My 1st P2 (XC70) Project impossible? Topic is solved

[keaunym]

With so few miles on this car, why do you suspect there are so many problems? Could it have been in a flood? Or perhaps this is more typical of these cars than I thought?

[precopster]

Anything's possible I guess.
The CEM reports the same mileage as speedo so if water was an issue it would likely have unmatched modules.

No evidence of water ingress that I can see.

PDM, ETM, CCM. REM, transmission; all these faults are typical P2 issues; I just got one with all of them at the same time. Just my luck. Except for the missing ABS fuse of course.

Leaving it sitting in a sunny backyard with no cover for 3.5 yrs dried out the diaphragm in the booster because the pedal was fine 1 year ago when I tried to repair the trans.

It certainly drives like a low kilometre car suspension-wise. It is SO MUCH quieter than wife's 2002 XC70 with 322K kilometres. Body is quiet and tight and very little shock enters the cabin.

[precopster]

This car is living up to the thread's name (Project Impossible) and the brakes seem to elude providing a solid, firm and consistent pedal. Rarely it's hard and most of the time it's squishy and way too low.

I replaced the ABS pump unit, the master cylinder, the brake booster and bled at all possible brake hose junctions and still the pedal is awful. Can't get it registered or sold with the brakes the way they are.

Next plan is to replace the calipers one by one. I'm thinking that a sticking caliper can provide a mushy pedal.

[precopster]

Made a set of subframe dropppers yesterday from M14 high tensile threaded rod so I could replace the booster with a new one. Pedal stays assisted well after 5 minutes for one pump of the pedal after the engine has been turned off and the infernal hissing from the old booster has stopped after engine has been turned off.

Pedal still sinks to below what is comfortable for me. Have to go through Vida this evening for the official bleeding procedure for these P2s. There must be something I've missed.

[precopster]

That's an XC90 master cylinder and reservoir in that pic above by the way. I tore one off our 2006 XC90 for testing and still the same result.

Had a look at Vida's bleeding procedure. They suggest pressurising the reservoir with a pump and to have the pedal depressed while draining the bleeder nipples.

So one of these is on the way: Too bad I get "Error parsing server" when I tried to add a pic

[precopster]

Picked up one of these vacuum hand pumps for $25 inc shipping and after evacuating/bleeding at the wheels 4 times with the brake pedal depressed, performing a rain dance and exercising demons from the car it finally has a good pedal.

I hope my roadworthy tester will take another look early next year.

[abscate]

Mike...can you comment on having to drop the subframe to do the brake booster R/R?

I'm surprised you have to do this.

[precopster]

On RHD cars you just don't have clearance from the cylinder head. I actually had to hang the right side of the subframe with no bolts in at all and lower it using the longest tools on the left in order to remove the brake booster. I didn't need to drain fluids due to the amount of flex in all the hoses. The trickiest part was the steering coupling but even that would be easy next time around.

On LHD cars I looked at the procedure on Vida for brake booster removal and it was dead easy. These tools could be used for transmission R & R on virtually all P80s and P2s. I'm glad I have them in the tool shed for next time.

[abscate]

Ah - I numbskulled the fact that you are RHD - clarity bursts upon me like a supernova...

[precopster]

It passed the inspection!! I steam cleaned the carpets, gave it a wash and have it listed on a local car site.

A list of some of the new components:

4 brand new tyres and wheel alignment
Genuine Volvo Rear Main Seal
Timing belt and tensioner/pulley
New Hepu Water Pump
New ATE Brake Booster
All cam seals
New Turbo hoses
PCV System
New Radiator Hoses
Coolant Tank and sensor
New front ball joints
New Inner Tie Rods
New Genuine Spring Seats
New rear brake pads