control valve (2).

HINT: Lubricate the control valve using soap solution for easier installation.

INSTALLING THE PROTECTIVE COVERS


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 134: Identifying Firewall Upper Protective Cover Nut


Courtesy of VOLVO CARS CORPORATION

Install:

 the protective cover for the firewall


 the plastic nut.
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 135: Identifying Brake Fluid Reservoir Protective Cover


Courtesy of VOLVO CARS CORPORATION

Install the protective cover over the brake fluid reservoir. Carefully lift up the cowl. Install the 2 clips for the
protective cover.
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 136: Identifying Cowl Fasteners


Courtesy of VOLVO CARS CORPORATION

Install the 3 clips holding the cowl.

FINISHING
2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 137: Identifying Battery Box


Courtesy of VOLVO CARS CORPORATION

Install:

 the battery box


 the 3 M6 screws
 the battery. See BATTERY .

VACUUM PUMP, BRAKE BOOSTER

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.


2012 Volvo C30 T-5
BRAKES Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement And Installation

Fig. 138: Locating Brake Booster Vacuum Pump (Inset Removing Vacuum Lines)
Courtesy of VOLVO CARS CORPORATION

Torque: M6

10 Nm

INSTALLATION

To install, reverse the removal procedure.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

ACCESSORIES AND EQUIPMENT

Instrumentation - Installation Instructions, Accessories

TRIP COMPUTER
TRIP COMPUTER

 Turn the ignition key to position 0


 Move the steering wheel to its rearmost position.

Fig. 1: Identifying Upper Steering Column Cover


Courtesy of VOLVO CARS CORPORATION

 Carefully pry the upper steering column cover off the lower cover. Using a plastic weatherstrip tool, pry
at the rear edge in the join between the steering column covers. The steering column covers are secured to
each other by catches (1) on the inside
 Fold the upper steering column cover towards the combined instrument panel. Secure it in the folded up
position.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 2: Identifying Steering Column Cover Screws


Courtesy of VOLVO CARS CORPORATION

 Remove the upper screws (1) from the lower steering column cover
 Unscrew the lower screw (2) a few turns
 Fold the lower steering column cover down slightly, so that the mounting point for the left-hand control
stalk is exposed.

Fig. 3: View Of Left-Hand Control Stalk Screws


Courtesy of VOLVO CARS CORPORATION

 Remove the left-hand control stalk. First remove the two screws. Then carefully pull the stalk outwards
until it releases from the connector on the inside.

 Press the new stalk into place where the old one was positioned. Tighten the stalk using the existing
screws
 Reinstall the lower steering column cover. Tighten
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

 Reinstall the upper steering column cover.

 Program the function using VIDA (Volvo scan tool).

COMBINED INSTRUMENT PANEL, R-DESIGN


COMBINED INSTRUMENT PANEL, R-DESIGN

Fig. 4: Identifying Ignition Switch Turned To Position 0


Courtesy of VOLVO CARS CORPORATION

 Turn the ignition switch to position 0.

NOTE: Wait at least three minutes before unplugging the connectors or removing other
electrical equipment.

Fig. 5: Identifying Steering Wheel In Lowest Position


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Courtesy of VOLVO CARS CORPORATION

 Adjust the steering wheel to the outermost and lowermost position.


 Remove the two screws at the upper edge of the surround for the combined instrument panel.
 Remove the surround.

Fig. 6: View Of Instrument Panel Screws


Courtesy of VOLVO CARS CORPORATION

 Remove the two screws at the sides of the instrument panel.


 Raise it slightly and unhook it from the holder on the inside of the instrument panel.
 Lift the instrument panel out and disconnect the connector.

NOTE: Do not damage the instrument panel. The glass is easily scratched.

 Place the instrument panel to one side.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 7: Installing Instrument Panel Connector


Courtesy of VOLVO CARS CORPORATION

 Take the new instrument panel and connect the connector.


 Insert it in position and hook it onto the holder on the inside.
 Tighten using the two screws.

Fig. 8: View Of Instrument Panel Surround Screws


Courtesy of VOLVO CARS CORPORATION

Fig. 9: Identifying VIDA (Volvo Scan Tool) To Program Software


Courtesy of VOLVO CARS CORPORATION

 Download software for the relevant vehicle type in accordance with the service information in VIDA
(Volvo scan tool).

PARKING ASSISTANCE, FRONT


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

PARKING ASSISTANCE, FRONT

Fig. 10: Identifying Front Parking Assistance Sensor


Courtesy of VOLVO CARS CORPORATION

Fig. 11: Cleaning Sensors


Courtesy of VOLVO CARS CORPORATION

 Clean the sensors. Use: Isopropanol


 Allow to dry.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 12: Matting Surface Down


Courtesy of VOLVO CARS CORPORATION

 Carefully mat the surface down. Use: Glasspaper, grade P1000

Fig. 13: Cleaning Sensors


Courtesy of VOLVO CARS CORPORATION

 Clean the sensors again.


 Use: Isopropanol
 Allow to dry.
 Avoid contact with the cleaned surfaces.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 14: View Of Painting Sensors


Courtesy of VOLVO CARS CORPORATION

CAUTION: Protect the connections' contact surfaces against paint.

 Paint the sensors in the same color code as the vehicle.


 Use Volvo Touch-up paint. (Only use base coat.)
 Use: Volvo 2-K Varnish. P/N: 31335447

NOTE: Also read the instructions on the spray can.

Fig. 15: Installing Rear Parking Assistance Sensor Bezel


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

CAUTION: The paint must have dried after the first application.

Fig. 16: Identifying Ignition Switch Turned To Position 0


Courtesy of VOLVO CARS CORPORATION

 Turn the ignition switch to position 0.

NOTE: Wait at least one minute before unplugging the connectors or removing
other electrical equipment.

Fig. 17: Identifying Screws Holding Engine Splash Guard


Courtesy of VOLVO CARS CORPORATION

 Raise the car


 Remove the screws and the engine splash guard.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 18: Identifying Removal Of Nozzle Covers


Courtesy of VOLVO CARS CORPORATION

 Lower the car


 Carefully grasp the cover for the high pressure washing for the headlamps and pull until the catches are
accessible.

Fig. 19: Identifying Catch Pressed Up


Courtesy of VOLVO CARS CORPORATION

 Press the catch up. Remove the cover. Do not damage the painted surfaces or the washer nozzles.
 Carry out on both sides
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 20: Identifying Clips And Screws


Courtesy of VOLVO CARS CORPORATION

 Push in the center of the five clips (1). Remove the clips.
 Remove the two screws (2)

Fig. 21: Removing Inner Wing Screws


Courtesy of VOLVO CARS CORPORATION

 Remove the screws for the inner wing.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 22: Identifying Prying Points


Courtesy of VOLVO CARS CORPORATION

 Take a weatherstrip tool and pry between the headlamp bumper cover (1)
 Then insert the weatherstrip tool in the cut-out (2) and pull straight out until the hooks (3) release
 Repeat the operation on the other side

Fig. 23: Pulling Bumper Cover Straight Out


Courtesy of VOLVO CARS CORPORATION

HINT: Removal of the bumper is facilitated if carried out by 2 people.

 Pull the ends of the bumper cover straight out so that the release from the wing liner.
 Pull the bumper cover straight out until the hooks under the headlamps release, detach the connectors for
the fog lamps and place the bumper cover on a surface that will not damage the paint.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 24: Locating Markings Inside Bumper Cover


Courtesy of VOLVO CARS CORPORATION

 Locate the 4 markings on the inside of the bumper cover.


 Mark the center with a scribe.

Fig. 25: Drilling Holes In Centers Of Markings


Courtesy of VOLVO CARS CORPORATION

 Drill holes in the centers of the markings using a Ø 3 mm (7/64) diameter drill bit.
 Drill out the holes. Use a Ø10 mm (25/64") diameter drill bit.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 26: Identifying Special Tool P/N 9997234


Courtesy of VOLVO CARS CORPORATION

 Enlarge the holes in the bumper cover using hole tool P/N 9997234 . Place the hole tool's support sleeve
on the inside, and the cutting component on the outside of the bumper cover.

Fig. 27: Cleaning And Applying Activator


Courtesy of VOLVO CARS CORPORATION

 Clean the inside of the bumper cover using a mild soap solution.
 Clean around the holes and the markings using isopropanol.
 Allow to dry.
 Apply a thin layer of activator, part no. 8637 076 , to the cleaned surfaces and let dry for approx. 10 min.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 28: Identifying Holder


Courtesy of VOLVO CARS CORPORATION

 Take the 4 holders from the kit.


 Clean the surfaces as shown in the illustration. Use: Isopropanol
 Allow to dry.
 Apply a thin layer and even layer of activator. art. no.. 8637076 .

Fig. 29: Identifying Markings In Member


Courtesy of VOLVO CARS CORPORATION

NOTE: There are two types of member (energy absorbing).

Plastic member:

 Saw along the 2 markings, only through the outer part.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Foam member (EPS):

 Remove the foam member from the collision member.


 Saw along the 2 markings.
 Reinstall the foam member.

Fig. 30: Identifying Panel


Courtesy of VOLVO CARS CORPORATION

 Remove the panel.

Fig. 31: Identifying Soundproofing Panel Clips


Courtesy of VOLVO CARS CORPORATION

 Remove the 2 clips and the soundproofing panel.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 32: Identifying Front Sill Molding


Courtesy of VOLVO CARS CORPORATION

 Detach the front sill molding by first pulling it backwards at the front edge and then straight up so that the
clips release.

Fig. 33: Removing Rear Sill Molding


Courtesy of VOLVO CARS CORPORATION

 Detach the rear sill molding by first pulling it up at the front edge, and then unhooking it at the rear edge.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 34: Identifying Rear Seat Cushion


Courtesy of VOLVO CARS CORPORATION

 Pull off the seat cushion for the rear seat, 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. 35: Identifying Central Arm Rest


Courtesy of VOLVO CARS CORPORATION

 Fold the central arm rest forward.


 Remove the central arm rest by grasping each end and pulling upwards until it releases at the rear edge
from the backrest's lugs (1).
 Then pull forwards until the holders (2) on the sides of the backrest have slid out of the corresponding
cut-out (3) in the central arm rest.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 36: Identifying Backrest Cover


Courtesy of VOLVO CARS CORPORATION

NOTE: Applies to right-hand drive cars. Must not be mirrored.

 Fold the backrest forward.


 Remove the cover for the backrest's right-hand mounting.

Fig. 37: Identifying Locking Sleeve And Screw


Courtesy of VOLVO CARS CORPORATION

 Remove the screw and the locking sleeve.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 38: View Of Backrest Stowed


Courtesy of VOLVO CARS CORPORATION

 Fold the backrest away from the right-hand mounting.


 Pull it out from the mounting at the arm rest and remove it.

Fig. 39: Identifying Rubber Door Molding RH


Courtesy of VOLVO CARS CORPORATION

 Pull off the rubber molding at the rear edge of the right-hand door opening.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 40: Identifying B Pillar Panel


Courtesy of VOLVO CARS CORPORATION

 Detach the B pillar panel at the rear edge by prying the sides using a weatherstrip tool until the 2 clips
release.

Fig. 41: View Of Safety Clip Strap


Courtesy of VOLVO CARS CORPORATION

 Unhook the safety clip from the panel.


 Angle out the panel at the lower edge, and then unhook it at the upper edge so that the upper clip releases.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 42: Identifying Rear Seat RH Panel


Courtesy of VOLVO CARS CORPORATION

 Remove the screw from the right-hand panel.


