Installing Extra Control Valve (25-0036)

INSTALLING EXTRA CONTROL VALVE

TECHNICAL SERVICE BULLETIN

BACKGROUND

Long crank on start could be caused by exhaust gasses remaining the intake manifold from the previous engine shut down. Installing a vent valve will allow the intake manifold to purge the gasses into the exhaust system. Follow the installation instructions below if this condition is experienced.

Model	Chassis No.
S40/V40 2001-	600 000 -

Description	Quantity	P/N
Kit	1	30662287
Cable tie	4	983750

Description	P/N
Hose clamp pliers	9512619 (available from SPX) or equivalent hose clamp plier such as Oetiker Side Jaw Pincer, part # 14100083.

INLET AND EXHAUST MANIFOLDS

Extra control valve, installing 

1. Valve assembly

   Position the plug (1) on the underside of the valve connection.

   Partially remove the two locking tabs from the tie strap (2) as illustrated (see Fig 1 ).

   Install the tie strap (2) on the valve as indicated in the drawing. Secure the tie strap.

   Connect the vacuum hose (3) to the valve.

   Fig 1: Valve Assembly

   
2. Installing the T-piece (see Fig 2 )

   If necessary remove the cover for the throttle housing.

   Cut the hose (A) at 60 mm.

   Cut (B) 10 mm from the existing hose.

   Place two new hose clamps.

   Install the T-piece with the extra connection pointing downwards.

   Do not secure the hose clamps yet.

   Fig 2: Installing T-piece

   
3. Installing the valve (see Fig 3 )

   Press the tie strap, with the valve, into the free hole in the battery tray.

   If there is no free hole, drill a hole (A) with a diameter of 6.5 mm on the vertical edge of the battery tray.

   Ensure that the electrical connection is directed upwards.

   Place two new hose clamps and connect the hose (1) to the T-piece in the hose. Tighten those hose clamps.

   Install the connector on the valve.

   Route the wiring (2) to the evaporative emission (EVAP) valve on the radiator.

   Fig 3: Installing Valve

   
4. Connecting and securing wiring (see Fig 4 )
   WARNING: Switch off the ignition.

   Detach the connector from the evaporative emissions (EVAP) valve. Route in the direction of the headlamp.

   Route and connect the connector from the new cable harness to the evaporative emissions (EVAP) valve.

   Connect the detached connector to the new cable harness.

   Route the ground cable via the rear of the headlamp to the battery negative terminal.

   Install the ground cable terminal (1) on the battery negative lead using the existing bolt without detaching the negative lead.

   Secure the cable harness using the tie straps. Secure the cable harnesses so that it does not chafe, touch moving parts or cause ratting, and so that it is not under tension.

   Fig 4: Connecting & Securing Wiring

   
5. Securing hoses and checking the function (see Fig 5 )

   Move the hoses away from other components. Secure the hoses using a tie strap where necessary. Ensure that no moving parts are in contact with the assembled system.

   Secure the hose clamps (1).

   Check the function by switching of and on the ignition. Check whether the valve switches on and off.

   When the engine is switched off it is possible that a hissing sound may be heard for a few seconds.

   Fig 5: Securing Hoses & Checking Function

   

WARRANTY STATEMENT  : Claims may be submitted under the New Car Warranty when there is a documented customer complaint, using claim type 01.

Operation No.	Labor Description	Time Allowance
99803-2	Valve vacuum hose install	0.4 hr