Recall - Brake Booster Check Valve/Hose Replacement
NO: 52-04DATE: 11/22/04
MODEL:
S/V 40
M. YEAR:
2004
CHASSIS:
069532 - 089717 (NOTE: RETAILERS MUST CONFIRM VEHICLE ELIGIBILITY)
SUBJECT:
Recall Campaign 137: Brake Vacuum Valve/Hose Assembly, Inspect/Replace
REFERENCE:
SMB 52-137, PB 52-137, VADIS
This TNN supersedes the previous TNN 52-04 dated 6-30-04. Please update your files.
DESCRIPTION:
Volvo Cars of North America, LLC and Volvo Cars Canada Ltd. (Volvo) have determined in certain 2004 S40 and V40 vehicles, the non-return valve may crack due to a poor weld, causing a vacuum leak. The non-return valve holds residual vacuum in the brake booster and is incorporated in the vacuum valve/hose assembly.
If this occurs, more pedal force may be required to stop the vehicle. This limited braking power can affect the vehicle's stopping performance, increasing the risk of a crash. Also, you may experience a rough engine idle.
Parts Information
SERVICE:
Checking the date code on the brake vacuum valve 1
Disconnect the connector.
Read and note the date code.
Note:
If the code is not visible, proceed to step 2.
If the date code is one of the following:
29 08 03
01 09 03
02 09 03
03 09 03
then proceed to step 3.
If the date code is not on the list above, the vacuum valve is functioning correctly and does not need to be replaced.
Connect the connector to the brake vacuum valve.
Removing the vacuum valve 2
Perform this step only if the date code is not visible without removing the vacuum valve. Before starting work: Press down the brake pedal until there is no negative pressure (vacuum) in the brake servo.
Note!
Clean the area around the terminal for the vacuum hose.
Remove:
- the quick-release connector for the vacuum hose on the additional vacuum pump
- turbocharged engines: the vacuum hose from the clip (2) and from the brake servo
- the connection from the brake servo.
Read the date code on the brake vacuum valve. If necessary, move the valve upwards at an angle to make the digits more visible. If the date code is one of the following:
29 08 03
01 09 03
02 09 03
03 09 03
then proceed to step 3.
If the date code is not on the list above, the vacuum valve is functioning correctly and does not need to be replaced.
Install the brake vacuum valve (1) in the brake servo.
Hint: Apply a little white vaseline or soap to the connection at the brake servo.
Install:
- the vacuum hose in the clip (2)
- the quick-release connector for the vacuum hose connection by pressing it onto the additional vacuum pump. Check the connection
- the connector (1) on the brake vacuum valve.
Proceed to step 5.
Removing the vacuum hose 3
Before starting work: Press down the brake pedal until there is no negative pressure (vacuum) in the brake servo.
Note!
Clean the area around the terminal for the vacuum hose.
Remove:
- the quick-release connector (2) for the vacuum hose on the additional vacuum pump
- the connection to the brake servo
- the vacuum hose out of the clip
- the vacuum hose for the intake manifold by pressing the lock washer (1) while pulling the vacuum hose out.
The vacuum hose must not be reused.
Installing the brake vacuum hose 4
Position the new brake vacuum hose.
Install the brake vacuum valve.
Hint: Apply a little white vaseline or soap to the connection at the brake servo.
Install:
- the vacuum hose in the intake manifold. Check the locking by pulling the vacuum hose
- the brake vacuum valve (1) in the brake servo
- the vacuum hose in the existing clip
- the quick-release connector for the vacuum hose connection by pressing it onto the additional vacuum pump. Check the locking
- the connector (1) on the brake vacuum valve
- non turbocharged engines: the protective cover for the throttle body (TB).
Checking the function 5
Turn the ignition off, press down the brake pedal a few times until there is no longer any negative pressure (vacuum) in the brake servo.
Turn the ignition key to position II and listen for the operation of the additional vacuum pump. The vacuum pump stops after a short time.
Note
If the pump fails to start, fault trace as per VADIS.
Start the engine and let it idle.
Press down the brake pedal a few times and check whether the additional vacuum pump starts working.
Note
If the Pump continues to run while the engine is running please fault trace as per VADIS.