 Carefully pull off the panel from the body side. It is secured by eleven clips on the inside.

Fig. 43: Identifying Trunk Floor Cover


Courtesy of VOLVO CARS CORPORATION

 Lift up the floor hatch at the rear edge.


 Pull it backwards so that it detaches at the front edge.
 Turn the cover and lift out.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 44: Identifying Tailgate's Sill Panel


Courtesy of VOLVO CARS CORPORATION

 Remove the tailgate's sill panel by pulling it up until the four clips on the upper side and the catches at the
lower edge release.

Fig. 45: Identifying Right-Hand Rear Side Panel


Courtesy of VOLVO CARS CORPORATION

 Remove the clips at the rear edge of the right-hand rear side panel.
 Carefully pull the side panel off, starting at the front edge/upper edge and then straight back until all clips
at the top edge have released.
 Fold the panel inwards. Release it from the anchorage eyelets and lift it out of the load floor support.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 46: View Of Spare Wheel, Jack And Other Parts From Storage Compartment
Courtesy of VOLVO CARS CORPORATION

 Lift out the spare wheel, jack and other parts from the storage compartment in the cargo floor support.

Fig. 47: Identifying Spare Wheel Compartment Screws


Courtesy of VOLVO CARS CORPORATION

 Remove the 4 screw clips.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 48: Identifying Cable Routing In Engine Bay


Courtesy of VOLVO CARS CORPORATION

NOTE: Ensure that the cable harness does not lie against any moving components or
too close to heat sources.

 Take the short cable harness from the kit.


 Remove the taped connector from the cable harness.
 Pull the end with the loose terminals in under the headlamp
 Continue to pull the cable harness (1) along the right-hand side of the car, under the expansion tank down
to the cowl panel.
 Route the cable so that it is concealed and cannot be damaged or worn. Secure the cable harness using tie
straps so that it does not move.

Fig. 49: Identifying Floor Mat


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

 Unscrew the clips holding the floor carpet.


 Push the floor carpet to one side to access the cowl panel inside.
 Take care not to create folds in the carpet.

Fig. 50: Locating Hole Under Insulation Panel For Rubber Grommet
Courtesy of VOLVO CARS CORPORATION

 Locate the hole for the rubber grommet under the insulation panel.
 Make a small cut in the insulation panel starting just above the hole, continue to the center of the hole and
then straight down.

Fig. 51: Pushing Carpet Tabs To One Side


Courtesy of VOLVO CARS CORPORATION

 Push the carpet tabs to one side to access the rubber grommet in the cowl panel.
 Remove the rubber grommet.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 52: Removing Rubber Grommet


Courtesy of VOLVO CARS CORPORATION

NOTE: Applies to cars with parking heaters Protect the coolant hose on the horizontal
connection of the water pump when making the markings for holes.

 Pierce holes through the heat insulation panel and out into the engine compartment, for hole-marking in
the heat insulation panel in the engine compartment.

Fig. 53: Cutting Out Hole In Heat Insulation


Courtesy of VOLVO CARS CORPORATION

 Raise the car.


 Cut out a hole in the heat insulation that is approx. 20 mm (25/32".) larger than the size of the rubber
grommet.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 54: Cutting Top Off Smaller Rubber Nipples


Courtesy of VOLVO CARS CORPORATION

 Take the rubber grommet from the kit and cut the top off the smaller rubber nipples
 Lubricate the rubber grommet. Use low temperature grease (P/N 1161417).
 Thread the rubber grommet on the cable harness.
 Route the cable harness in through the hole and press the rubber grommet into the hole so that it seals
properly.
 Pull the cable harness so that the correct length remains in the engine compartment.
 Make sure that the heating hose for the cable harness is in contact against the rubber grommet and secure
it with a tie strap.

Fig. 55: Identifying Connector


Courtesy of VOLVO CARS CORPORATION

 Lower the car.


1. 1 Blue (BL)
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

2. 2 Green (GN)
3. 3 Violet (VO)
4. 4 Yellow (Y)
5. 5 White (W)
6. 6 Black (SB)
 Release the catch on the connector that was taped.
1. 1 Blue (BL)
2. 2 Green (GN)
3. 3 Violet (VO)
4. 4 Yellow (Y)
5. 5 White (W)
6. 6 Black (SB)
 Connect the pre-routed cable harness terminals in the connector as follows.
1. 1 Blue (BL)
2. 2 Green (GN)
3. 3 Violet (VO)
4. 4 Yellow (Y)
5. 5 White (W)
6. 6 Black (SB)
 Press back the connector's catch.

Fig. 56: Identifying Connection Of Long Cable


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Courtesy of VOLVO CARS CORPORATION

 Take the long cable harness from the kit. Connect it to the connector which has just been prepared.
 Route the cable harness from the lower edge of the A pillar and further back at the sill and under the
carpet.
 Fold back the carpet and screw the clip into place.

Fig. 57: View Of Routed Cable Harness


Courtesy of VOLVO CARS CORPORATION

 Route the cable harness further back and under the seat support and backwards and into the cargo
compartment, along the existing cable harnesses.
 Position the cable harness so that it does not get trapped or damaged.

Fig. 58: Routing Cable To Right Rear Corner Of Cargo Floor Support
Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

the right rear corner of the cargo floor support.


 Position the cable so that is does not get trapped or damaged.

Fig. 59: Locating Parking Assistance Module (PAM)


Courtesy of VOLVO CARS CORPORATION

 Lift up the right-hand side cargo floor support.


 Locate the parking assistance module (PAM). It is secured on the right-hand side of the cargo
compartment floor, under the cargo floor support.

Fig. 60: Connecting Pre-Routed Cable To Vacant Connection (Middle) On Parking Assistance Module
(PAM)
Courtesy of VOLVO CARS CORPORATION

NOTE: Ensure that the connector's catch clicks and is securely positioned.

 Connect the pre-routed cable to the vacant connection (middle) on the parking assistance module (PAM).
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 61: Securing Double-Backed Tape On Holder


Courtesy of VOLVO CARS CORPORATION

 Remove the protective film from one side of the double-backed tape.
 Secure the tape on the holder.

Fig. 62: Installing Centering Tool In Holder


Courtesy of VOLVO CARS CORPORATION

 Remove the remaining protective film on the holder.


 Install the centering tool in the holder according to the illustration.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 63: Locating Holders On Bumper Cover


Courtesy of VOLVO CARS CORPORATION

NOTE: The holders must be mounted turned against the holes as shown in the
illustration. The holders must also be horizontal and in line with the bumper
cover.

 Press in the holder on the bumper cover.


 Repeat the steps for the other holders.

Fig. 64: Connect Cable Harness Connectors To Sensors


Courtesy of VOLVO CARS CORPORATION

NOTE: The large gray connector must be on the right-hand side.

 Connect the cable harness connectors to the sensors.


 Install the sensors in their holders.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 65: Securing End Of Cable Harness At Sensor To Bumper Cover


Courtesy of VOLVO CARS CORPORATION

 Secure the end of the cable harness at the sensors to the bumper cover using butyl tape.

Fig. 66: Securing Cable Harness To Bumper Cover


Courtesy of VOLVO CARS CORPORATION

NOTE: The large gray connector must be on the right-hand side.

 Secure the cable harness to the bumper cover using butyl tape in the locations shown in the illustration.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 67: Securing Assembled Connector On Member


Courtesy of VOLVO CARS CORPORATION

 Hold the bumper up against the car and connect the connector for the sensor cable to the connector at the
car.
 Secure the assembled connector on the member (1) . Use a tie strap on each side of the connector.
 Connect the connectors to any foglamps.
 Slide the bumper cover into the correct position

Fig. 68: Guiding Lower Edge Of Bumper Cover Into Guides


Courtesy of VOLVO CARS CORPORATION

 Guide the lower edge of the bumper cover into the guides.
 Reinstall the bumper cover by repeating points in reverse order.
 Reinstall the engine splash guard.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 69: Identifying Panel Screw


Courtesy of VOLVO CARS CORPORATION

 Reinstall the side panel.


 Reinstall the clip for the cargo floor support.
 Reinstall the sill trim panel.

Fig. 70: Locating Ten Panel Clips


Courtesy of VOLVO CARS CORPORATION

NOTE: There are ten clips on the reverse of the panel that must all engage in the body.
Take care when aligning so that the clips do not break. Broken clips must be
replaced with new ones.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 71: Identifying Panel Clips And Screws


Courtesy of VOLVO CARS CORPORATION

 Reinstall the side panel, ensure that all clips engage.


 Tighten the panel using existing screws.

Fig. 72: View Of B Pillar Panel Clips


Courtesy of VOLVO CARS CORPORATION

 Reinstall the panel with the safety clip and the weatherstrip.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 73: View Of Rear Sill Trim Panel


Courtesy of VOLVO CARS CORPORATION

 Reinstall the rear sill trim panel, the 2 guides must be in the corresponding cut-outs in the side panel.
 Reinstall the front sill trim panel.
 Reinstall the backrest. Tighten the screws to 15 Nm (11 lbf. ft.) .
 Reinstall the arm rest.
 Reinstall the seat cushion.

Fig. 74: Identifying VIDA (Volvo Scan Tool) To Program Software


Courtesy of VOLVO CARS CORPORATION

 Download software (application) for the accessory's function using VIDA (Volvo scan tool).

PARKING ASSISTANCE, FRONT, CHASSIS NUMBER 190000- (2010-2012)


PARKING ASSISTANCE, FRONT, CHASSIS NUMBER 190000-
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 75: Identifying Front Parking Assistance Sensor


Courtesy of VOLVO CARS CORPORATION

Fig. 76: Cleaning Sensors


Courtesy of VOLVO CARS CORPORATION

 Clean the sensors. Use: Isopropanol.


 Allow to dry.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 77: Matting Surface Down


Courtesy of VOLVO CARS CORPORATION

 Carefully mat the surface down. Use: Glasspaper, grade P1000

Fig. 78: Cleaning Sensors


Courtesy of VOLVO CARS CORPORATION

 Clean the sensors again. Use: Isopropanol


 Allow to dry.
 Avoid contact with the cleaned surfaces.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 79: View Of Painting Sensors


Courtesy of VOLVO CARS CORPORATION

CAUTION: Protect the connections' contact surfaces against paint.

 Paint the sensors in the same color code as the vehicle.


 Use Volvo Touch-up paint. (Only use base coat.)
 Use: Volvo 2-K Varnish. P/N: 31335447

NOTE: Also read the instructions on the spray can.

Fig. 80: Installing Rear Parking Assistance Sensor Bezel


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

CAUTION: The paint must have dried after the first application.

Fig. 81: Locating Engine Splash Guard Screws


Courtesy of VOLVO CARS CORPORATION

 Raise the car.


 Remove the screws and the engine splash guard.

APPLIES TO VEHICLES WITH HEADLAMP WASHING

Fig. 82: Pulling Out Cover


Courtesy of VOLVO CARS CORPORATION

 Pull out the cover so that the nozzle is visible.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

APPLIES TO VEHICLES WITH HEADLAMP WASHING

Fig. 83: Removing Headlamp Washer Nozzle Cover


Courtesy of VOLVO CARS CORPORATION

CAUTION: Do not damage painted surfaces and high pressure washer nozzles.

 Repeat on the other side.

APPLIES TO ALL VEHICLES

Fig. 84: View Of Front Bumper Cover Upper Mounting Screws


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 85: Identifying Fender Liner Screws


Courtesy of VOLVO CARS CORPORATION

 Carry out on both sides.

