Starter Motor Replacement- Struggling.

Paul240480 · Mar 23rd, 2020, 16:02

Due to the starter needing a sharp whack to wake it up far too often I began replacing it today. Got a used original from a Volvo breakers with a year guarantee.
Removed the old one, which is a Bosch.
I’ve got as far as seating the replacement ready to bolt up.
Got the trigger wire (green) re-connected.
But the two big red wires with the washer type ‘ends’ that go onto the solonoid are where I’ve stumbled. Now only one will reach, the other is about 2 inches ‘short’. Obviously it’s caught up on something but can’t for the life of me work it out.
Just wondered if anyone else has had this issue doing theirs and could point me in the right direction. I given up for today, and will go back after sleeping on it!
Thanks in advance.
EDIT: Might help if I tell you which car, it’s the 99’ T5 SE auto.

Paul240480 · Mar 23rd, 2020, 22:17

Wasn’t expecting any replies. Just sounding off really. Sure I’ll crack it. Thanks for looking anyways.
Hey if I ever put this one up in sales, ignore it’s a turd .
Never had a Volvo like it. Lol.

Baffler · Mar 24th, 2020, 04:24

Seeing as you haven't bolted it up yet I'd be tempted to remove it again and compared both starter motors side by side. It may just be the positive lug is in a different location on the new solenoid as opposed to your original.

Paul240480 · Mar 26th, 2020, 15:50

Baffler , you were spot on, it’s taken me all this time struggling and pulling my hair out. The two are slightly different, the old one has the solenoid on the side, so the wires reach.
The supplied one has it on top, so only one wire reaches. And yes it’s taken all this time to realise. DOH!

Paul240480 · Mar 26th, 2020, 17:23

I sent an email to the Volvo Saab breakers I got the starter from with the pic in the above post just before posting.
Got a reply, the correct part is being sent out today. Great service.

cheshired5 · Mar 26th, 2020, 19:13

You could open up the solenoid or main motor and find that there's very little required to restore its operation.
There are starter refurbishment videos on my YouTube channel.

Paul240480 · Mar 26th, 2020, 19:51

Thanks Chesh, I’ll take a peek. The ‘old’ one which is a Bosch does the random no start thing. As in nothing when you turn the key. A quick love tap with a bar and off it goes again, lol.

cheshired5 · Mar 26th, 2020, 21:57

The solenoid internals may just need a clean or you could just swap over the entire solenoid from the replacement unit if it's compatible.
3 x Torx screws and one nut removal is normally all that's required.

Baffler · Mar 27th, 2020, 04:52

Quote:

Originally Posted by Paul240480

I sent an email to the Volvo Saab breakers I got the starter from with the pic in the above post just before posting.
Got a reply, the correct part is being sent out today. Great service.

Are they letting you keep the other? If so it looks like you have a spare for your '04

Paul240480 · Mar 27th, 2020, 07:26

Yes , no mention of having to return it. It was £30 quid or so delivered, I’m sure they can swallow that.
If it fits the phase 2 then that’s fab.

Mar 23rd, 2020, 16:02	#1
Paul240480 Ovlovnut Last Online: Feb 25th, 2024 08:58 Join Date: May 2006 Location: Nivillac View Photos By: Paul240480	Starter Motor Replacement- Struggling. Due to the starter needing a sharp whack to wake it up far too often I began replacing it today. Got a used original from a Volvo breakers with a year guarantee. Removed the old one, which is a Bosch. I’ve got as far as seating the replacement ready to bolt up. Got the trigger wire (green) re-connected. But the two big red wires with the washer type ‘ends’ that go onto the solonoid are where I’ve stumbled. Now only one will reach, the other is about 2 inches ‘short’. Obviously it’s caught up on something but can’t for the life of me work it out. Just wondered if anyone else has had this issue doing theirs and could point me in the right direction. I given up for today, and will go back after sleeping on it! Thanks in advance. EDIT: Might help if I tell you which car, it’s the 99’ T5 SE auto. __________________ 2004 V70 2.4SE Auto 'The Welshmobile’ 2002 Laika Ecovip 400i ( Motorhome on an Iveco 2.8TD) http://www.gitessouthbrittany.com/ http://moncopainmonchien.jimdo.com/ Last edited by Paul240480; Mar 23rd, 2020 at 16:08.

