Power Brake Booster RHD Cars, Replacement: Finishing

WARNING: This page is about a different car, the 2002 Volvo C70, 2001 Volvo C70, 2000 Volvo C70, 1999 Volvo C70, and 1998 Volvo C70. However, it is still accessible from the selected car via links, so may be relevant.

Install:

brake pipe on mountings on firewall.
connectors to pedal position sensor and brake fluid reservoir.
electrical lead to mountings on power brake booster.

In cars with manual gearshift (transmission):

Install hose to clutch cylinder. Remove hose clip.
If necessary, bleed clutch and check level in brake fluid reservoir. Use genuine Volvo DOT 4+ brake fluid when topping up.

Fig 1: Identifying Components To Be Removed For Power Brake Booster Replacement

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install torque bracket to torque arm.

NOTE: Use new bolt and locknut. Locknut P/N: M8 (older models) 948 645-7 M10 (later models) 971 098-9 On later models, locknut is included as standard.

Tighten:

M8 nuts to 18 Nm (13 ft. lb) and turn through 120°.
M10 nuts to 35 Nm (26 ft. lb) and turn through 90°.

Install:

ground braid to firewall.
air hose to air filter casing.
sparkplug leads to coil and to mountings on air filter casing.
positive battery leads to mountings on battery shelf.
battery leads to battery.

In cars with automatic gearshift:

Install oil cooling hose to radiator. Use new O-ring.

In cars with turbo:

Install turbocharger air pipe to hose connector by upper intercooler connector.
Install engine oil cooling hose to radiator. Use new O-ring.