Fig. 86: Prying Between Headlamp Bumper Cover


Courtesy of VOLVO CARS CORPORATION

 Take a weatherstrip tool and pry between the headlamp bumper cover.
 Pull straight out until the catches release.
 Repeat the operation on the other side.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 87: Removing Front Bumper Cover


Courtesy of VOLVO CARS CORPORATION

HINT: Removal of the bumper is facilitated if carried out by 2 people.

APPLIES TO VEHICLES WITH FOG LAMPS

Fig. 88: Removing Fog Lamp Connector


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 89: Locating Markings Inside Bumper Cover


Courtesy of VOLVO CARS CORPORATION

 Locate the 4 markings on the inside of the bumper cover.

Fig. 90: Marking Centers With Scribe


Courtesy of VOLVO CARS CORPORATION

 Mark the center with a scribe.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 91: Drilling Through Center Markings


Courtesy of VOLVO CARS CORPORATION

1. Ø 3 mm (7/64")
2. Ø 10 mm (25/64")

Fig. 92: Identifying Special Tool 9997234


Courtesy of VOLVO CARS CORPORATION

Use special tool: 9997234

NOTE: The hole tool's support sleeve must be on the inside, and the cutting part on the
outside of the bumper casing.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 93: Cleaning With Isopropanol


Courtesy of VOLVO CARS CORPORATION

Use: Isopropanol

 Allow to dry.

Fig. 94: Applying Activator


Courtesy of VOLVO CARS CORPORATION

Use: 8637076 - Activator

 Apply a thin and even layer.

CAUTION: Allow to dry for at least 10 minutes.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 95: Identifying Cleaned Cradle Area


Courtesy of VOLVO CARS CORPORATION

Use: Isopropanol

 Allow to dry.

Fig. 96: Applying Activator To Cradle


Courtesy of VOLVO CARS CORPORATION

Use: 8637076 - Activator

 Apply a thin and even layer.

CAUTION: Allow to dry for at least 10 minutes.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 97: Sawing Along Markings In Member


Courtesy of VOLVO CARS CORPORATION

NOTE: There are two types of member (energy absorbing).

Plastic member:

 Saw along the 2 markings, only through the outer part.

Foam member (EPS):

 Remove the foam member from the collision member.


 Saw along the 2 markings.
 Reinstall the foam member.

Fig. 98: Identifying Panel


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

 Remove the panel.

Fig. 99: Identifying Soundproofing Panel Clips


Courtesy of VOLVO CARS CORPORATION

 Remove the 2 clips and the soundproofing panel.

Fig. 100: Identifying Front Sill Molding


Courtesy of VOLVO CARS CORPORATION

 Detach the front sill molding by first pulling it backwards at the front edge and then straight up so that the
clips release.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 101: Removing Rear Sill Molding


Courtesy of VOLVO CARS CORPORATION

 Detach the rear sill molding by first pulling it up at the front edge, and then unhooking it at the rear edge.

Fig. 102: Identifying Rear Seat Cushion


Courtesy of VOLVO CARS CORPORATION

 Pull off the seat cushion for the rear seat, 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.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 103: Identifying Central Arm Rest


Courtesy of VOLVO CARS CORPORATION

 Fold the central arm rest forward.


 Remove the central arm rest by grasping each end and pulling upwards until it releases at the rear edge
from the backrest's lugs (1) .
 Then pull forwards until the holders (2) on the sides of the backrest have slid out of the corresponding
cut-out (3) in the central arm rest.

APPLIES TO ALL VEHICLES

Fig. 104: View Of Routed Cable Harness


Courtesy of VOLVO CARS CORPORATION

 Route the cable harness further back and under the seat support and backwards and into the cargo
compartment, along the existing cable harnesses.
 Position the cable harness so that it does not get trapped or damaged.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

PARKING ASSISTANCE, REAR


PARKING ASSISTANCE, REAR

Fig. 105: Identifying Front Parking Assistance Sensor


Courtesy of VOLVO CARS CORPORATION

Fig. 106: Cleaning Sensors


Courtesy of VOLVO CARS CORPORATION

 Clean the sensors. Use: Isopropanol


 Allow to dry.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 107: Matting Surface Down


Courtesy of VOLVO CARS CORPORATION

 Carefully mat down the surface. Use Glasspaper, grade P1000.

Fig. 108: Cleaning Sensors


Courtesy of VOLVO CARS CORPORATION

 Clean the sensors again. Use: Isopropanol.


 Allow to dry.
 Avoid contact with the cleaned surfaces.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 109: View Of Painting Sensors


Courtesy of VOLVO CARS CORPORATION

CAUTION: Protect the connections' contact surfaces against paint.

 Paint the sensors in the same color code as the vehicle.


 Use Volvo Touch-up paint. (Only use base coat.)
 use Volvo 2-K Varnish. P/N: 31335447 .

NOTE: Also read the instructions on the spray can.

Fig. 110: Installing Rear Parking Assistance Sensor Bezel


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

CAUTION: The paint must have dried after the first application.

Fig. 111: Identifying Ignition Switch Turned To Position 0


Courtesy of VOLVO CARS CORPORATION

 Turn the ignition key to position 0.

NOTE: Wait at least three minutes before unplugging the connectors or removing
other electrical equipment.

Fig. 112: Identifying Screws On Rear Bumper Cover End


Courtesy of VOLVO CARS CORPORATION

 Remove the 3 x screws on the rear bumper cover's end.


 Repeat the operation on the other side.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 113: Identifying Lower Bumper Cover Screws


Courtesy of VOLVO CARS CORPORATION

 Remove the 2 x screws on the underneath of the bumper cover.

Fig. 114: Removing Tailgate Stops


Courtesy of VOLVO CARS CORPORATION

 Remove the tailgate's 2 x stops by turning them a quarter turn and pulling straight up.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 115: Applying Piece Of Tape To Wing Edge


Courtesy of VOLVO CARS CORPORATION

 Apply a piece of tape to the wing edge on the right and left-hand side to protect the edge when the corner
of the bumper cover is removed.

Fig. 116: Removing Rear Bumper Cover From Body


Courtesy of VOLVO CARS CORPORATION

 Remove the bumper cover from the body by carefully prying off the ends using a weatherstrip tool.
 Pull the cover from the tail lamp and rear edge of the wing on each side. It is secured by four catches at
the tail lamp and four at the rear edge of the rear wing.
 Pull the bumper cover straight back.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 117: Identifying License Plate Lighting Connector


Courtesy of VOLVO CARS CORPORATION

 Disconnect the connector for the license plate lighting on the left-hand side.
 Place the bumper cover on a protective surface.
 Remove the pieces of tape.

Fig. 118: Locating Markings On Inside Of Bumper Cover


Courtesy of VOLVO CARS CORPORATION

 Locate the 4 x markings on the inside of the bumper cover.


 Mark center with a scribe.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 119: Drilling Holes In Centers Of Markings


Courtesy of VOLVO CARS CORPORATION

 Drill holes in the centers of the markings using a Ø 3 mm (7/64) diameter drill bit.
 Drill out the holes. Use a Ø10 mm (25/64") diameter drill bit.

Fig. 120: Identifying Special Tool P/N 9997234


Courtesy of VOLVO CARS CORPORATION

 Enlarge the holes in the bumper cover using hole tool P/N 9997234 . Place the hole tool's support sleeve
on the inside, and the cutting component on the outside of the bumper cover.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 121: Cleaning Inside Of Bumper Cover And Applying Activator


Courtesy of VOLVO CARS CORPORATION

 Clean the inside of the bumper cover using a mild soap solution.
 Clean around the holes and the markings using isopropanol.
 Allow to dry.
 Apply a thin layer of activator, part no. 8637076 , to the cleaned surfaces and let dry for approx. 10 min.

Fig. 122: Identifying Holder


Courtesy of VOLVO CARS CORPORATION

 Take the 4 holders from the kit.


 Clean the surfaces as shown in the illustration using isopropanol.
 Allow to dry.
 Apply a thin and even layer of activator part no. 8637076 , on the cleaned surfaces and let dry for at least
10 min.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 123: Identifying Rear Seat Cushion


Courtesy of VOLVO CARS CORPORATION

 Pull off the seat cushion for the rear seat, 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. 124: Identifying Central Arm Rest


Courtesy of VOLVO CARS CORPORATION

 Fold the central arm rest forward.


 Remove the central arm rest by grasping each end and pulling upwards until it releases at the rear edge
from the backrest's lugs (1).
 Then pull forwards until the holders (2) on the sides of the backrest have slid out of the corresponding
cut-out (3) in the central arm rest.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 125: Identifying Backrest Cover


Courtesy of VOLVO CARS CORPORATION

 Fold the backrest forward.


 Remove the cover for the backrest's right-hand mounting.

Fig. 126: Identifying Locking Sleeve And Screw


Courtesy of VOLVO CARS CORPORATION

 Remove the screw and the locking sleeve.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 127: View Of Backrest Stowed


Courtesy of VOLVO CARS CORPORATION

 Fold the backrest away from the right-hand mounting.


 Pull it out from the mounting at the arm rest and remove it.

Fig. 128: Identifying Rubber Door Molding RH


Courtesy of VOLVO CARS CORPORATION

 Pull off the rubber molding at the rear edge of the right-hand door opening.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 129: Identifying B Pillar Panel


Courtesy of VOLVO CARS CORPORATION

 Detach the B pillar panel at the rear edge by prying the sides using a weatherstrip tool until the 2 x clips
release

Fig. 130: View Of Safety Clip Strap


Courtesy of VOLVO CARS CORPORATION

 Unhook the safety clip from the panel.


 Angle out the panel at the lower edge, and then unhook it at the upper edge so that the upper clip releases.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 131: Identifying Rear Seat RH Panel


Courtesy of VOLVO CARS CORPORATION

 Remove the screw from the right-hand panel in the rear seat.
 Carefully pull off the panel from the body side. It is secured by ten clips on the inside.
 Unhook it from the sill at the front edge.

Fig. 132: Identifying Trunk Floor Cover


Courtesy of VOLVO CARS CORPORATION

 Lift up the floor hatch at the rear edge.


 Pull it backwards so that it detaches at the front edge.
 Turn the cover and lift out.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 133: Identifying Tailgate's Sill Panel


Courtesy of VOLVO CARS CORPORATION

 Remove the tailgate's sill panel by pulling it up until the four clips on the upper side and the catches at the
lower edge release.

Fig. 134: Identifying Right-Hand Rear Side Panel


Courtesy of VOLVO CARS CORPORATION

 Remove the clips at the rear edge of the right-hand rear side panel.
 Carefully pull the side panel off, starting at the front edge/upper edge and then straight back until all clips
at the top edge have released.
 Fold the panel inwards. Release it from the anchorage eyelets and lift it out of the load floor support.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 135: View Of Spare Wheel, Jack And Other Parts From Storage Compartment
Courtesy of VOLVO CARS CORPORATION

 Lift out the spare wheel, jack and other parts from the storage compartment in the cargo floor support.

Fig. 136: Identifying Spare Wheel Compartment Screws


Courtesy of VOLVO CARS CORPORATION

 Remove the 4 x screw clips in the cargo floor support.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 137: Installing Tape On Holders


Courtesy of VOLVO CARS CORPORATION

 Remove the protective film from one side of the double-backed tape.
 Secure the tape on the holder.

Fig. 138: Installing Centering Tool In Holder


Courtesy of VOLVO CARS CORPORATION

 Remove the remaining protective film.


