I can't explain what happened in this circumstance. As I said before, there is no way under normal circumstances that the ports for each brake circuit inside the warning valve can be blocked by the moving parts that are inside the warning valve.
We've had to replace quite a few of the warning switches because someone didn't remove the switch before bleeding the brakes. But none of those cars came to us with issues traceable back to the warning valve. In most cases, the damaged switches had to be replaced so the light on the dash wouldn't stay on.
All I can think of is maybe the pistons inside the warning valve were stuck to the point where the tip of the switch provided enough resistance so that the pistons wouldn't move and maybe that trapped some air inside. But there should have been more than plenty of hydraulic pressure to move the pistons during normal bleeding as this is exactly what damages the tip of the switch. Maybe he didn't press down hard enough on the brake pedal while bleeding the brakes the 1st time.
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Eric Hi Performance Automotive Service (formerly OVO or Old Volvos Only) Torrance, CA 90502 hiperformanceautoservice.com or oldvolvosonly.com
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