Is your Volvo’s AC system blowing weak or no air at all? A faulty blower motor could be the culprit. Replacing it yourself can save you significant money compared to dealership service. This comprehensive guide provides a step-by-step walkthrough for replacing the blower motor in 2007 and newer Volvo S80, and 2008 and newer V70/XC70 models. While this job requires patience and some specialized tools, it’s achievable for the determined DIYer.
Important Note: The Essential Tool
Before we begin, a crucial warning: you absolutely must have Volvo special tool 9997284. This tool is specifically designed to remove the blower motor and is not optional. Attempting to remove the blower motor without it can lead to frustration and potentially damage to your vehicle. While considering tools, you might wonder, Can You Use Magnetic Tools Working On Car Ac Module? In general, magnetic tools can be helpful for retrieving dropped fasteners in tight engine bays. However, when working around sensitive electronic modules like the car’s AC module or CEM (Central Electronic Module) as we will be in this procedure, it’s wise to exercise caution. While not strictly prohibited, avoid direct contact of strong magnets with electronic components to prevent any potential unintended effects. For this blower motor job, magnetic tools are not specifically required, but magnetic trays can be useful for organizing the various screws and bolts you’ll be removing.
Estimated Time: 4-6 hours (for a first-timer)
Tools Required:
- Volvo special tool 9997284
- T20 Torx driver
- 8mm nut driver
- 10mm nut driver
- Ratchet set with 8mm, 10mm, 11mm, 12mm, and 13mm sockets
- Small diagonal cutters
- Small needle-nose pliers
- Head-mounted light (essential for visibility in tight spaces)
- Flexibility (or consider removing the passenger seat and carpeting)
Optional Tools:
- Weatherstrip clip removal tool (or similar clip removal pliers)
- Trouble light
- Mirror
- Diagnostic tool (like DiCE and VIDA) to verify CEM operation and reset SRS if needed
Step-by-Step Blower Motor Replacement Guide
Step 1: Preparation
Park your Volvo in a location where you have easy access to the passenger side. You’ll also need driver’s side access, but primarily the passenger side for this procedure. Turn your car on and set the AC to recirculate. This step is important for later in the removal process.
Alt text: Location of the blower motor in a Volvo S80, situated in the passenger footwell area.
Step 2: Passenger Seat Adjustment
Move the passenger seat as far back as it will go to maximize your workspace. Unlock all doors for easier access.
Step 3: Disconnect Battery
Safety first! Disconnect the negative battery cable. Wait at least 3 minutes before proceeding to allow the car’s electrical system to fully discharge.
Step 4: Steering Wheel Adjustment
Lower the steering wheel all the way down and pull it out as far as it extends. This creates more room to work in the dashboard area.
Step 5: Instrument Trim Panel Removal
Gently pull the black instrument trim panel towards you. It’s usually held in place by clips and should detach with firm but careful pressure.
Alt text: Removing the black instrument trim panel in a Volvo S80 by pulling it towards the user to access the steering column covers.
Step 6: Upper Steering Column Cover Removal
Use a plastic spudger or bone tool to carefully pry off the top steering column cover. Start at one corner and gently work your way across, releasing the clips.
Alt text: Using a spudger tool to remove the top steering column cover of a Volvo S80, starting from the edge to unclip it.
Step 7: Instrument Cluster Screw Removal
Locate and remove the four T20 Torx screws that secure the instrument cluster.
Step 8: Instrument Cluster Prying
Using the bone tool again, gently pry the top of the instrument cluster towards you. This will allow you to access the electrical connector.
Alt text: Tilting the instrument cluster forward in a Volvo S80 using a bone tool to access the connectors behind it.
Step 9: Instrument Cluster Disconnection and Removal
Carefully remove the instrument cluster, unplug the electrical connector on the left side, and set the cluster aside in a safe place.
Step 10: Blower Motor Connector Disconnection
Using a flashlight to improve visibility, locate the blower motor in the passenger footwell area. Reach in (you’ll likely be doing this blindly) and disconnect the electrical connector by squeezing the tabs on the top and bottom of the connector.
Alt text: Hand reaching to disconnect the electrical connector of the blower motor in a Volvo S80, highlighting the location and type of connector.
Step 11: Right Door Threshold Trim Removal
Remove the right door opening threshold trim by pulling it straight up. This trim piece pivots towards the rear of the car, so work from the front to the back when removing it.
