Mechanics

R & R STARTER

1997 Volvo V90

Electrical problem
1997 Volvo V90 6 cyl Two Wheel Drive Automatic 200010 miles

I am attempting to replace the starter on my car. I consulted a repair manual for removal instructions and it seemed pretty straightforward. The manual indicated that the starter is held to the bellhousing by only two bolts. I removed those two bolts but the starter wouldn't budge. Turns out there is also a bracket attached to the front of the starter in an inaccessible location. I next tried to get to the bracket by removing the intake plenum. Unfortunately, the plenum is secured at its bottom by a single nut right above the left motor mount in a " you can't get there from here" position. What is the correct way to remove and re-install the starter on this vehicle?
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Jrkreiger
February 6, 2010.




Remove air duct to air cleaner (ACL) housing.
Remove 4 screws holding the fan shroud and relay bracket.
Remove relay bracket and disconnect engine cooling fan (FC) connector from relay.
Turbocharged engines: Disconnect charge air hose from charge air cooler (CAC).
Remove cable from 2 clips on cover.
Disconnect vacuum hoses from cover.
Remove vacuum valve from cover.
Disassemble engine cooling fan (FC) connector.
Remove engine cooling fan (FC) with shroud.

Remove throttle pulley cover.
Turbocharged engines: Remove intermediate hose from pipe between turbocharger (TC) and charge air cooler (CAC) and hang hose to intake manifold on the throttle mechanism.

Remove plastic solenoid cover.
Remove bracket screw from engine.
Disconnect all cables from starter motor.
Remove screws holding starter motor.
Lift starter motor.
Remove nuts holding bracket.
Hope this helps.

JIS001
Feb 7, 2010.


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