Volvo C30 2007 Installation and operating manual

2007-2013 VOLVO C30 SERVICE
AND REPAIR MANUAL

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

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

Fi
g
. 2: Identif
y
in
g
Generator B+ Terminal And Bolts
Courtesy of VOLVO CARS CORPORATION
Remove the following items:
1. Torque: Generator B+ terminal
15 Nm
2. Torque: M8
24 Nm
INSTALLATION
To install, reverse the removal procedure.
GENERATOR (B5254T3; 2007, B5254T7; 2008-12)
REMOVAL
Fig. 3: Identifying Ignition In OFF Position
Courtesy of VOLVO CARS CORPORATION
Remove the air filter housing. See AIR CLEANER HOUSING
Remove the throttle body. See THROTTLE BODY
Remove the auxiliaries belt. See ACCESSORY DRIVE BELT TENSIONER
NOTE: Removal steps in this procedure may contain installation details.
2012 Volvo C30 T-5
ELECTRICAL Alternator And Regulator - Removal, Replacement And Installation

Fig. 4: Identifying Oil Stick Bracket Bolt
Courtesy of VOLVO CARS CORPORATION
Fig. 5: Identifying Generator B+ Terminal And Nuts
Courtesy of VOLVO CARS CORPORATION
Remove the following items:
1. Torque: Generator B+ terminal
15 Nm
2. Torque: M10
50 Nm
INSTALLATION
To install, reverse the removal procedure.
2012 Volvo C30 T-5
ELECTRICAL Alternator And Regulator - Removal, Replacement And Installation

GENERATOR PULLEY, GENERATOR (B5244S4; 2007-11, B5254T7; 2008-12)
REMOVAL AND INSTALLATION
Remove the alternator. See GENERATOR (B5254T3; 2007, B5254T7; 2008-12) or GENERATOR
(B5244S4; 2007-11)
Fig. 6: Identifying Spanner 9997113
Courtesy of VOLVO CARS CORPORATION
see 9997113 see 9997113
CHARGE REGULATOR
CHARGE REGULATOR (B5244S4; 2007-11, B5254T3; 2007, B5254T7; 2008-12)
REMOVAL
Special tools
999 7113 Spanner
Tool number: 999 7113
Tool description: Spanner
Tool boards: 30
NOTE: Removal steps in this procedure may contain installation details.
2012 Volvo C30 T-5
ELECTRICAL Alternator And Regulator - Removal, Replacement And Installation

Fig. 7: Identifying Nuts
Courtesy of VOLVO CARS CORPORATION
Remove the generator (GEN). See GENERATOR (B5244S4; 2007-11) or GENERATOR (B5254T3; 2007,
B5254T7; 2008-12).
Fig. 8: Identifying M4 Generator Bolts
Courtesy of VOLVO CARS CORPORATION
Torque: M4
3.5 Nm
INSTALLATION
To install, reverse the removal procedure
2012 Volvo C30 T-5
ELECTRICAL Alternator And Regulator - Removal, Replacement And Installation

ELECTRICAL
Battery And Mounting - Removal, Replacement And Installation
BATTERY
REMOVAL
See SAFETY INFORMATION BATTERY AND CHARGING
Fig. 1: Identifying Underhood Torsion Rod, Nuts And Cover
Courtesy of VOLVO CARS CORPORATION
Torque: M8
24 Nm
Fig. 2: View Of Battery And Cover
NOTE: Removal steps in this procedure may contain installation details.
2012 Volvo C30 T-5
ELECTRICAL Battery And Mounting - Removal, Replacement And Installation
2012 Volvo C30 T-5
ELECTRICAL Battery And Mounting - Removal, Replacement And Installation

Courtes
y
of VOLVO CARS CORPORATION
Perform battery disconnecting and connecting, see BATTERY DISCONNECTING AND CONNECTING
Fig. 3: Locating Battery Box And Terminal Connector Bolts
Courtesy of VOLVO CARS CORPORATION
Fig. 4: Identifying Battery, Holder And Bolts
Courtesy of VOLVO CARS CORPORATION
Torque: M6
10 Nm
INSTALLATION
To install, reverse the removal procedure.
VEHICLES WITH BATTERY MONITORING SENSOR (BMS)
Reset accordin
g
to DIAGNOSTICS/VEHICLE COMMUNICATION/CEM/Advanced/Resettin
g
information
2012 Volvo C30 T-5
ELECTRICAL Battery And Mounting - Removal, Replacement And Installation

when replacing battery (main battery) function. VIDA (Volvo Scan Tool) is necessary to perform this
p
rocedure.
2012 Volvo C30 T-5
ELECTRICAL Battery And Mounting - Removal, Replacement And Installation

