2007 xc90 3.2 Brake vacuum pump oil leak

canimkid · Post by **canimkid** » 11 Aug 2014, 19:57

2007 xc90 3.2 with 140k it has a small oil leak coming from the brake vacuum pump I read there is a rebuild kit available has anyone rebuilt this pump ? how long did it take ? where to get the parts? is there a video available ?

Baileysxc90 · Post by **Baileysxc90** » 13 Sep 2014, 21:27

I just rebuilt my vacuum pump in my 07 xc90 3.2 . I got the gasket kit from my local Volvo dealer $60 and was able to do the rebuild in about 2 hrs. I was also unable to find any videos on the rebuild, but it is an easy repair and requires no special tools.

canimkid · Post by **canimkid** » 25 Sep 2014, 22:33

Thanks for the info just picked up the rebuild kit from my Volvo dealer and will install it soon

Indy V70 XC · Post by **Indy V70 XC** » 01 Dec 2014, 15:20

Bailey:

Can you recall some of the main steps. Specifically, what had to come off the engine to get the left bolt, and how was the vacuum line removed without braking anything?

The rest looks super easy.

Thanks!

canimkid · Post by **canimkid** » 01 Dec 2014, 19:27

The mounting bracket for the air conditioning pump has to be removed, remove this first then remove the vacuum pump once the vacuum pump is removed then remove vacuum pump hose it is much easier to remove this hose with the vacuum pump removed.

Indy V70 XC · Post by **Indy V70 XC** » 04 Dec 2014, 19:22

Finished! Not hard to work myself through, but here is the basic idea:

1. Remove Plastic 3.2 engine cover. This pulls off and is held in place with compression rubber pieces
2. Remove air supply plastic cover, which is also simply snapped on to its base
3. Loosen and disconnect air supply hose by loosening clamp with a flathead screwdriver and gently pulling away from housing
4. Remove power steering reservoir from bracket and allow to stand freely. You can do this by pulling it up and to one direction from the bracket
5. Remove (2) 8MM bolts which secure power steering reservoir bracket. Set aside for future use.
6. Remove A/C support bracket, which is held in place by (2) 10MM bolts and (1) 13MM bolt. All bolts have different length, so remember their placement
7. Remove vacuum line fitting from vacuum pump. Do this by gently prying the plastic ring up and over the male end vacuum pump fitting. You will need to loosen it on two ends. Then, simply pull it away from the pump. The fitting in the vacuum pump is removed later.
8. Remove (2) 10MM bolts holding the vacuum pump. Have a shop towel and plastic bag handy to catch the vacuum pump as there will be oil coming out. Gently move it away from the engine, in the orientation it is in.
9. Once oil has drained out, use a tool to compress the (2) clips on the vacuum pump plastic fitting. Clean surfaces
10. Remove small o-ring from engine mating pump side
11. Remove (5) torx bolts from pump, and open case. Remove and replace large o-ring inside pump after cleaning mating surfaces
12. Ensure the (2) black pieces which move inside the pump on the ends of a long shaft do not fall off
13. Close pump back up with enclosed (5) new torx bolts
14. Clean exterior housing thoroughly
15. Replace engine side o-ring
16. Replace vacuum pump plastic fitting and ensure it is fully seated and the two clips engage.
17. Reverse of removal. Done! Should take under 2 hours.

Bshoemake · Post by **Bshoemake** » 09 Mar 2015, 13:22

Just purchased a 2007 s80 and believe I have the same leak. Any difference between the s80 and xc90 3.2?

camarkim · Post by **camarkim** » 27 Mar 2015, 21:41

My independent Volvo mechanic recommended we get this fixed on our 2007 XC90 3.2. I declined for now. Reading this thread, I'm wondering why he quoted us $450? Maybe a whole new vacuum pump? I think I'd rather DIY it with this rebuild kit.

wa5pcg · Post by **wa5pcg** » 03 Sep 2018, 20:34

Link to a video: