Installing Pipes

INSTALL THE BRAKE PIPES

Fig 1: Identifying Brake Lines

Courtesy of VOLVO CARS CORPORATION

Tighten the pipes to 17 Nm .

INSTALL THE INTEGRATED RELAY / FUSEBOX

Fig 2: Identifying Integrated Relay Fusebox Bracket

Courtesy of VOLVO CARS CORPORATION

Install:

the bracket and the integrated relay / fusebox in the mounting
screw in the bracket. Tighten to 10 Nm .

INSTALL THE CABLE HOLDER AND PLASTIC CAP

Fig 3: Identifying Plastic Cap And Cable Holder

Courtesy of VOLVO CARS CORPORATION

Install:

the cable holder. Tighten the nuts, Tighten to 10 Nm
the positive cable and integrated relay / fusebox nut. Tighten to 25 Nm
the screw on the clamp around the positive cable
the plastic cap at the positive cable.

INSTALL THE AIR CLEANER (ACL) HOUSING

Fig 4: Identifying Air Cleaner (ACL) Housing

Courtesy of VOLVO CARS CORPORATION

Connect all the air hoses and connectors to the air cleaner (ACL) housing.

Tighten the hose clamp.

Fold the air intake in under the front cover plate.

Locate it in its mounting and press it into place.

The positioning of the air intake can be seen through an oblong hole in the front cover plate.

FILL AND BLEED THE BRAKE SYSTEM

Remove the pedal jack.

Fill and bleed the brake system. See BRAKE SYSTEM, BLEEDING (USING BLEEDING UNIT) .

CHECKING FOR AIR IN THE BRAKE SYSTEM AND FOR BRAKE FLUID LEAKAGE

Fig 5: Bleeding Brake System

Courtesy of VOLVO CARS CORPORATION

Check if there is still air in the system. Press down the brake pedal using a jack at a pressure equivalent to heavy braking, 200 Nm . With the engine off and the brake pedal depressed 3-4 times, the pedal travel must not exceed 40-mm.

If the pedal travel exceeds this limit, bleed again and re-check the pedal travel.

Check that no leakage occurs from the brake nipples, hoses and joints.

Remove the bleed unit connector from the brake fluid reservoir.

Check that the brake fluid level is not above maximum.