Alt text: Removing the right door threshold trim in a Volvo S80 by pulling upwards to detach the clips.
Step 12: Front Door Opening Trim Removal
Remove the front door opening trim by first pulling up at the bottom section. Then, pull it towards you from the vertical part. Finally, slide the part off the catch located at the top.
Alt text: Removing the lower section of the front door opening trim of a Volvo S80 by pulling upwards.
Alt text: Detaching the side section of the front door opening trim in a Volvo S80 by pulling it outwards from the door frame.
Step 13: Dashboard Side Trim Removal
Use the bone tool or spudger to remove the dashboard side trim panel. Gently pry it away from the dashboard to release the clips.
Alt text: Using a bone tool to detach the dashboard side trim panel in a Volvo S80.
Step 14: Tunnel Console Trim Removal
Remove the tunnel console trim by prying it up, starting nearest the seat and working your way towards the front of the car.
Alt text: Prying up the tunnel console trim in a Volvo S80, starting from the rear and moving towards the front.
Step 15: Soundproofing Removal
Remove the soundproofing panel. It’s held in place by two T20 Torx screws.
Alt text: Removing the soundproofing panel in a Volvo S80 by unscrewing two Torx screws.
Step 16: Glove Box Fastener Removal
Remove the glove box fasteners. These include two 8mm bolts and four T20 Torx screws located inside the glove box, and an additional two 8mm bolts and two T20 Torx screws found underneath the glove box door.
Alt text: Close-up of the fasteners inside the glove box of a Volvo S80 that need to be removed.
Alt text: Fasteners located on the glove box door of a Volvo S80 being removed.
Alt text: Underneath view showing the fasteners below the glove box in a Volvo S80 that need to be detached.
Step 17: Glove Box Light Connector Disconnection
Reach to the rear of the glove box and disconnect the electrical connection for the glove box light (green connector).
Alt text: Disconnecting the green electrical connector for the glove box light in a Volvo S80.
Step 18 (Optional): Glove Box Light Removal
Depending on your model year, you might need to remove the glove box light itself. If necessary, pry it downwards and disconnect the leads.
Alt text: Removing the glove box light from a Volvo S80 by prying it downwards.
Step 19: Glove Box Removal
Pull the glove box straight out. If you encounter resistance, stop and check underneath. Locate an electrical harness zip-tied to the right corner of the glove box. Blindly cut the zip tie. Continue pulling out the glove box until you find a gray electrical connector (valet lock). Unplug it and deroute the wire by pulling forward on the female socket to disengage it from its mounting point.
Alt text: Zip tie location on the glove box of a Volvo S80 that needs to be cut before removal.
Alt text: Location of the gray valet lock electrical connector that needs to be unplugged during glove box removal in a Volvo S80.
Step 20: Duct Removal
Remove the duct located behind the glove box. It usually pulls straight out or may have clips holding it in place.
Alt text: Removing the air duct behind the glove box in a Volvo S80 to access components behind it.
Step 21: CEM Connector Removal
Pull back the carpet towards the passenger seat to access the CEM (Central Electronic Module). Locate the CEM and remove five connectors. The three larger connectors are removed by pressing down on the center of the latch and rotating the lever away from the connector. The other two connectors can be removed by pushing the latch and pulling the connector body out. Be cautious around the CEM and its connectors as these are sensitive electronic components.
Alt text: Removing the electrical connectors from the Central Electronic Module (CEM) in a Volvo S80.
Step 22: CEM Rotation
Push up on the rightmost latch on top of the CEM and rotate the CEM towards you to approximately a 45-degree angle.
Alt text: Rotating the CEM module in a Volvo S80 to a 45-degree angle for better access.
Step 23: CEM Removal
Remove the CEM and set it aside in a safe, static-free location.
(Step 23A – If equipped with iPod module): If your Volvo has an iPod accessory module, locate and remove it. Unplug the two connectors and set the module aside. Important: Exercise extreme caution when unplugging the connector with orange cables – these are fiber optic cables and must not be bent tighter than a 2.5-inch radius to avoid damage.
Alt text: Removing the iPod module in a Volvo S80, highlighting the fiber optic cables that require careful handling.
