96 850 Turbo Wagon Mechanic's Challenge

FlipIt · Post by **FlipIt** » 05 Jan 2011, 04:01

precopster wrote:These motors will not start without the large IAC tube connected. Not sure about the connector, though.

At this point I'm not trying to start the engine. I was just checking for spark. I have a lot of hose and wiring routing corrections to perform before running the engine. Thanks for the serpentine belt routing diagrams.

FlipIt · Post by **FlipIt** » 05 Jan 2011, 12:23

With the ignition on there was no voltage at the ignition coil primary so I disconnected the electrical connector to the ignition output module and measured voltages and resistance. There was battery voltage on the Blu/Red wire, ground on the black wire and about 0.6 volts on the Yel/Wht wire that goes to the ECU. I then disconnected one of the leads between the module and the coil and measured resistance. The coil primary resistance was about 1.5 ohms and the output module resistance was infinity. I conclude that the output driver of the module is blown.

: IgnMdul.jpg (55.34 KiB) Viewed 2141 times

I found a used ignition coil/module assembly on eBay for $20 that includes shipping and I've ordered it.

FlipIt · Post by **FlipIt** » 05 Jan 2011, 14:48

I removed the battery and tray and cleaned the area beneath it. I have several questions.

: UndrTray.jpg (87.92 KiB) Viewed 2133 times

The red arrow identifies a short, broken section of black rigid vacuum hose clamped to the hood release cable. Is this the remains of the original hose that was replaced by the white semi-rigid vacuum hose with a section of black flexible hose that changes back to white semi-rigid?

The blue arrow identifies a clamp attached to the hood release cable. Was this to hold the original black rigid vacuum hose?

The yellow arrow identifies a metal mount that could hold an electrical connector. Which one?

Should the blue section of battery to chassis ground cable be forward of the battery as shown or aft with the other section?

Does anyone have a photo of this area to post?

FlipIt · Post by **FlipIt** » 05 Jan 2011, 18:40

Nevermind, I found the answers to the questions in my previous post on another thread:
http://www.volvoforums.com/forum/showthread.php?t=29883

This photo shows the battery holder.

: BatHldr.jpg (44.82 KiB) Viewed 2121 times

This photo shows the routing of the battery cables.

: BatCbls.jpg (48.55 KiB) Viewed 2121 times

This photo shows the vacuum lines under the battery tray and the electrical connector mounted.

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This photo shows the mounting of the vacuum pump under the battery tray and the vacuum line to it.

: BatVacPump.jpg (45.14 KiB) Viewed 2121 times

FlipIt · Post by **FlipIt** » 05 Jan 2011, 18:47

This photo shows the broken off transmission vent.

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Fortunately the upper section was trapped under the wiring harness so I only have to replace some rubber hose.

FlipIt · Post by **FlipIt** » 05 Jan 2011, 18:53

These large cast aluminum items were in the parts box. I suspect they are heat shields that fit between the engine and the firewall.

: AlumPcs.jpg (51.87 KiB) Viewed 2120 times

I'll be searching for a drawing or photo showing how to install them. I have no idea where the bracket/support in the lower left goes.

FlipIt · Post by **FlipIt** » 07 Jan 2011, 10:52

I found a diagram of a C70 exhaust system. It indicates that the aluminum parts and bracket in the previous post are associated with protecting the underbody and not the firewall. Apparently the exhaust system was removed to replace the head gasket and the shields were never reinstalled. I've ordered an 850 service manual DVD. Hopefully it will help me reassemble the vehicle.

FlipIt · Post by **FlipIt** » 11 Jan 2011, 07:57

While waiting for my ignition module to arrive (paid for on 5 Jan but not shipped until 10 Jan) I brushed the corrosion from the battery off the area below it, primed and then painted it.

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As I stated in an earlier post the electrical wiring was in poor condition. Many of the looms were broken and the boots at the connectors were missing. I purchased wire loom lengths of various sizes, electrical tape and tie wraps to make repairs.

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I reinforced the normal diameter looms with short sections of larger diameter.

The loom to the fuel injectors was completely replaced.

: LoomInjs.jpg (72.51 KiB) Viewed 2075 times

I used a tie wrap before and after the wire split out for each injector.

I need to tape the ends of the to be determined connector aft of the intake filter enclosure identified by the red arrow. I also need to determine where to mount it.

: Cnx.jpg (78.22 KiB) Viewed 2075 times

Does anyone know if something should be connected to the connector identified with the yellow arrow?

FlipIt · Post by **FlipIt** » 11 Jan 2011, 09:26

I found a post on this forum stating that the unused connector is the service starter connector that bypasses everything except the transmission range selector. According to my 1995 850 wiring diagram the connector should be on the passenger side instead of the driver side but the color (green/red) is correct. It will be useful when performing future compression and ignition tests.

I've searched thru the wiring diagrams and can't find a connection with the correct wire colors to match the other connector that needs electrical tape.

Klausc · Post by **Klausc** » 11 Jan 2011, 09:36

In the left hand drive cars, the starter bypass is on the driver's side.
I would still have used large diameter and cheap vacuum lines to cover the wiring instead of the plastic wrap that Volvo uses.
Nice job on the fender under the battery tray!!

96 850 Turbo Wagon Mechanic's Challenge

Re: 96 850 Turbo Wagon Mechanic's Challenge