Starter Not Disengage 1997 850 T5 RESOLVED, wiring wrong

[drzaeis]

To rule out tumbler issue...
- Remove the Ignition Switch (LEFT of steering column).
- Use a flat blade screwdriver to crank the car and then bring the screwdriver back to position II (run).

* If the starter stops running ---> tumbler issue (I have a spare one lying around)
* If the starter continues to run ---> problem with starter solenoid (whoever rebuilt it probably did not lube the solenoid properly) and/or wiring.

already did this..starter still runs...

[drzaeis]

Elaborate on how you have the starter wired.

The large main terminal should have both the battery and the alternator wires, together on the same large terminal. The green/red wire then goes to the small lug on the solenoid.

...Lee

Lee,

here is a pic of the wiring, after I start the car if I pull the little green wire the starter still runs...

here is the pic of the wiring..maybe I should try another starter???

[abscate]

I think that is a firm diagnosis of a bad starter solenoid.

[jimmy57]

The cable you have on inboard stud should not be there (brown cable). Only the braided little piece of wire that goes into motor case of starter. Your alternator is running the starter motor the way it is wired according to the picture.

The battery is the red one and when you turn the key the green wire turns on the solenoid and starter works as it should. Then alternator starts charging and runs the starter motor with its output.

Both of those cable will fit only the outboard longer stud but I think the brown one is turned a half turn as shown.

I'm going to remember this. That is a neat trick to pull on a buddy. Well, maybe not a buddy.

[abscate]

Nice catch Jimmy...

+10,000

[drzaeis]

The cable you have on inboard stud should not be there (brown cable). Only the braided little piece of wire that goes into motor case of starter. Your alternator is running the starter motor the way it is wired according to the picture.

The battery is the red one and when you turn the key the green wire turns on the solenoid and starter works as it should. Then alternator starts charging and runs the starter motor with its output.

Both of those cable will fit only the outboard longer stud but I think the brown one is turned a half turn as shown.

I'm going to remember this. That is a neat trick to pull on a buddy. Well, maybe not a buddy.

so I should move the inboard cable, (brown as you say but it looks black to me), to where? both should be on the outer stud? then the inner stud only has the braided wire that goes to the motor case??

thank you thank you!!! I think we're getting close...I hope!

[cn90]

Interesting re brown wire...

But according to the thread below, that extra wire is feeding the aux fan:

https://www.matthewsvolvosite.com/forums ... =1&t=36780

Below is the schematic of the wire that "JPC412" and "BEJinFbk" talked about in the thread above:

AuxFan.JPG (67.05 KiB) Viewed 897 times

[cn90]

O.P.

I still think you should do the screwdriver trick I mentioned above to r/o the tumbler.

[jimmy57]

Yes, the short stud is only for the braided wire that comes out of starter motor case right by it. The other large cable, whatever color, is supposed to be on the stud with the red cable already there. The starter solenoid does two things: It pulls the solenoid armature (aka "plunger") in so it pulls the pinion into flywheel teeth and the armature depresses a button that pushes a copper disc against the heads of the two studs to connect them. This connection sends battery voltage to the inboard stud for the starter motor lead to run the motor and nothing else connects there.

[drzaeis]

Interesting re brown wire...

But according to the thread below, that extra wire is feeding the aux fan:

https://www.matthewsvolvosite.com/forums ... =1&t=36780

Below is the schematic of the wire that "JPC412" and "BEJinFbk" talked about in the thread above:

AuxFan.JPG

Got it. Both red wires are supposed to be on the outer terminal...one is from the battery the other goes to the alternator.

THANKS EVERYONE!!!!