Step 24: Cable Clip and Connector Removal from CEM Bracket
Using a weatherstrip removal tool or similar, remove all the round cable clips from the CEM bracket. The white/gray connector at the top needs to be demated using its lever, then slipped off its bracket by pushing down on the black clip and sliding it to the left. Demate the two power cable connectors on top of the bracket, and remove them by squeezing the tabs that hold them to the mounting hole.
Step 25: CEM Bracket Removal
Remove the CEM bracket itself. It’s secured by three 13mm nuts. (Torque to 24Nm upon reinstallation).
Alt text: Location of the CEM bracket and surrounding components in a Volvo S80, indicating removal points.
Alt text: Detailed view of the CEM bracket removal area, showing connectors and clips to be detached.
Step 26: Air Quality Sensor and Recirculation Damper Motor Cable
Look upwards towards the top of the dash. If your Volvo is equipped with an Air Quality Sensor, remove it by unplugging it, rotating it anticlockwise, and removing it. Then, unplug and deroute the 3-wire recirculation damper motor cable.
Alt text: Removing the Air Quality Sensor in a Volvo S80 by unplugging and rotating it.
Step 27: Recirculation Damper Unit Removal
Now for a slightly tricky part. Remove the three T20 Torx screws holding the recirculation damper unit. The screw nearest to you is the hardest to see – remove it first by feel. The other two are closer but behind the unit. Remove the damper unit by twisting it slightly anticlockwise while gently coaxing it out. A trouble light and mirror can be helpful here if you’re struggling to see.
Alt text: Removing the Recirculation Damper Unit in a Volvo S80, showing its location and mounting.
Step 28: Tool 7284 Inner Part Mounting
Mount the inner part (alignment pin) of tool 7284 onto the fan hub of the blower motor and tighten the thumbscrew.
Alt text: Mounting the inner part of Volvo special tool 7284 onto the blower motor fan hub in a Volvo S80.
Step 29: Tool 7284 Outer Part Mounting
Holding tool 7284 straight up and down, place the outer part of the tool over the alignment pin and fully seat it in the fan. Tighten the thumbscrew.
Alt text: Mounting the outer part of Volvo special tool 7284 onto the blower motor assembly in a Volvo S80.
Step 30: Blower Motor Removal with Tool 7284
Have an assistant push down on the locking tab while you push in and turn tool 15-degrees anticlockwise. Alternatively, using needle-nose pliers, break the mounting tab on the fan by pulling up on it (as shown in the image).
Alt text: Breaking the mounting tab on the Volvo blower motor fan to facilitate removal using tool 7284.
Step 31: Tool Mounting on New Blower Motor
Remove tool 7284 from the old fan. Mount the tool onto the new blower motor, repeating steps 28 and 29.
Alt text: Mounting Volvo special tool 7284 onto the new blower motor before installation into the Volvo S80.
Step 32: New Blower Motor Installation
Replace the blower motor. Hold it at approximately 15-degrees anticlockwise from straight up and down, then turn it clockwise until the tool is straight up and down. Attempt to pull the blower straight away from the mounting point to ensure that all four locking lugs have properly engaged.
Step 33: Tool Removal
Remove tool 7284 by first undoing the outer thumbscrew, and then the inner thumbscrew.
Reassembly and Final Steps
Assembly is essentially the reverse of disassembly, with a few important considerations:
- Recirculation Damper Screws: The 3x T20 screws for the recirc damper are non-magnetic. Use tape or a gripping screwdriver to assist in replacing them.
- Repowering the Car: When reconnecting power, first connect the negative battery cable. Then, insert the key into the ignition and press and hold the start/stop button until all the instrument panel lights illuminate (this is effectively putting the key in position II). Crucially, do not be inside the car when doing this, as a safety precaution in case an airbag were to deploy unexpectedly. Do not enter the vehicle until the SRS light has turned off (after approximately 30 seconds) or remains on for longer than 5 minutes (indicating a fault). It’s normal for the CEL (Check Engine Light) to flash briefly.
- Diagnostic Check (Optional): If you have access to DiCE and VIDA, finalize the job by running the CEM procedure “Checking communication and control module” located under Vehicle Communication -> CEM. This will help ensure all systems are functioning correctly.
By following these steps, you can successfully replace your Volvo’s blower motor and restore proper AC and heating function. Remember to take your time, be patient, and double-check all connections during reassembly.