 Install the centering tool in the holder as shown in the illustration.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 139: Mounting Holders In Bumper Cover


Courtesy of VOLVO CARS CORPORATION

 Press in the cradle on the bumper cover.

NOTE: The holders must be mounted turned against the holes as shown in the
illustration. The holders must also be horizontal and in line with the bumper
cover.

 Repeat the steps for the other holders.

Fig. 140: Connect Cable Harness Connectors To Sensors


Courtesy of VOLVO CARS CORPORATION

 Connect the cable harness connectors to the sensors.


 Install the sensors in their holders.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

NOTE: The large grey connector must be on the right-hand side.

Fig. 141: Securing Cable Harness


Courtesy of VOLVO CARS CORPORATION

 Press the cable harness holder onto the flanges of the bumper cover.

Fig. 142: Identifying Rubber Seal Below Right-Hand Tailgate Stop


Courtesy of VOLVO CARS CORPORATION

 Remove the rubber seal that is below the right-hand tailgate stop.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 143: Pulling Cable Through Hole In Cargo Compartment


Courtesy of VOLVO CARS CORPORATION

 Take the cable harness with the rubber grommet from the kit.
 Pull the cable harness through the hole in the cargo compartment.
 Place the rubber grommet in position.
 Press the connector on the plastic bracket.

Fig. 144: Identifying Control Module And Holder


Courtesy of VOLVO CARS CORPORATION

 Take the control module and holder from the kit.


 Press the holder onto the reverse of the control module.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 145: Connecting Pre-Routed Cable Harness Connector To Control Module


Courtesy of VOLVO CARS CORPORATION

 Connect the pre-routed cable harness connector to the control module.

NOTE: Ensure that the connector's catches click and are properly secured.

Fig. 146: Lifting Right-Hand Side Cargo Floor Support


Courtesy of VOLVO CARS CORPORATION

 Raise the right-hand side cargo floor support.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 147: Identifying Green 5 Pin Connector


Courtesy of VOLVO CARS CORPORATION

 Locate the green 5 pin connector that is taped to the ordinary cable harness on the vehicle.
 Remove the tape and connect the connector to the control module's cable harness.

Fig. 148: Pressing Control Module Onto Floor Studs With Connections Facing Forward In Vehicle
Courtesy of VOLVO CARS CORPORATION

 Locate the 2 studs on the floor.


 Press the control module onto these with the connections facing forward in the vehicle.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 149: Securing Cable Harness Using Tie Straps


Courtesy of VOLVO CARS CORPORATION

 Secure the cable harness using 3 x tie straps.

Fig. 150: Identifying Trailer Module Connector And Ground Lead


Courtesy of VOLVO CARS CORPORATION

Applies to vehicles with tow bar wiring.

 Detach the towbar wiring connector from the Trailer Module (TRM).
 Disconnect the ground lead.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 151: Identifying Secondary Lock


Courtesy of VOLVO CARS CORPORATION

 Release the terminal locking by pressing the catch down and pulling the locking straight out.

Fig. 152: View Of Cable Lug From Connector


Courtesy of VOLVO CARS CORPORATION

Applies to vehicles with tow bar wiring.

 Disconnect all terminals from the connector.

NOTE: Note the location of the cables in the connector.

 Use special tool 9512810 or 9512632.


 Insert the tool in the connector and release the locking.
 Pull out the cable with terminal.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

 Pull out the cable harness through the rubber grommet.


 Remove the rubber grommet, it shall not be re-used.

Fig. 153: Identifying Rubber Spout And Tow Bar Wiring


Courtesy of VOLVO CARS CORPORATION

Applies to vehicles with tow bar wiring.

 Cut off the free rubber spout (1) on the rubber grommet of the PAS wiring.
 Thread the tow bar wiring through. Lubricate the tow hitch wiring using Volvo's low temperature grease
and thread the tow bar wiring (2) through.
 Connect the terminals to the connector.
 Secure the locking and connect to the trailer module (TRM).

Fig. 154: Identifying Connectors And Wiring


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

 The existing 5 pin green connector is connected to the trailer module (TRM) (1).
 Detach the connector to the control module and connect it to the PAS wiring (2).
 Disconnect the 5 pin green connector (3) that is taped to the wiring and connect it to the trailer module
(TRM).

Fig. 155: Connecting Parking Assistance Connector And License Plate Lighting Connector And Re-
Installing Bumper Cover
Courtesy of VOLVO CARS CORPORATION

 Raise the bumper cover to the car.


 Connect the connectors for parking assistance and license plate lighting.
 Reinstall the bumper cover with its screws.
 Reinstall the stops for the tailgate.

Fig. 156: Identifying Panel Screw


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Reinstall in the cargo compartment:

 side panel
 clips for the cargo floor support
 sill molding
 sill trim panel
 applicable spare wheel
 jack and other parts in the cargo floor support
 the floor hatch

Fig. 157: Locating Ten Panel Clips


Courtesy of VOLVO CARS CORPORATION

NOTE: There are 10 clips on the reverse of the panel that must engage in the body.
Take care when aligning so that the clips do not break. Broken clips must be
replaced with new ones.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 158: Identifying Panel Clips And Screws


Courtesy of VOLVO CARS CORPORATION

 Reinstall the side panel by first aligning it on the sill at the front edge and then pressing it against the
body side, ensure that all clips engage.
 Tighten the panel using existing screws.

Fig. 159: View Of B Pillar Panel Clips


Courtesy of VOLVO CARS CORPORATION

 Reinstall the panel with the safety clip.


 Reinstall the weatherstrip.

Reinstall:

 backrest - tighten the screw to 15 Nm (11 lbf. ft) .


 the armrest
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

 cushion

Fig. 160: Identifying VIDA (Volvo Scan Tool) To Program Software


Courtesy of VOLVO CARS CORPORATION

 Download software (application) for the accessory's function using VIDA (Volvo scan tool).

PARKING ASSISTANCE, REAR, CHASSIS NUMBER 190000- (2010-2012)


PARKING ASSISTANCE, REAR, CHASSIS NUMBER 190000-

Fig. 161: Identifying Rear Parking Assistance Sensor


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 162: Parking Assistance Sensor Cleaning


Courtesy of VOLVO CARS CORPORATION

 Clean the sensors. Use: Isopropanol.


 Allow to dry.

Fig. 163: Identifying Glasspaper


Courtesy of VOLVO CARS CORPORATION

 Carefully mat down the surface. Use Glasspaper, grade P1000.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 164: Parking Assistance Sensor Cleaning


Courtesy of VOLVO CARS CORPORATION

 Clean the sensors again. Use: Isopropanol.


 Allow to dry.
 Avoid contact with the cleaned surfaces.

Fig. 165: Cleaning Cradles Using Isopropanol


Courtesy of VOLVO CARS CORPORATION

 Clean the cradles. Use: Isopropanol.


 Allow to dry.
 Avoid contact with the cleaned surfaces.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 166: Applying Bonding Primer P/N 31335448 To Cleaned Surface


Courtesy of VOLVO CARS CORPORATION

 Apply primer to the cleaned surface. Use: Bonding primer for plastic. P/N: 31335448 .

CAUTION: Allow to dry at a temperature of at least +20°C for 10 min, before


painting.

NOTE: Also read the instructions on the spray can.

Fig. 167: Protect Electrical Connectors


Courtesy of VOLVO CARS CORPORATION

CAUTION: protect the connections' contact surface against paint.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

 Paint the sensors in the same color code as the vehicle.


 use Volvo Touch-up paint. (Only use base coat.)
 Use: Volvo 2-K Varnish. P/N: 31335447 .

NOTE: Also read the instructions on the spray can.

Fig. 168: Applying Bonding Primer P/N 31335448 To Cleaned Surface


Courtesy of VOLVO CARS CORPORATION

 Paint the holders in the same color code as the vehicle.


 Use Volvo Touch-up paint (Only use base coat.)
 Use: Volvo 2-K Varnish. P/N: 31335447 .

NOTE: Also read the instructions on the spray can.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 169: Installing Sensor Bezel


Courtesy of VOLVO CARS CORPORATION

CAUTION: The paint must have dried after the first application.

Fig. 170: Installing Rear Parking Assistance Sensors


Courtesy of VOLVO CARS CORPORATION

Fig. 171: Identifying Fender Liner Screws


Courtesy of VOLVO CARS CORPORATION

 Applies to both discs.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 172: Identifying Underside Screws


Courtesy of VOLVO CARS CORPORATION

Fig. 173: Identifying Area For Applying Tape


Courtesy of VOLVO CARS CORPORATION

 Applies to both sides.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 174: Prying Edge Of Rear Bumper Cover


Courtesy of VOLVO CARS CORPORATION

 Applies to both sides.

Fig. 175: Removing Rear Bumper Cover


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 176: Removing Connector


Courtesy of VOLVO CARS CORPORATION

Fig. 177: Locating Markings Inside Bumper Cover


Courtesy of VOLVO CARS CORPORATION

 Locate the 4 markings on the inside of the bumper cover.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 178: Marking Centers With Scribe


Courtesy of VOLVO CARS CORPORATION

 Mark center with a scribe.

Fig. 179: Drilling Through Centers


Courtesy of VOLVO CARS CORPORATION

1. Ø 3 mm (7/64")
2. Ø 10 mm (25/64")
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 180: Identifying Special Tool P/N 9997234


Courtesy of VOLVO CARS CORPORATION

 Use special tool: P/N 9997234

NOTE: The hole tool's support sleeve must be on the inside, and the cutting part
on the outside of the bumper casing.

Fig. 181: Identifying Special Tool P/N 9997392


Courtesy of VOLVO CARS CORPORATION

 Use special tool: P/N 9997392 Hole tool

NOTE: The hole tool's support sleeve must be on the inside, and the cutting part
on the outside of the bumper casing.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 182: Cleaning Surfaces Using Isopropanol (1 Of 3)


Courtesy of VOLVO CARS CORPORATION

 Clean the surfaces. Allow to dry.

Use: Isopropanol

Fig. 183: Cleaning Surfaces Using Isopropanol (2 Of 3)


Courtesy of VOLVO CARS CORPORATION

 Clean the surfaces. Allow to dry.

Use: Isopropanol
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 184: Cleaning Surfaces Using Isopropanol (3 Of 3)


Courtesy of VOLVO CARS CORPORATION

 Clean the surfaces. Allow to dry.

Use: Isopropanol

Fig. 185: Applying Activator P/N 8637076 (1 Of 3)


Courtesy of VOLVO CARS CORPORATION

 Apply a thin and even layer of activator. Allow to dry for at least 10 minutes.

Use:P/N 8637076 Activator


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 186: Applying Activator P/N 8637076 (2 Of 3)


Courtesy of VOLVO CARS CORPORATION

 Apply a thin and even layer of activator. Allow to dry for at least 10 minutes.

Use:P/N 8637076 Activator

Fig. 187: Applying Activator P/N 8637076 (3 Of 3)


Courtesy of VOLVO CARS CORPORATION

 Apply a thin and even layer of activator. Allow to dry for at least 10 minutes.

Use: P/N 8637076 Activator.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 188: Identifying Rear Seat Cushion


Courtesy of VOLVO CARS CORPORATION

 Pull off the seat cushion for the rear seat, first at the front edge where it is secured by two cradles. Then at
the rear edge where it is secured by one cradle.
 Remove the seat cushion.

Fig. 189: Identifying Central Arm Rest


Courtesy of VOLVO CARS CORPORATION

 Fold the central arm rest forward.


