Charlie,

I don't think you fixed your problem.

Yes you repaired the electric air pump, and I commend you on that. And it sounds like you got to it just in time.

But the point is, how did it get that way? This air pump design is not unique to Volvo--it is used on many cars. The problem is that Volvo did a lousy job in locating the pump at such a low elevation and in procuring defective air valves.

This air pump was never designed to operate in the presence of water. So where did the water come from?

First, what does this pump do? It injects fresh air into the exhaust manifold in order to assist the catalytic converter in doing its job (a simplified explaination). When the pump is not operating, the air valve is supposed to close and seal off the airpump from the exhaust stream. Why? Because the exhaust stream is laden with warm, moist air, which, when it hits the cool pump, or it's associated tubing, condenses into water.

The point is that that water came from somewhere. Where it came from is your improperly functioning air valve.

You said you tested your air valve. I suspect you tested your air valve for basic functioning. I suspect that you did not test to see if the exhaust side of the air valve was sealing 100%. In fact, testing for this is very difficult.

Bottom line, replace your air valve with a new unit (I believe they have been improved) and you shouldn't have to repair your pump again.

Ken