Brake Fluid Reservoir, Replacing, L.H.D

Brake fluid reservoir, replacing

Removal

Preparations




Switch off the ignition.
Clean around filler cap at the connector between the reservoir and master cylinder and at any hose connector. This is to ensure that no contaminants enter the brake system.
Place paper under the master cylinder. This is to protect the paintwork from damage if brake fluid is spilled.
Secure the pedal in the depressed position. Use a pedal jack.

Remove the upper engine stabilizer brace





Remove:
- the mounting screws for the torque rod
- the screw and nut for the engine mounting and torque rod
- the screw for the oil hose clamp
- the engine stabilizer brace.

Preparations for removing the brake fluid reservoir




Block the hose to the clutch cylinder.Applies to cars with manual transmissions.

Remove the plastic cap and the cable holder
See Brake pipe master cylinder / ABS unit, replacing, B5254T2 Brake Pipe Master Cylinder / ABS Unit, Replacing

Pull out the master cylinder
Remove the connector from the brake fluid level sensor.
Remove the mounting nuts from the master cylinder.
Pull out the cylinder slightly.

Remove the brake fluid reservoir





Remove:
- the screw on the side of the brake fluid reservoir
- the brake fluid reservoir from the master cylinder. Pull the reservoir straight up
- the hose for the clutch cylinder. Applies to cars with manual transmissions.

Cleaning and checking




Check the brake fluid reservoir, the level switch, the check valves and seals.
Replace the seals if necessary.
Carefully clean the components that were not replaced. Clean off all contaminants and old brake fluid. Use new brake fluid.

Installation

Install the brake fluid reservoir




Check that all connections are free of contaminants.
Lubricate the O-rings and any hoses with brake fluid or glycerin.

Note! Donotuse a soap solution or mineral oil to lubricate the hoses. Use brake fluid or glycerin.

Install:
- the hose for the clutch cylinder. Remove the hose clip
- the brake fluid reservoir from directly above
- the screw on side of the brake fluid reservoir. Tighten to 3.5 Nm.

Install the master cylinder




Tighten the mounting nuts. Tighten to 25 Nm.
Connect the connector on the brake fluid reservoir.
Install the nut for the positive cable. Fold back the positive cable. Tighten the nut at the wheel arch. Tighten to 25 Nm.

Install the upper torque rod





Install:
- the engine stabilizer brace. Tighten the mounting screws. Tighten to 50 Nm
- the screw and a new nut for the engine mounting. Tighten to 80 Nm
- the screw for the oil hose clamp.

Finishing work




Fill the brake fluid reservoir with new brake fluid. Use Volvo Genuine parts, DOT 4+.
Remove the pedal jack.

Cars with manual transmissions: Bleed the clutch

If necessary:
Bleed the brake system. See Brake system, bleeding (using bleeding unit) Brake System, Bleeding (Using Bleeding Unit)
Bleed the system again if the pedal travel is more than 40 mm.
Check for leakage.
The brake fluid level must not be above the maximum mark.