 Remove the central arm rest by grasping each end and pulling upwards until it releases at the rear edge
from the backrest's lugs (1).
 Then pull forwards until the holders (2) on the sides of the backrest have slid out of the corresponding
cut-out (3) in the central arm rest.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 190: Identifying Backrest Cover


Courtesy of VOLVO CARS CORPORATION

 Fold the backrest forward.


 Remove the cover for the backrest's right-hand mounting.

Fig. 191: Identifying Locking Sleeve And Screw


Courtesy of VOLVO CARS CORPORATION

 Remove the screw and the locking sleeve.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 192: View Of Backrest Stowed


Courtesy of VOLVO CARS CORPORATION

 Fold out the backrest from the right mounting. Pull the backrest out from the mounting at the armrest and
remove it.

NOTE: The backrest may be securely attached.

Fig. 193: Identifying Rubber Door Molding RH


Courtesy of VOLVO CARS CORPORATION

 Pull off the rubber molding at the rear edge of the right-hand door opening.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 194: Identifying B Pillar Panel


Courtesy of VOLVO CARS CORPORATION

 Detach the B pillar panel at the lower edge by prying the sides using a weatherstrip tool until the 2 x clips
release

Fig. 195: View Of Safety Clip Strap


Courtesy of VOLVO CARS CORPORATION

 Unhook the safety clip from the panel.


 Angle out the panel at the lower edge, and then unhook it at the upper edge so that the upper clip releases.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 196: Identifying Rear Seat RH Panel


Courtesy of VOLVO CARS CORPORATION

 Remove the screw from the right-hand panel in the rear seat.
 Carefully pull off the panel from the body side. It is secured by 11 clips on the inside.
 Unhook it from the sill at the front edge.

Fig. 197: Identifying Trunk Floor Cover


Courtesy of VOLVO CARS CORPORATION

 Lift up the floor hatch at the rear edge.


 Pull it backwards so that it detaches at the front edge.
 Turn the cover and lift out.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 198: Identifying Tailgate's Sill Panel


Courtesy of VOLVO CARS CORPORATION

 Remove the tailgate's sill panel by pulling it up until the 4 clips on the upper side and the catches at the
lower edge release.

Fig. 199: Identifying Right-Hand Rear Side Panel


Courtesy of VOLVO CARS CORPORATION

 Remove the clips at the rear edge of the right-hand rear side panel.
 Carefully pull the side panel off, starting at the front edge/upper edge and then straight back until all clips
at the top edge have released.
 Fold the panel inwards. Release it from the anchorage eyelets and lift it out of the load floor support.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 200: View Of Spare Wheel, Jack And Other Parts From Storage Compartment
Courtesy of VOLVO CARS CORPORATION

 Lift out the spare wheel, jack and other parts from the storage compartment in the cargo floor support.

Fig. 201: Identifying Spare Wheel Compartment Screws


Courtesy of VOLVO CARS CORPORATION

 Remove the 4 screw clips from the cargo floor support.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 202: Installing Cradle


Courtesy of VOLVO CARS CORPORATION

NOTE: Prepare and install one cradle at a time.

Fig. 203: Applying Tape P/N 1161347


Courtesy of VOLVO CARS CORPORATION

 Use: 1161347 Tape.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 204: Peeling Backing From Tape


Courtesy of VOLVO CARS CORPORATION

Fig. 205: Applying Adhesive


Courtesy of VOLVO CARS CORPORATION

 Apply a thin layer and even layer of adhesive.

CAUTION: The adhesive must not come into contact with the tape.

Use special tool P/N 9512767 Adhesive gun

 Use P/N 116173 Mixing pipe


 Use P/N 9511027 Adhesive
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 206: Locating Cradles


Courtesy of VOLVO CARS CORPORATION

 Note the location of the cradles.

Fig. 207: Press Holder Towards Casing (1 Of 2)


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 208: Press Holder Towards Casing (2 Of 2)


Courtesy of VOLVO CARS CORPORATION

 Press the holder towards the casing, but only at the places where there is tape.

Fig. 209: Removing Centering Tool From Cradle


Courtesy of VOLVO CARS CORPORATION

 Hold the cradle securely when removing the centering tool.


 Repeat the method steps on the other cradle.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 210: Applying Tape P/N 1161347


Courtesy of VOLVO CARS CORPORATION

 Use: 1161347 Tape.

Fig. 211: Peeling Backing From Tape


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 212: Applying Adhesive


Courtesy of VOLVO CARS CORPORATION

 Apply a thin layer and even layer of adhesive.

CAUTION: The adhesive must not come into contact with the tape.

 Use special tool P/N 9512767 Adhesive gun


 Use P/N 116173 Mixing pipe
 Use P/N 9511027 Adhesive

Fig. 213: Locating Cradles


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 214: Installing Cradle (1 Of 2)


Courtesy of VOLVO CARS CORPORATION

Fig. 215: Installing Cradle (2 Of 2)


Courtesy of VOLVO CARS CORPORATION

 Press the holder towards the casing, but only at the places where there is tape.
 Repeat the method steps on the other cradle.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 216: Pressing Cable Harness Clips Into Flanges Of Bumper Cover
Courtesy of VOLVO CARS CORPORATION

 Press the cable harness clips onto the flanges of the bumper cover.

Fig. 217: Identifying Sensor Connector


Courtesy of VOLVO CARS CORPORATION

 Connect the two painted sensors to the two outer connections.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 218: Installing Sensor To Cradle


Courtesy of VOLVO CARS CORPORATION

Fig. 219: Identifying Rubber Seal Below Right-Hand Tailgate Stop


Courtesy of VOLVO CARS CORPORATION

 Remove the rubber seal that is below the right-hand tailgate stop.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 220: Pulling Cable Through Hole In Cargo Compartment


Courtesy of VOLVO CARS CORPORATION

 Take the cable harness with the rubber grommet from the kit.
 Pull the cable harness through the hole in the cargo compartment.
 Place the rubber grommet in position.
 Press the connector on the plastic bracket.

Fig. 221: Identifying Control Module And Holder


Courtesy of VOLVO CARS CORPORATION

 Take the control module and holder from the kit.


 Press the holder onto the reverse of the control module.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 222: Connecting Pre-Routed Cable Harness Connector To Control Module


Courtesy of VOLVO CARS CORPORATION

 Connect the pre-routed cable harness connector to the control module.

NOTE: Ensure that the connector's catches click and are properly secured.

Fig. 223: Lifting Right-Hand Side Cargo Floor Support


Courtesy of VOLVO CARS CORPORATION

 Raise the right-hand side cargo floor support.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 224: Identifying Green 5 Pin Connector


Courtesy of VOLVO CARS CORPORATION

 Locate the green 5 pin connector that is taped to the ordinary cable harness on the vehicle.
 Remove the tape and connect the connector to the control module's cable harness.

Fig. 225: Pressing Control Module Onto Floor Studs With Connections Facing Forward In Vehicle
Courtesy of VOLVO CARS CORPORATION

 Locate the 2 studs on the floor.


 Press the control module onto these with the connections facing forwards in the vehicle.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 226: Securing Cable Harness Using Tie Straps


Courtesy of VOLVO CARS CORPORATION

 Secure the cable harness using 3 x tie straps.

Fig. 227: Identifying Secondary Lock


Courtesy of VOLVO CARS CORPORATION

Applies to vehicles with tow bar wiring.

 Detach the towbar wiring connector from the Trailer Module (TRM).
 Release the terminal locking by pressing the catch down and pulling the locking straight out.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 228: View Of Cable Lug From Connector


Courtesy of VOLVO CARS CORPORATION

Applies to vehicles with tow bar wiring.

 Disconnect all terminals from the connector.

NOTE: Note the location of the cables in the connector.

 Use special tool P/N 9512810 or P/N 9512632 .


 Insert the tool in the connector and release the locking.
 Pull out the cable with terminal.
 Pull out the cable harness through the rubber grommet.
 Remove the rubber grommet, it shall not be re-used.

Fig. 229: Identifying Rubber Spout And Tow Bar Wiring


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Applies to vehicles with tow bar wiring.

 Cut off the free rubber spout (1) on the rubber grommet of the PAS wiring.
 Lubricate the tow hitch wiring using Volvo's low temperature grease and thread the tow bar wiring (2)
through.
 Connect the terminals to the connector.
 Secure the locking and connect to the trailer module (TRM).

Fig. 230: Identifying Connectors And Wiring


Courtesy of VOLVO CARS CORPORATION

Applies to vehicles with tow bar wiring.

 The existing 5 pin green connector is connected to the trailer module (TRM) (1).
 Disconnect the connector for the control module and connect it to the cable harness of parking assistance
(2).
 Disconnect the 5 pin green connector (3) that is taped to the cable harness and connect it to the trailer
module (TRM).
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 231: Connecting Parking Assistance Connector And License Plate Lighting Connector And Re-
Installing Bumper Cover
Courtesy of VOLVO CARS CORPORATION

Applies to all models

 Raise the bumper cover to the car.


 Connect the connectors for parking assistance and license plate lighting.
 Reinstall the bumper cover with its screws.
 Reinstall the stops for the tailgate.

Fig. 232: Identifying Panel Screw


Courtesy of VOLVO CARS CORPORATION

Reinstall in the cargo compartment:

 side panel
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

 clips for the cargo floor support


 sill molding
 sill trim panel
 applicable spare wheel
 jack and other parts in the cargo floor support
 the floor hatch

Fig. 233: Locating Ten Panel Clips


Courtesy of VOLVO CARS CORPORATION

NOTE: There are 10 clips on the reverse of the panel that must engage in the
body. Take care when aligning so that the clips do not break. Broken clips
must be replaced with new ones.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 234: Identifying Panel Clips And Screws


Courtesy of VOLVO CARS CORPORATION

 Reinstall the side panel by first aligning it on the sill at the front edge and then pressing it against the
body side, ensure that all clips engage.
 Tighten the panel using existing screws.

Fig. 235: View Of B Pillar Panel Clips


Courtesy of VOLVO CARS CORPORATION

Reinstall:

 the panel with the safety clip and sill molding.


 backrest, tighten the screw to 15 Nm (11 lbf. ft) .
 the armrest
 cushion
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 236: Identifying VIDA (Volvo Scan Tool) To Program Software


Courtesy of VOLVO CARS CORPORATION

 Download software (application) for the accessory's function using VIDA (Volvo scan tool).

PARKING ASSISTANCE, REAR, START/STOP (2010-2012)


PARKING ASSISTANCE, REAR, START/STOP

NOTE: There may be components in the accessories kit that are not used for this
installation.

Fig. 237: Identifying Front Parking Assistance Sensor


Courtesy of VOLVO CARS CORPORATION

Fig. 238: Cleaning Sensors


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Courtesy of VOLVO CARS CORPORATION

 Clean the sensors. Use: Isopropanol.


 Allow to dry.

Fig. 239: Matting Surface Down


Courtesy of VOLVO CARS CORPORATION

 Carefully mat down the surface. Use Glasspaper, grade P1000.

Fig. 240: Cleaning Sensors


Courtesy of VOLVO CARS CORPORATION

 Clean the sensors again. Use: Isopropanol.


 Allow to dry.
 Avoid contact with the cleaned surfaces.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 241: Cleaning Cradles Using Isopropanol


Courtesy of VOLVO CARS CORPORATION

 Clean the cradles. Use: Isopropanol.


 Allow to dry.
 Avoid contact with the cleaned surfaces.

Fig. 242: Applying Bonding Primer P/N 31335448 To Cleaned Surface


Courtesy of VOLVO CARS CORPORATION

 Apply primer to the cleaned surface. Use: Bonding primer for plastic. P/N: 31335448.

