2004 S60 Help identify valve on vacuum tube

[wrw0010]

Can someone help identify the valve assembly (?) below?

It sits right in front of the air filter box. The cap has come off and possibly a diaphragm. I went by the Volvo dealer today (without the vehicle because it was having work done elsewhere) but forgot to take a photo with me. I was unable to identify the part from the schematics they showed me.

I can hear it whistling so I am nearly positive this is where my vacuum leak is coming from.

[wrw0010]

After looking though a bunch of threads, I think this may be the brake booster switch. The only thing is I don't see a harness that would connect to this and the brake booster switch has a socket on top.

[S60T5SE]

My car is a little different under the hood than yours, so I am not 100% sure, but I believe that is the switch to the brake booster vacuum assist pump. If it is, you're certainly missing a few parts.....

https://www.matthewsvolvosite.com/forums ... =9&t=43817

HTH.

Jeff

[wrw0010]

My car is a little different under the hood than yours, so I am not 100% sure, but I believe that is the switch to the brake booster vacuum assist pump. If it is, you're certainly missing a few parts.....

https://www.matthewsvolvosite.com/forums ... =9&t=43817

HTH.

Jeff

Yes, I think you are correct. The whole top seems to be gone. I think I found the harness though.

[abscate]

A nice cork will plug that temporarily until you get one from a pick and pull.

Part number 3141 666 271828 available at a hardware store near you. I think I would try a rubber stopper whose minor diameter just fits in the opening and precisely 3 fig newtons of thumb pressure to fit it.

[wrw0010]

A nice cork will plug that temporarily until you get one from a pick and pull.

Part number 3141 666 271828 available at a hardware store near you. I think I would try a rubber stopper whose minor diameter just fits in the opening and precisely 3 fig newtons of thumb pressure to fit it.

Auto parts stores didn't have it in stock. Volvo dealer has the switch and it's only $70. Going to pick it up today. Any tricks to getting the old switch off the hoses/new one on?

[regent]

I was so glad to discover that my 02S60 did not come with an air pump - just a straight hose w/check valve from the intake mfld to the brake booster. Wo-hoo!

[jimmy57]

I guess there should be a sticky or FAQ link.
These booster vacuum switches will eventually crack on all P2, P1, and the NedCar S40/V40 models.

The spring inside exerts force on the end cap with the electrical switch.
The cap has 4 reliefs where 4 tabs on the body of the switch engage. The cap will crack and then the tabs no longer hold and the switch flies apart.

If you get JB Weld quick set formula and mix up approximately 1/2 inch line each of both parts. Smear all around on side of cap and then wrap gently with electrical tape in such a way that the electrical tape sticks over the vaccum T side of switch to make a form. The JB Weld will ooze to the top of the form and run around the edge of the switch body. Set it upright so the JB Weld doesn't run away and let it cure. I guess I should mention that cleaning switch body with rubbing alcohol first is a good idea so any oily residue will not impede the adhesion of JB weld to the switch body.

I have repaired some broken ones using a C Clamp to hold it together so it can be JB Weld fixed but this requires that you find all the parts.

[abscate]

What's the function of this switch? Is it telling the ECU to shut off boost if brake vacuum falls?

[jimmy57]

The switch turns on the electric vac pump. Single CVVT engines have some vacuum reduction when cold started but dual CVVT have 4-6 inches of vac in that situation and the brake pedal can be hard and make car hard to stop.