Mar 23rd, 2020, 22:17	#2
Paul240480 Ovlovnut Last Online: Feb 25th, 2024 08:58 Join Date: May 2006 Location: Nivillac View Photos By: Paul240480	Wasn’t expecting any replies. Just sounding off really. Sure I’ll crack it. Thanks for looking anyways. Hey if I ever put this one up in sales, ignore it’s a turd . Never had a Volvo like it. Lol. __________________ 2004 V70 2.4SE Auto 'The Welshmobile’ 2002 Laika Ecovip 400i ( Motorhome on an Iveco 2.8TD) http://www.gitessouthbrittany.com/ http://moncopainmonchien.jimdo.com/

Mar 24th, 2020, 04:24	#3
Baffler Premier Member Last Online: Today 00:01 Join Date: Dec 2002 Location: Co. Limerick, Ireland	Seeing as you haven't bolted it up yet I'd be tempted to remove it again and compared both starter motors side by side. It may just be the positive lug is in a different location on the new solenoid as opposed to your original. __________________ Liam... '96 854 TDI SE, '99 V70 2.5D S, '05 C70 2.0T Collection, '05 S80 2.0T SE, '15 V70 D4 SE Lux Nav.

Mar 26th, 2020, 15:50	#4
Paul240480 Ovlovnut Last Online: Feb 25th, 2024 08:58 Join Date: May 2006 Location: Nivillac View Photos By: Paul240480	Baffler , you were spot on, it’s taken me all this time struggling and pulling my hair out. The two are slightly different, the old one has the solenoid on the side, so the wires reach. The supplied one has it on top, so only one wire reaches. And yes it’s taken all this time to realise. DOH! __________________ 2004 V70 2.4SE Auto 'The Welshmobile’ 2002 Laika Ecovip 400i ( Motorhome on an Iveco 2.8TD) http://www.gitessouthbrittany.com/ http://moncopainmonchien.jimdo.com/

Mar 26th, 2020, 17:23	#5
Paul240480 Ovlovnut Last Online: Feb 25th, 2024 08:58 Join Date: May 2006 Location: Nivillac View Photos By: Paul240480	I sent an email to the Volvo Saab breakers I got the starter from with the pic in the above post just before posting. Got a reply, the correct part is being sent out today. Great service. __________________ 2004 V70 2.4SE Auto 'The Welshmobile’ 2002 Laika Ecovip 400i ( Motorhome on an Iveco 2.8TD) http://www.gitessouthbrittany.com/ http://moncopainmonchien.jimdo.com/

Mar 26th, 2020, 19:13	#6
cheshired5 Premier Member Last Online: Dec 26th, 2021 13:42 Join Date: Dec 2013 Location: Crewe	You could open up the solenoid or main motor and find that there's very little required to restore its operation. There are starter refurbishment videos on my YouTube channel. __________________ 2002 S60 SE D5 Manual 209000 miles

Mar 26th, 2020, 19:51	#7
Paul240480 Ovlovnut Last Online: Feb 25th, 2024 08:58 Join Date: May 2006 Location: Nivillac View Photos By: Paul240480	Thanks Chesh, I’ll take a peek. The ‘old’ one which is a Bosch does the random no start thing. As in nothing when you turn the key. A quick love tap with a bar and off it goes again, lol. __________________ 2004 V70 2.4SE Auto 'The Welshmobile’ 2002 Laika Ecovip 400i ( Motorhome on an Iveco 2.8TD) http://www.gitessouthbrittany.com/ http://moncopainmonchien.jimdo.com/

Mar 26th, 2020, 21:57	#8
cheshired5 Premier Member Last Online: Dec 26th, 2021 13:42 Join Date: Dec 2013 Location: Crewe	The solenoid internals may just need a clean or you could just swap over the entire solenoid from the replacement unit if it's compatible. 3 x Torx screws and one nut removal is normally all that's required. __________________ 2002 S60 SE D5 Manual 209000 miles

Mar 27th, 2020, 07:26	#10
Paul240480 Ovlovnut Last Online: Feb 25th, 2024 08:58 Join Date: May 2006 Location: Nivillac View Photos By: Paul240480	Yes , no mention of having to return it. It was £30 quid or so delivered, I’m sure they can swallow that. If it fits the phase 2 then that’s fab. __________________ 2004 V70 2.4SE Auto 'The Welshmobile’ 2002 Laika Ecovip 400i ( Motorhome on an Iveco 2.8TD) http://www.gitessouthbrittany.com/ http://moncopainmonchien.jimdo.com/

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