CAUTION: Allow to dry at a temperature of at least +20°C for 10 min, before


painting.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

NOTE: Also read the instructions on the spray can.

Fig. 243: Protect Electrical Connectors


Courtesy of VOLVO CARS CORPORATION

CAUTION: Protect the connections' contact surfaces against paint.

 Paint the sensors in color code 426 .


 Use Volvo Touch-up paint. (Only use base coat.)
 Use: Volvo 2-K Varnish. P/N: 31335447.

NOTE: Also read the instructions on the spray can.

Fig. 244: Protect Electrical Connectors


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Courtesy of VOLVO CARS CORPORATION

CAUTION: Protect the connections' contact surfaces against paint.

 Paint the sensors in the same color code as the vehicle.


 Use Volvo Touch-up paint. (Only use base coat.)
 Use: Volvo 2-K Varnish. P/N: 31335447.

NOTE: Also read the instructions on the spray can.

Fig. 245: Applying Bonding Primer P/N 31335448 To Cleaned Surface


Courtesy of VOLVO CARS CORPORATION

 Paint the holders in the same color code as the vehicle.


 Use Volvo Touch-up paint. (Only use base coat.)
 Use: Volvo 2-K Varnish. P/N: 31335447.

NOTE: Also read the instructions on the spray can.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 246: Installing Rear Parking Assistance Sensor Bezel


Courtesy of VOLVO CARS CORPORATION

CAUTION: The paint must have dried after the first application.

Fig. 247: Installing Rear Parking Assistance Sensors


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 248: Identifying Fender Liner Screws


Courtesy of VOLVO CARS CORPORATION

 Carry out on both sides.

Fig. 249: Identifying Underside Screws


Courtesy of VOLVO CARS CORPORATION

 Remove the screws.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 250: Identifying Area For Applying Tape


Courtesy of VOLVO CARS CORPORATION

 Carry out on both sides.

Fig. 251: Prying Edge Of Rear Bumper Cover


Courtesy of VOLVO CARS CORPORATION

 Carry out on both sides.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 252: Removing Rear Bumper Cover


Courtesy of VOLVO CARS CORPORATION

Fig. 253: Removing Connector


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 254: Locating Markings On Inside Of Bumper Cover (1 Of 2)


Courtesy of VOLVO CARS CORPORATION

 Locate the 2 x markings on the inside of the bumper cover.

Fig. 255: Locating Markings On Inside Of Bumper Cover (2 Of 2)


Courtesy of VOLVO CARS CORPORATION

 Locate the 2 markings on the inside of the bumper cover.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 256: Marking Centers With Scribe


Courtesy of VOLVO CARS CORPORATION

 Mark center with a scribe.

Fig. 257: Drilling Through Centers


Courtesy of VOLVO CARS CORPORATION

1. Ø 3 mm (7/64")
2. Ø 10 mm (25/64")
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 258: Identifying Special Tool P/N 9997234


Courtesy of VOLVO CARS CORPORATION

 Use special tool: P/N 9997234

NOTE: The hole tool's support sleeve must be on the inside, and the cutting part
on the outside of the bumper casing.

Fig. 259: Identifying Special Tool P/N 9997392


Courtesy of VOLVO CARS CORPORATION

 Use special tool:P/N 9997392 Hole tool

NOTE: The hole tool's support sleeve must be on the inside, and the cutting part
on the outside of the bumper casing.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 260: Cleaning Surfaces Using Isopropanol (1 Of 3)


Courtesy of VOLVO CARS CORPORATION

 Clean the surfaces. Allow to dry.

Use:Isopropanol

Fig. 261: Cleaning Surfaces Using Isopropanol (2 Of 3)


Courtesy of VOLVO CARS CORPORATION

 Clean the surfaces. Allow to dry.

Use: Isopropanol
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 262: Cleaning Surfaces Using Isopropanol (3 Of 3)


Courtesy of VOLVO CARS CORPORATION

 Clean the surfaces. Allow to dry.

Use:Isopropanol

Fig. 263: Applying Activator P/N 8637076


Courtesy of VOLVO CARS CORPORATION

 Apply a thin and even layer of activator. Allow to dry for at least 10 minutes.

Use: P/N 8637076 Activator


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 264: Applying Activator P/N 8637076 (1 Of 3)


Courtesy of VOLVO CARS CORPORATION

 Apply a thin and even layer of activator. Allow to dry for at least 10 minutes.

Use: P/N 8637076 Activator

Fig. 265: Applying Activator P/N 8637076 (2 Of 3)


Courtesy of VOLVO CARS CORPORATION

 Apply a thin and even layer of activator. Allow to dry for at least 10 minutes.

Use: P/N 8637076 Activator .


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 266: Applying Activator P/N 8637076 (3 Of 3)


Courtesy of VOLVO CARS CORPORATION

 Apply a thin and even layer of activator. Allow to dry for at least 10 minutes.

Use: P/N 8637076 Activator .

Fig. 267: Identifying Rear Seat Cushion


Courtesy of VOLVO CARS CORPORATION

 Pull off the seat cushion for the rear seat, first at the front edge where it is secured by two cradles. Then at
the rear edge where it is secured by one cradle.
 Remove the seat cushion.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 268: Identifying Central Arm Rest


Courtesy of VOLVO CARS CORPORATION

 Fold the central arm rest forward.


 Remove the central arm rest by grasping each end and pulling upwards until it releases at the rear edge
from the backrest's lugs (1).
 Then pull forwards until the holders (2) on the sides of the backrest have slid out of the corresponding
cut-out (3) in the central arm rest.

Fig. 269: Identifying Backrest Cover


Courtesy of VOLVO CARS CORPORATION

 Fold the backrest forward.


 Remove the cover for the backrest's right-hand mounting.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 270: Identifying Locking Sleeve And Screw


Courtesy of VOLVO CARS CORPORATION

 Remove the screw and the locking sleeve.

Fig. 271: View Of Backrest Stowed


Courtesy of VOLVO CARS CORPORATION

 Fold out the backrest from the right mounting. Pull the backrest out from the mounting at the armrest and
remove it.

NOTE: The backrest may be securely attached.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 272: Identifying Rubber Door Molding RH


Courtesy of VOLVO CARS CORPORATION

 Pull off the rubber molding at the rear edge of the right-hand door opening.

Fig. 273: Identifying B Pillar Panel


Courtesy of VOLVO CARS CORPORATION

 Detach the B pillar panel at the lower edge by prying the sides using a weatherstrip tool until the 2 x clips
release
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 274: View Of Safety Clip Strap


Courtesy of VOLVO CARS CORPORATION

 Unhook the safety clip from the panel.


 Angle out the panel at the lower edge, and then unhook it at the upper edge so that the upper clip releases.

Fig. 275: Identifying Rear Seat RH Panel


Courtesy of VOLVO CARS CORPORATION

 Remove the screw from the right-hand panel in the rear seat.
 Carefully pull off the panel from the body side. It is secured by 11 clips on the inside.
 Unhook it from the sill at the front edge.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 276: Identifying Trunk Floor Cover


Courtesy of VOLVO CARS CORPORATION

 Lift up the floor hatch at the rear edge.


 Pull it backwards so that it detaches at the front edge.
 Turn the cover and lift out.

Fig. 277: Identifying Tailgate's Sill Panel


Courtesy of VOLVO CARS CORPORATION

 Remove the tailgate's sill panel by pulling it up until the 4 clips on the upper side and the catches at the
lower edge release.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 278: Identifying Right-Hand Rear Side Panel


Courtesy of VOLVO CARS CORPORATION

 Remove the clips at the rear edge of the right-hand rear side panel.
 Carefully pull the side panel off, starting at the front edge/upper edge and then straight back until all clips
at the top edge have released.
 Fold the panel inwards. Release it from the anchorage eyelets and lift it out of the load floor support.

Fig. 279: View Of Spare Wheel, Jack And Other Parts From Storage Compartment
Courtesy of VOLVO CARS CORPORATION

 Lift out the spare wheel, jack and other parts from the storage compartment in the cargo floor support.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 280: Identifying Spare Wheel Compartment Screws


Courtesy of VOLVO CARS CORPORATION

 Remove the 4 screw clips from the cargo floor support.

Fig. 281: Peeling Backing From Tape


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 282: Installing Tape


Courtesy of VOLVO CARS CORPORATION

Fig. 283: Identifying Cutting Dimensions (1 Of 2)


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 284: Identifying Cutting Dimensions (2 Of 2)


Courtesy of VOLVO CARS CORPORATION

Fig. 285: Installing Cradle


Courtesy of VOLVO CARS CORPORATION

NOTE: Prepare and install one cradle at a time.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 286: Peeling Backing From Tape


Courtesy of VOLVO CARS CORPORATION

Fig. 287: Locating Cradles


Courtesy of VOLVO CARS CORPORATION

 Note the location of the cradles.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 288: Installing Cradle (1 Of 2)


Courtesy of VOLVO CARS CORPORATION

Fig. 289: Installing Cradle (2 Of 2)


Courtesy of VOLVO CARS CORPORATION

 Press the cradle against the cover.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 290: Removing Centering Tool From Cradle


Courtesy of VOLVO CARS CORPORATION

 Hold the cradle securely when removing the centering tool.


 Repeat the method steps on the other cradle.

Fig. 291: Applying Tape P/N 1161347


Courtesy of VOLVO CARS CORPORATION

 Use: 1161347 Tape.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 292: Peeling Backing From Tape


Courtesy of VOLVO CARS CORPORATION

Fig. 293: Applying Adhesive


Courtesy of VOLVO CARS CORPORATION

 Apply a thin layer and even layer of adhesive.

CAUTION: The adhesive must not come into contact with the tape.

 Use special tool P/N 9512767 Adhesive gun


 Use P/N 116173 Mixing pipe
 Use P/N 9511027 Adhesive
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 294: Locating Cradles


Courtesy of VOLVO CARS CORPORATION

 Note the location of the cradles.

Fig. 295: Installing Cradle (1 Of 2)


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 296: Installing Cradle (2 Of 2)


Courtesy of VOLVO CARS CORPORATION

 Press the holder towards the casing, but only at the places where there is tape.
 Repeat the method steps on the other cradle.

Fig. 297: Pressing Cable Harness Clips Into Flanges Of Bumper Cover
Courtesy of VOLVO CARS CORPORATION

 Press the cable harness clips onto the flanges of the bumper cover.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 298: Identifying Sensor Connector


Courtesy of VOLVO CARS CORPORATION

 Connect the two silver sensors to the two center connections.

Fig. 299: Installing Sensor To Cradle


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 300: Identifying Rubber Seal Below Right-Hand Tailgate Stop


Courtesy of VOLVO CARS CORPORATION

 Remove the rubber seal that is below the right-hand tailgate stop.

Fig. 301: Pulling Cable Through Hole In Cargo Compartment


Courtesy of VOLVO CARS CORPORATION

 Take the cable harness with the rubber grommet from the kit.
 Pull the cable harness through the hole in the cargo compartment.
 Place the rubber grommet in position.
 Press the connector on the plastic bracket.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 302: Identifying Control Module And Holder


Courtesy of VOLVO CARS CORPORATION

 Take the control module and holder from the kit.


 Press the holder onto the reverse of the control module.

Fig. 303: Connecting Pre-Routed Cable Harness Connector To Control Module


Courtesy of VOLVO CARS CORPORATION

 Connect the pre-routed cable harness connector to the control module.

