Volvo Repair: brakes, rotors, brake pads and rotors, engine vacuum

Question
I just bought a 2000 s40 turbo, I felt a slight pulsation coming from the front of the car and the car did not stop immediately when I pushed on the brake pedal.  Took it to a brake shop and was told I needed front brake pads and rotors.  My brother-in-law is a mechanic and said he could do it several hundred cheaper.  The tire shop put the old brakes back on, but the brakes were hard to push and they stopped worse after they checked them. Brother-in-law put brakes and rotors on, but brakes are still hard to push and don't stop good.  He suggests driving for several days and if they still have the same problem he would bleed the brakes.  What is your advise?

Answer
Well there are 3 things to check.  Number one is the rotors and pads will work MUCH better if they are factory parts.  I don't know what it is about those pads in particular but the aftermarkets just suck.  The rotors on volvos also cannot be resurfaced/cut.  They will warp every time if you try to do that.  That is probably how you got the pulsation in the first place.  Second this car uses a vacuum pump to suplement engine vacuum since there is less vacuum on turbo motors (like yours is).  The 2000 models used to have a vacuum pump under the fender lining but they would fill with water and short out.  A new design was introduced that put a new design vacuum pump under the fuse panel.  It is a silver cylinder about the size of a can of coke.  Look and see if it has been installed.  IT IS AN ACTIVE RECALL labeled recall 129.  You can call any volvo dealer and give them your VIN and they can tell you if it has been performed.  Lastly the vacuum hose that goes to the booster from the throttle body has a electronic sensor on it near the booster.  Sometimes it will come apart (and then your booster will get no vacuum).  Check to make sure it is one piece.  There are other possibilities but check those first because one of them is most likely your problem.  If they aren't check the brakes at each wheel more carefully.

James