Recall - Brake Vacuum Replacement
S40 (-04)/V402000
Section:
5
Group:
52
No.:
0011
Year:
04
Month:
03
Background:
Volvo Cars North America LLC (Volvo) has decided that a defect related to motor vehicle safety exists in certain model year 2000 S40 and V40 vehicles. Under certain circumstances, water may enter the electrical brake vacuum pump, causing the pump to not function. This will require more brake force to stop the vehicle. However, this is primarily noticed at cold start. This limited braking power can affect the vehicle's stopping performance.
The corrective action will be to replace the vacuum pump with a new pump of a modified design. This new pump will be placed in a new location to prevent water intrusion.
Competence requirement
Volvo Level 2 Technician
Material
Vacuum pump
Additional vacuum pump, replacing
1. Preparatory work
Make a note of the anti-theft radio code.
Switch off the ignition.
Caution!
Press down the brake pedal a few times until there is no longer any negative pressure (vacuum) in the brake servo.
Remove:
- the battery negative lead
- the battery positive lead
- the protective cover over the battery
- the battery clamp and the battery.
2. Removing the air cleaner (ACL)
Remove:
- the connector for the mass air flow (MAF) sensor
- the turbocharger (TC) control valve from the air cleaner (ACL)
- the air inlet hose on the mass air flow (MAF) sensor side
- the 2 mountings for the cable harness from the air cleaner (ACL) housing
- the air intake at inner fender
- the mounting screws
- the air cleaner (ACL).
Note!
Plug off the air inlet hose.
3. Removing the vacuum hose
Note!
Clean the area around the vacuum hose terminal before removal.
Remove:
- the connection from the brake servo
- the bolt and clamp from the vacuum hose (will be re-used)
- the protective cover for the throttle housing
- the vacuum hose from the intake manifold by pressing in the locking ring (1) while pulling the vacuum hose out
- the quick-release connector for the vacuum hose to the additional vacuum pump
- the vacuum hose. This will not be re-used
- the bolt (2) from the vacuum pipe on the side member.
4. Installing the protective sleeve for the throttle cable
Remove:
- the protective cover from the connector bracket fire wall
- the throttle cable out from the clip (1).
Install:
- the protective sleeve (2) over the throttle cable. Slide the protective sleeve as far as possible towards the firewall.
- the throttle cable in the clip (1).
5. Installing the new vacuum hose
Position the vacuum hose between the intake manifold and the brake servo.
Install:
- the vacuum hose in the manifold. Check the locking by pulling on the vacuum hose
- the vacuum hose control valve (1) in the brake servo
- the clamp (2) and bolt on the vacuum hose. Tighten to 6 Nm
6. Removing the complete additional vacuum pump assembly
Remove:
- the left front wheel
- the front fender liner. Bend the fender liner backwards
- the vacuum hose from the vacuum pipe
- the clamp (1) from the vacuum pipe
- the connector (2)
- the three mounting screws
- the vacuum pump assembly. This vacuum pump assembly will not be re-used.
Route the wiring and connector (2) via the existing inner fender hole into the engine compartment.
7. Removing the vacuum pipe from the side member
Remove:
- the clamp from the vacuum pipe at the side member
- the vacuum pipe.
Note!
The vacuum pipe must be bent before it can be removed. This vacuum pipe will not be re-used.
Clean the vacuum pipe and pump assembly screw positions. Apply rust proofing agent P/N 1161480.
Install:
- the front fender liner
- the left front wheel.
8. Removing the connector bracket from the transmission (to lower the position of the connectors)
Remove:
- the shifting cable out off the clip (1)
- the clip (1) from the bracket
- the upper tie strap (2) from the cable harness
- the two mounting screws
- the connectors by lifting the catches (3) and slide it from the bracket. Note the position of the connectors on the bracket
- the bracket and remove at the side the cable harness.
9. Installing the new connector bracket on the transmission
Install:
- the connectors on the bracket in their original positions and check the locking
- the cable harness tie strap on the side
- the bracket on the transmission. Tighten to 10 Nm
- the clip (1) for the shifting cable
- the shifting cable in the clip (1)
- the new tie strap (2) and cable harness.
10. Installing the extra cable harness
Remove:
- the relay/fuse box from the bracket
- the rear clamp from the cable harness.
Move the relay/fuse box to one side.
Position the connector (1) at the front. Route the new cable harness over the engine compartment cable harness.
Connect the connector (1) to the connector from the old vacuum pump.
Use tie straps to clamp the wiring as illustrated.
Note!
Ensure that the cable harness is not trapped or in contact with moving components or sharp edges.
11. Installing a new additional vacuum pump and bracket
Note!
Check that the existing nuts (1) are in good assembly conditions.
Position the vacuum pump bracket and relay bracket (2) on the inner fender by two screws.
Tighten to 21 Nm.
Press the quick release connector of the vacuum hose on the vacuum pump. Check the locking.
12. Installing the new cable harness and relay
Connect:
- the connector (1) to the vacuum hose control valve on the brake servo
- the extra cable harness connector (2) to the vacuum pump
- the relay (3) to the connector on the extra cable harness.
Install the relay (3) on the bracket (4). Tighten to 5 Nm.
13. Installing the relay/fuse box
Reinstall the relay/fuse box.
Replace fuse no. 22 (10 A) with the 15 A fuse. Clean the area where the label will be applied. Install the label on the inside of the cover
Reinstall the cover on the fuse box.
14. Installing components
Note!
Do not connect the battery negative lead.
Install:
- the air cleaner (ACL)
- the protective cover for the throttle housing
- the protective cover from the connector bracket fire wall
- the battery and battery clamp
- the protective cover over the battery
- the battery positive lead.
15. Connecting the battery and checking function
Turn the ignition to position II.
Warning!
Ensure that no one is in the car when the battery is connected.
Connect the battery negative lead.
Re-enter the radio code.
Set the car clock to the correct time.
Function test:
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.
Start the engine and let it idle.
Press down the brake pedal a few times and check whether the additional vacuum pump starts working.