NOTE: Ensure that the connector's catches click and are properly secured.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 304: Lifting Right-Hand Side Cargo Floor Support


Courtesy of VOLVO CARS CORPORATION

 Raise the right-hand side cargo floor support.

Fig. 305: Identifying Green 5 Pin Connector


Courtesy of VOLVO CARS CORPORATION

 Locate the green 5 pin connector that is taped to the ordinary cable harness on the vehicle.
 Remove the tape and connect the connector to the control module's cable harness.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 306: Pressing Control Module Onto Floor Studs With Connections Facing Forward In Vehicle
Courtesy of VOLVO CARS CORPORATION

 Locate the 2 studs on the floor.


 Press the control module onto these with the connections facing forwards in the vehicle.

Fig. 307: Securing Cable Harness Using Tie Straps


Courtesy of VOLVO CARS CORPORATION

 Secure the cable harness using 3 x tie straps.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 308: Identifying Secondary Lock


Courtesy of VOLVO CARS CORPORATION

Applies to vehicles with tow bar wiring.

 Detach the towbar wiring connector from the Trailer Module (TRM).
 Release the terminal locking by pressing the catch down and pulling the locking straight out.

Fig. 309: View Of Cable Lug From Connector


Courtesy of VOLVO CARS CORPORATION

 Disconnect all terminals from the connector.

NOTE: Note the location of the cables in the connector.

 Use special tool P/N 9512810 or P/N 9512632 .


 Insert the tool in the connector and release the locking.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

 Pull out the cable with terminal.


 Pull out the cable harness through the rubber grommet.
 Remove the rubber grommet, it shall not be re-used.

Fig. 310: Identifying Rubber Spout And Tow Bar Wiring


Courtesy of VOLVO CARS CORPORATION

 Cut off the free rubber spout (1) on the rubber grommet of the PAS wiring.
 Lubricate the tow hitch wiring using Volvo's low temperature grease and thread the tow bar wiring (2)
through.
 Connect the terminals to the connector.
 Secure the locking and connect to the trailer module (TRM).

Fig. 311: Identifying Connectors And Wiring


Courtesy of VOLVO CARS CORPORATION

 The existing 5 pin green connector is connected to the trailer module (TRM) (1).
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

 Disconnect the connector for the control module and connect it to the cable harness of parking assistance
(2).
 Disconnect the 5 pin green connector (3) that is taped to the cable harness and connect it to the trailer
module (TRM).

APPLIES TO ALL MODELS

Fig. 312: Connecting Parking Assistance Connector And License Plate Lighting Connector And Re-
Installing Bumper Cover
Courtesy of VOLVO CARS CORPORATION

 Raise the bumper cover to the car.


 Connect the connectors for parking assistance and license plate lighting.
 Reinstall the bumper cover with its screws.
 Reinstall the stops for the tailgate.

Fig. 313: Identifying Panel Screw


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Courtesy of VOLVO CARS CORPORATION

Reinstall in the cargo compartment:

 side panel
 clips for the cargo floor support
 sill molding
 sill trim panel
 applicable spare wheel
 jack and other parts in the cargo floor support
 the floor hatch

Fig. 314: Locating Ten Panel Clips


Courtesy of VOLVO CARS CORPORATION

NOTE: There are 10 clips on the reverse of the panel that must engage in the
body. Take care when aligning so that the clips do not break. Broken clips
must be replaced with new ones.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 315: Identifying Panel Clips And Screws


Courtesy of VOLVO CARS CORPORATION

 Reinstall the side panel by first aligning it on the sill at the front edge and then pressing it against the
body side, ensure that all clips engage.
 Tighten the panel using existing screws.

Fig. 316: View Of B Pillar Panel Clips


Courtesy of VOLVO CARS CORPORATION

Reinstall:

 the panel with the safety clip and sill molding.


 backrest, tighten the screw to 15 Nm (11 lbf. ft) .
 the armrest
 cushion
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Installation Instructions, Accessories

Fig. 317: Identifying VIDA (Volvo Scan Tool) To Program Software


Courtesy of VOLVO CARS CORPORATION

 Download software (application) for the accessory's function using VIDA (Volvo scan tool).
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

ACCESSORIES AND EQUIPMENT

Instrumentation - Removal, Replacement And Installation

COMBINED INSTRUMENT
COMBINED INSTRUMENT PANEL

REMOVAL

CAUTION: The control module must be removed, reinstalled and downloaded with
software before the control module is replaced.

Fig. 1: Identifying Ignition In OFF Position


Courtesy of VOLVO CARS CORPORATION

Fig. 2: Removing/Installing Air Bag


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

Fig. 3: Identifying Instrument Panel Bezel Screws


Courtesy of VOLVO CARS CORPORATION

Fig. 4: Identifying Instrument Panel Screws


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

Fig. 5: View Of Instrument Panel Connector


Courtesy of VOLVO CARS CORPORATION

CAUTION: Take extra care when handling the component.

INSTALLATION

To install, reverse the removal procedure.

Order and download software according to 30668197

Set the clock.

WARNING SYSTEM
POSITION SENSOR, BRAKE PEDAL

NOTE: The graphics in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the graphics is always correct.

PREPARATORY WORK
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

Fig. 6: Identifying Battery Box


Courtesy of VOLVO CARS CORPORATION

Remove:

 the battery. See BATTERY


 the 3 screws
 the battery box.

REMOVAL

REMOVING SPLASH GUARDS


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

Fig. 7: Identifying Cowl Fasteners


Courtesy of VOLVO CARS CORPORATION

Remove the 3 clips holding the cowl.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

Fig. 8: Identifying Brake Fluid Reservoir Protective Cover


Courtesy of VOLVO CARS CORPORATION

Carefully lift up the cowl. Remove the 2 clips for the protective cover. Remove the protective cover over the
brake fluid reservoir.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

Fig. 9: Identifying Firewall Upper Protective Cover Nut


Courtesy of VOLVO CARS CORPORATION

Remove

 the plastic nut, x1


 the upper protective cover for the firewall.

REMOVING THE PEDAL SENSOR


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

Fig. 10: Identifying Pressure Sensor


Courtesy of VOLVO CARS CORPORATION

Pull out the pressure sensor (1) to eliminate any vacuum in the power brake booster. Disconnect the connector
(2).
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

Fig. 11: Identifying Pedal Sensor


Courtesy of VOLVO CARS CORPORATION

Open the snap ring and pull out the pedal sensor.

HINT: The opening on the snap ring points straight down. The snap ring does not need to be completely
removed, just opened.

NOTE: Make sure that the O-ring is also removed.

INSTALLATION

INSTALLING THE PEDAL SENSOR

NOTE: For tightening torques, see TIGHTENING TORQUE .

Press in the new pedal sensor.

NOTE: Use new O-ring. The pedal sensor can only be installed in one position, i. e. with
the guide pin pointing straight up.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

Fig. 12: Identifying Pressure Sensor


Courtesy of VOLVO CARS CORPORATION

Lubricate with soap solution and install the pressure sensor (1). Connect the connector (2).

INSTALLING THE PROTECTIVE COVERS


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

Fig. 13: Identifying Firewall Upper Protective Cover Nut


Courtesy of VOLVO CARS CORPORATION

Install:

 the protective cover for the firewall


 the plastic nut, x1.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

Fig. 14: Identifying Brake Fluid Reservoir Protective Cover


Courtesy of VOLVO CARS CORPORATION

Install the protective cover over the brake fluid reservoir. Carefully lift up the cowl. Install the 2 clips for the
protective cover.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

Fig. 15: Identifying Cowl Fasteners


Courtesy of VOLVO CARS CORPORATION

Install the 3 clips holding the cowl.

FINISHING

Install:

 the battery box


 the 3 M6 screws
 the battery as shown. See BATTERY .

SENSOR FOR INDICATOR AND WARNING SYSTEMS (2007-12)


ACCELEROMETER AND YAW ANGLE SENSOR

NOTE: The graphics in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the graphics is always correct.

PREPARATORY WORK
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

IGNITION OFF

Fig. 16: Identifying Ignition In OFF Position


Courtesy of VOLVO CARS CORPORATION

Ignition off.

REMOVAL

REMOVING PANEL AND SEAT RAIL


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

Fig. 17: Identifying Seat Rail Screws


Courtesy of VOLVO CARS CORPORATION

Remove:

 the panels over the screws for the seat rails


 the 4 M10 screws for the seat rails.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

Fig. 18: Slide Seat Back And Fold Carpet Aside


Courtesy of VOLVO CARS CORPORATION

Slide the seat back and fold the carpet to one side.

REMOVING BODY SENSOR CLUSTER (BSC)


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

Fig. 19: Identifying Body Sensor Cluster Bracket Screws


Courtesy of VOLVO CARS CORPORATION

NOTE: Handle the body sensor cluster (BSC) with care as it is sensitive to mechanical
damage.

Remove:

 the 2 screws for the bracket


 the connector
 the body sensor cluster (BSC).

Replace the sensor assembly together with the bracket.

INSTALLATION

NOTE: For tightening torques, see TIGHTENING TORQUE

INSTALLING BODY SENSOR CLUSTER (BSC)

Install:
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

 body sensor cluster (BSC)


 the 2 screws for the bracket. Tighten. See TIGHTENING TORQUE
 the connector.

INSTALLING PANEL AND SEAT RAIL

Fold the carpet back into position. Slide the seat back into position.

Install:

 the 4 M10 screws for the seat rails


 the panels over the screws for the seat rails.

FINISHING

CHECKING AND ADJUSTING

Perform calibration. See VIDA, Vehicle communication, calibration.

Fig. 20: Identifying Cluster Warning Symbol


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

Turn on the ignition.

In the event of a fault in the sensor, the warning symbol is constantly lit and a fault message appears in the
display on the driver information module (DIM).

Test drive the car after repair. See TEST DRIVE FORM (DSTC (DYNAMIC STABILITY AND
TRACTION CONTROL) /BRAKE CONTROL MODULE), DESCRIPTION

HANDBRAKE SWITCH (2007)

NOTE: As the graphics in this service information are used for different model years
and/or models, some variation may occur. However, the essential information in
the graphics is always correct.

PREPARATORY WORK

Remove center console. See FLOOR CONSOLE .

REMOVAL

REMOVING THE PARKING BRAKE SWITCH

Fig. 21: Removing Parking Brake Switch


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

Courtesy of VOLVO CARS CORPORATION

Remove:

 1 screw
 the connector
 the brake switch.

INSTALLATION

INSTALLING THE PARKING BRAKE SWITCH

Install:

 the brake switch


 the 1 M6 screw
 the connector.

FINISHING

Install the center console. See FLOOR CONSOLE .

HANDBRAKE SWITCH (2008-12)

NOTE: As the graphics in this service information are used for different model years
and/or models, some variation may occur. However, the essential information in
the graphics is always correct.

PREPARATORY WORK

Remove center console. See FLOOR CONSOLE .

REMOVAL

REMOVING THE PARKING BRAKE SWITCH


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

Fig. 22: Removing Parking Brake Switch


Courtesy of VOLVO CARS CORPORATION

Remove:

 1 screw
 the connector
 the brake switch.

INSTALLATION

INSTALLING THE PARKING BRAKE SWITCH

Install:

 the brake switch


 the 1 M6 screw
 the connector.

FINISHING

Install the center console. See FLOOR CONSOLE .


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

LEVEL SENSOR BRAKE FLUID

NOTE: The graphics in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the graphics is always correct.

On this car, the level sensor for the brake fluid is integrated in the brake fluid reservoir.

To replace the brake fluid reservoir, see RESERVOIR, BRAKE FLUID .