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

Fig. 2: Identifying Hose Strap
Courtesy of VOLVO CARS CORPORATION
Fig. 3: Identifying Hose
Courtesy of VOLVO CARS CORPORATION
Fig. 4: Identifying M8 And M10 Bolts
2012 Volvo C30 T-5
TRANSMISSION Manual Transmission

Remove the followin
g
items:
1. Torque: M8
24 Nm
2. Torque: M10
50 Nm
Fig. 5: Identifying M10 Bolts
Courtesy of VOLVO CARS CORPORATION
Torque: M10
50 Nm
Fig. 6: Removing Bevel Gear
Courtesy of VOLVO CARS CORPORATION
2012 Volvo C30 T-5
TRANSMISSION Manual Transmission

Fig. 7: Identifying Bevel Gear
Courtesy of VOLVO CARS CORPORATION
For information about transmission lubricants, see LUBRICANT TRANSMISSION
To install, reverse the removal procedure.
2012 Volvo C30 T-5
TRANSMISSION Manual Transmission

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

Fi
g
. 1: Identif
y
in
g
Screws For Cover Over Fan Housin
g
Courtesy of VOLVO CARS CORPORATION
Remove the 4 screws for the cover over the fan housing. Remove the cover.
Fig. 2: Identifying Fan Housing
Courtesy of VOLVO CARS CORPORATION
Carefully pull the fan housing straight out, viewed from the shorter side of the engine coolant heater. See the
illustration.
NOTE: The nearest connection pipe may need to be adjusted in order to remove the
cover. See: COOLANT PIPE FUEL-POWERED PREHEATER (TURBO) or
COOLANT PIPE FUEL-POWERED PREHEATER (NON-TURBO)
2012 Volvo C30 T-5
HVAC Automatic HVAC System

Fig. 3: Identifying Cable Terminals And Cables
Courtesy of VOLVO CARS CORPORATION
Remove:
the cable terminal and cable for the flame sensor in positions 1 and 2 (blue and brown)
the cable terminal and cable for the
g
low plu
g
in positions 9 and 12 (white and brown).
2012 Volvo C30 T-5
HVAC Automatic HVAC System

Fig. 4: Identifying Flame Sensor And Pressure Equalizer
Courtesy of VOLVO CARS CORPORATION
Disconnect the flame sensor (1) and with it the holder for the pressure equalizer (2).
Remove:
the glow plug
the pressure equalizer and the fuel pipe.
INSTALLATION
INSTALLING THE GLOW PLUG / PRESSURE EQUALIZER
Install:
the pressure equalizer
NOTE: Make sure that the O-ring and the filter are also removed. Otherwise the fan
motor has to be disconnected from the combustion housing.
NOTE: For tightening torques, see TIGHTENING TORQUE
2012 Volvo C30 T-5
HVAC Automatic HVAC System

the flame sensor together with the holder. Tighten
the glow plug. Tighten.
Install the cable terminals and cables in the connectors.
- Flame sensor in positions 1 and 2 (blue and brown).
- Glow plug in positions 9 and 12 (white and brown).
Carefully push the fan housing into place.
Ensure:
that the connector is not trapped
that the cable seal on the water pump is correctly positioned and that the cable runs behind the fan motor
like the others.
Install the cover using 4 screws.
If necessary, adjust the pipe connection, see: COOLANT PIPE FUEL-POWERED PREHEATER
(TURBO) or COOLANT PIPE FUEL-POWERED PREHEATER (NON-TURBO)
Install the control module, see: FUEL FIRED BOOSTER HEATER CONTROL UNIT (TURBO) or FUEL
FIRED BOOSTER HEATER CONTROL UNIT (NON-TURBO)
FINISHING
TESTING THE ENGINE COOLANT HEATER
Perform a performance test of the en
g
ine's preheater. See: FUEL-POWERED PREHEATER, CHECKING
NOTE: Route the cables behind the fan motor to the connector.
2012 Volvo C30 T-5
HVAC Automatic HVAC System

ACCESSORIES AND EQUIPMENT
Body Frame - Specifications, Mechanical
JACKING POINTS BODY
BODYWORK JACKING POINTS
LIFTING POINTS FOR LIFTING THE VEHICLE
Fig. 1: Identifying Lifting Points Of Vehicle
Courtesy of VOLVO CARS CORPORATION
When lifting the vehicle, the lifting points indicated in the graphic must be used.
The jacking plate must have a rubber pad to prevent damage to the vehicle.
Do not lift at the front suspension, as there is a risk of the wheel ali
g
nment bein
g
altered.
NOTE: The graphics in this service information are used for different model years
and/or models. Some variation may occur. However, the essential information in
the graphics is always correct.
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Body Frame - Specifications, Mechanical
2012 Volvo C30 T-5
ACCESSORIES AND EQUIPMENT Body Frame - Specifications, Mechanical