Volvo Coupes/Sedans/Wagons 1970-1989 Repair Guide

Starter

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REMOVAL & INSTALLATION



See Figures 1 and 2

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the leads from the starter motor. On later model cars, it may be necessary to loosen or remove other components to gain access to the starter bolts.
  4.  



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Fig. Fig. 1: Examples of alternators with internal regulators-amperage ratings appear on a plate on the alternator case



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Fig. Fig. 2: Examples of integrated voltage regulators found on 1983 and later Volvos

  1. Remove the bolts retaining the starter motor brace to the cylinder block (B21 through 1977 only) and the bolts retaining the starter motor to the flywheel housing and lift it off.
  2.  
  3. To reinstall, position the starter motor to the flywheel housing. Apply locking compound to the bolt threads and install the retaining bolts finger-tight. Tighten the bolts to approximately 25 ft. lbs. (34 Nm).
  4.  
  5. Connect the starter motor leads and the negative battery cable.
  6.  

DRIVE REPLACEMENT



See Figures 3, 4, 5, 6, 7 and 8

In order to remove the starter pinion drive, it is necessary to disassemble the starter. The procedure for disassembling the starter is as follows:



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Fig. Fig. 3: Lift up the brushes and remove the brush bridge



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Fig. Fig. 4: Use a socket to push back the stop collar and remove the snap-ring to remove the starter drive

  1. Remove the starter from the car.
  2.  
  3. Unscrew the two screws and remove the small cover from the front end of the starter shaft.
  4.  
  5. Unsnap the lockwasher and remove the adjusting washer from the front end of the shaft.
  6.  
  7. Unscrew the two screws retaining the commutator bearing shield and the shield.
  8.  
  9. Lift up the brushes and retainer and remove the brush bridge from the rotor shaft. The negative brushes are removed with the bridge while the positive brushes remain in the field winding. Do not remove the steel washer and the fiber washer at this time.
  10.  



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Fig. Fig. 5: Exploded view of the starter motor-common to all models through 1984



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Fig. Fig. 6: Exploded view of the starter motor-B28F and B280F engines



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Fig. Fig. 7: Exploded view of the starter motor-D24 and D24T engines

  1. Unscrew the nut retaining the field terminal connection to the control solenoid.
  2.  
  3. Unscrew the two solenoid-to-starter housing retaining screws and remove the solenoid.
  4.  
  5. Remove the drive end shield and rotor from the stator.
  6.  
  7. Remove the rubber and metal sealing washer from the housing.
  8.  
  9. Unscrew the nut and remove the screw on which the engaging arm pivots.
  10.  
  11. Remove the rotor, with the pinion and engaging arm attached, from the drive end shield.
  12.  
  13. Push back the stop washer and remove the snapring from the rotor shaft.
  14.  



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Fig. Fig. 8: Lubricate the starter motor as described upon reassembly

  1. Remove the stop washer and pull off the starter pinion.
  2.  

While the starter is disassembled, a few quick checks may be performed. Check the rotor shaft, commutator, and windings. If the rotor shaft is bent or worn, it must be replaced. Maximum rotor shaft radial throw is 0.003 in. (0.08mm). If the commutator is scored or worn unevenly, it should be turned by a machine shop. Minimum commutator diameter is 1.3 in. (33mm). Check the end shield, which houses the brushes, for excessive wear. Maximum bearing clearance is 0.005 in. (0.13mm).

  1. Lubricate the starter.
  2.  
  3. Press the starter pinion onto the rotor shaft. Install the stop washer and secure it with a new snapring.
  4.  
  5. Position the engaging arm on the pinion. Install the rotor into the drive end frame.
  6.  
  7. Install the screw and nut for the engaging arm pivot.
  8.  
  9. Install the rubber and metal sealing washers into the drive end housing.
  10.  
  11. Install the stator onto the rotor and drive end shield.
  12.  
  13. Position the solenoid so that the eyelet on the end of the solenoid plunger fits onto the engaging arm (shift lever). Tighten the solenoid retaining screws.
  14.  
  15. Place the metal and fiber washers on the rotor shaft.
  16.  
  17. Install the brush bridge on the rotor shaft and replace the brushes.
  18.  
  19. Fit the commutator bearing shield into position and install the retaining screws.
  20.  
  21. Install the adjusting washers and snap a new lockwasher into position on the end of the shaft. Make sure that the rotor axial clearance does not exceed 0.12 in. (0.03mm). If necessary, adjust the clearance with washers, maintaining a minimum clearance of 0.012 in. (0.05mm).
  22.  
  23. Replace the small cover over the front end of the shaft and install the two retaining screws.
  24.  
  25. Install the starter in the car.
  26.  

SOLENOID REPLACEMENT



If the starter will not crank, before replacing the solenoid check the battery for sufficient charge. If the no-crank condition persists when the battery is known to be good, connect a jumper wire between the positive terminal of the battery and the contact screw for the solenoid lead. If the solenoid engages the starter pinion, the starter switch or leads are at fault. If the starter still does not crank, replace the solenoid. To remove the solenoid:

  1. Remove the starter from the car as outlined in Starter Removal and Installation.
  2.  
  3. Unscrew the two solenoid-to-starter housing retaining screws and remove the solenoid.
  4.  
  5. As a final test, wipe the solenoid clean and press in the armature. Test its operation by connecting it to a battery. If the solenoid still does not function, replace it with a new unit.
  6.  
  7. Position the new solenoid so that the eyelet on the end of the plunger fits into the engaging arm. Tighten the retaining screws.
  8.  
  9. Replace the starter in the car as outlined in Starter Removal and Installation.
  10.  

 
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