OUTSIDE TEMPERATURE SENSOR (2007-11)

Operation Number(s): 38414-2

REMOVAL

Remove the following items:

 Rear view mirror's electric motor. See MOTOR, EXTERNAL MIRROR


 Rear view mirror cover. See COVER, EXTERNAL MIRROR .

Fig. 23: Identifying Outside Temperature Sensor Connector


Courtesy of VOLVO CARS CORPORATION

INSTALLATION

To install, reverse the removal procedure.

OUTSIDE TEMPERATURE SENSOR (2011 LATE -12)

REMOVAL

Remove mirror rear-view mirror external. See MIRROR, REAR VIEW MIRROR
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

Fig. 24: Identifying Outside Temperature Sensor (1 Of 3)


Courtesy of VOLVO CARS CORPORATION

Fig. 25: Identifying Outside Temperature Sensor (2 Of 3)


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

Fig. 26: Identifying Outside Temperature Sensor (3 Of 3)


Courtesy of VOLVO CARS CORPORATION

Carry out splicing of wire. See JOINING CABLES

INSTALLATION

To install, reverse the removal procedure.

PRESSURE SENSOR TIRE

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.

Remove the wheel.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

Fig. 27: Removing/Installing Sensor


Courtesy of VOLVO CARS CORPORATION

CAUTION: Do not use tools within the marked area.

CAUTION: Always start outside the marked area and continue in the direction from
the valve.

CAUTION: Release the tire bead from the wheel rim diagonally opposite to the valve.

Tighten the pressure sensor. See TIGHTENING TORQUE

INSTALLATION

To install, reverse the removal procedure

Install the wheel. See WHEELS

After replacing sensors, the control module does not need programming. The control module contacts the sensor
itself after a few minutes driving. LF initiator can be used.

TEMPERATURE SENSOR BATTERY


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

NOTE: The graphics in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the graphics is always correct.

PREPARATORY WORK

IGNITION OFF

Fig. 28: Identifying Ignition In OFF Position


Courtesy of VOLVO CARS CORPORATION

Ignition off.

Open the hood.

Remove the battery. See BATTERY .

REMOVAL

REMOVING THE TEMPERATURE SENSOR


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

Fig. 29: Identifying Temperature Sensor


Courtesy of VOLVO CARS CORPORATION

Remove:

 the connector
 the temperature sensor. Press in the locking catch on one side. Press up and press in the other locking
catch.

INSTALLATION

INSTALLING THE TEMPERATURE SENSOR

Install:

 the temperature sensor


 the connector
 the battery as shown: BATTERY .

TRANSMISSION INPUT SPEED SENSOR, REAR WHEELS

NOTE: The graphics in this service information are used for different model years
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

and/or models. Some variation may occur. However, the essential information in
the graphics is always correct.

PREPARATORY WORK

Ignition off.

REMOVAL

REMOVING THE SHOCK ABSORBER FOR VEHICLES EQUIPPED WITH NIVOMAT

Fig. 30: Identifying Lower Shock Mounting


Courtesy of VOLVO CARS CORPORATION

Remove:

 the M5 screw
 the shock absorber from the lateral link.

REMOVING THE WHEEL SENSOR


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

Fig. 31: Identifying Sensor Mounting Screw


Courtesy of VOLVO CARS CORPORATION

NOTE: Blow clean around the sensor using compressed air before removing.

Remove the sensor mounting screw. Pull out the connector.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

Fig. 32: Identifying Wheel Sensor


Courtesy of VOLVO CARS CORPORATION

Remove the wheel sensor.

INSTALLATION

INSTALLING THE WHEEL SENSOR

NOTE: For tightening torques, see TIGHTENING TORQUE .

Install:

 the wheel sensor in the connector


 the connector
 the M5 screw. Tighten. See TIGHTENING TORQUE .

FINISHING

INSTALLING THE SHOCK ABSORBER FOR VEHICLES EQUIPPED WITH NIVOMAT


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

Fig. 33: Identifying Lower Shock Mounting


Courtesy of VOLVO CARS CORPORATION

Install:

 the shock absorber from the lateral link


 the M5 screw. Tighten. See TIGHTENING TORQUE .

FUNCTION TEST

Read off any diagnostic trouble codes (DTCs) stored in the control module.

Erase.

Interrupt the diagnostic function by turning off the ignition.

Test drive the vehicle. See TEST DRIVE FORM (ABS), DESCRIPTION .

Check that no diagnostic trouble codes (DTCs) are stored. Interrupt the diagnostic function by turning off the
ignition.

TRANSMISSION INPUT SPEED SENSOR, FRONT WHEELS


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

NOTE: The graphics in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the graphics is always correct.

PREPARATORY WORK

Switch off the ignition.

Remove the wheel.

REMOVAL

REMOVING THE WHEEL SENSOR

Fig. 34: Identifying Wheel Sensor Connector


Courtesy of VOLVO CARS CORPORATION

NOTE: Blow clean around the sensor using compressed air before removing.

Remove the connector from the wheel sensor.


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

Fig. 35: Identifying Wheel Sensor Mounting Screw


Courtesy of VOLVO CARS CORPORATION

Remove:

 the M5 mounting screw for the wheel sensor


 the wheel sensor.

INSTALLATION

INSTALLING THE WHEEL SENSOR

NOTE: For tightening torques, see TIGHTENING TORQUE .

Install:

 the wheel sensor


 the M5 screw. Tighten. See TIGHTENING TORQUE
 the connector.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

Fig. 36: View Of Wheel Sensor Cable Routing


Courtesy of VOLVO CARS CORPORATION

Thoroughly check that the wheel sensor cable is routed as shown.

FINISHING

Install the wheel according to WHEELS .

FUNCTION TEST

Read off any diagnostic trouble codes (DTCs) stored in the control module.

Erase.

Interrupt the diagnostic function by turning off the ignition.

Test drive the car. See TEST DRIVE FORM (ABS), DESCRIPTION .

Check that no diagnostic trouble codes (DTCs) are stored. Interrupt the diagnostic function by turning off the
ignition.

TRANSMISSION INPUT SPEED SENSOR, INPUT SHAFT, TRANSAXLE (TSS) (B5244S4; 2007-10,
B5254T3; 2007, B5254T7; 2008-12)

NOTE: The graphics in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the graphics is always correct.

PREPARATORY WORK

DISCONNECTING THE BATTERY LEAD


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

Fig. 37: Identifying Battery Box


Courtesy of VOLVO CARS CORPORATION

Remove:

 the battery negative cable. See BATTERY DISCONNECTING AND CONNECTING


 the box for the battery.

REMOVAL

REMOVING THE SENSORS AND CABLE HARNESS

Fig. 38: View Of Sensors and Cable Harness


Courtesy of VOLVO CARS CORPORATION

NOTE: Make a note of the routing of the cable harness.

Disconnect the cable harness connector from the transmission control module (TCM).

Clean thoroughly around the sensors. Remove the sensors and the cable harness.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

INSTALLATION

INSTALLING THE SENSORS AND CABLE HARNESS

Fig. 39: View Of Sensors and Cable Harness


Courtesy of VOLVO CARS CORPORATION

Install:

 the new sensors. Apply a little automatic transmission fluid to the O-rings for the sensors. Tighten. See
TIGHTENING TORQUE
 the cable harness connector to the transmission control module (TCM).

FINISHING

INSTALLING THE BATTERY LEAD

Fig. 40: Identifying Battery Box


Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

 the box for the battery


 the battery negative lead. See BATTERY DISCONNECTING AND CONNECTING .

PRESSURE SENSOR, ENGINE OIL (B5244S4; B5254T3; 2007)

REMOVAL

NOTE: Removal steps in this procedure may contain installation details.

See information about lifting points body. See JACKING POINTS BODY

Fig. 41: Identifying Skid Plate Screws


Courtesy of VOLVO CARS CORPORATION

Fig. 42: View Of Oil Pressure Switch


Courtesy of VOLVO CARS CORPORATION

Torque: Oil pressure switch


2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Instrumentation - Removal, Replacement And Installation

15 Nm

INSTALLATION

To install, reverse the removal procedure.

SENSORS FOR CHECK AND WARNING SYSTEM


LEVEL SENSOR FUEL TANK (B5244S4; 2007-10, B5254T3; 2007, B5254T7; 2008-12)

NOTE: The graphics in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the graphics is always correct.

On these models, the level sensor is integrated in the fuel pump (FP).

To replace on AWD, see FUEL PUMP (B5254T7; 2008-12) .

To replace on FWD, see FUEL PUMP AND LEVEL SENSOR UNIT (B5244S4; 2007-10, B5254T3; 2007,
B5254T7; 2008-12) .
2012 Volvo C30 T-5
ENGINE Intake And Exhaust System - Installation Instructions, Accessories

ENGINE

Intake And Exhaust System - Installation Instructions, Accessories

END PIPES, 4 CYL (2010-12)


END PIPES, 4 CYL

Fig. 1: Identifying End Pipe


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APPLIES TO 4-CYL. PETROL

Fig. 2: Cutting Off Pipe


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2012 Volvo C30 T-5
ENGINE Intake And Exhaust System - Installation Instructions, Accessories

Fig. 3: Installing End Pipe Components - 4-Cyl. (1 Of 2)


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Fig. 4: Installing End Pipe Components - 4-Cyl. (2 Of 2)


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2012 Volvo C30 T-5
ENGINE Intake And Exhaust System - Installation Instructions, Accessories

Fig. 5: Identifying Lateral Distance


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Fig. 6: Tightening Clamp On End Pipe


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END PIPES, 5 CYL (2010-12)


END PIPES, 5 CYL
2012 Volvo C30 T-5
ENGINE Intake And Exhaust System - Installation Instructions, Accessories

Fig. 7: Installing End Pipe Components - 5-Cyl. (1 Of 8)


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Fig. 8: Installing End Pipe Components - 5-Cyl. (2 Of 8)


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2012 Volvo C30 T-5
ENGINE Intake And Exhaust System - Installation Instructions, Accessories

Fig. 9: Installing End Pipe Components - 5-Cyl. (3 Of 8)


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Fig. 10: Installing End Pipe Components - 5-Cyl. (4 Of 8)


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2012 Volvo C30 T-5
ENGINE Intake And Exhaust System - Installation Instructions, Accessories

Fig. 11: Installing End Pipe Components - 5-Cyl. (5 Of 8)


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Fig. 12: Installing End Pipe Components - 5-Cyl. (6 Of 8)


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2012 Volvo C30 T-5
ENGINE Intake And Exhaust System - Installation Instructions, Accessories

Fig. 13: Installing End Pipe Components - 5-Cyl. (7 Of 8)


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Fig. 14: Installing End Pipe Components - 5-Cyl. (8 Of 8)


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2012 Volvo C30 T-5
ENGINE Intake And Exhaust System - Installation Instructions, Accessories

Fig. 15: Identifying Lateral Distance


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Fig. 16: Tightening Clamp On End Pipe


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END PIPES, DOUBLE (2009)


END PIPES, DOUBLE

NOTE: When installing end pipes and skid plate at the same time, it is recommended to
cut the pipes before the skid plate is installed.
2012 Volvo C30 T-5
ENGINE Intake And Exhaust System - Installation Instructions, Accessories

Fig. 17: Cutting Off End Pipe


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 Use a pipe cutter and cut off the end pipe where it starts to widen, as close to the line as possible.
 File down the edges.

Fig. 18: Identifying End Pipe


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 Take the end pipe from the kit and insert it approx. 20 mm over the cut pipe, turned approximately as
shown.