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upgrade charging system?

Help, Advice and DIY Tutorials on Volvo's extremely popular car line -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, 850 R, 850 T5-R, 850 T5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

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erikv11
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erikv11

Re: upgrade charging system?

Post by erikv11 » Thu Jan 02, 2020 8:55 am

xHeart wrote: ↑
Mon Dec 30, 2019 8:52 am
You're correct Misha, the reading at battery cable while idling is 13.5-13.6v, so yes, it is higher than the reading at the cig.lighter.

Unless otherwise, ordering this item https://www.fcpeuro.com/products/volvo- ... 70-9456836
Image
This is a low quality, thin gauge, cable. Same if you buy it from Volvo or from aftermarket suppliers. I've put in a couple of these cables but much prefer to build my own with heavier gauge cable where I have the time.

When using this cable I've also run the new cable in parallel with the old cable, since you have to just leave the old one there. It can only help. Yes there is room at the starter for both lugs.
'95 854 T5-R, Motronic 4.4, 185k
'96 855 NA, 145k
'98 S70 NA, 220k (living out west)
'98 V70, T5 tune-injectors-turbo, LPT engine, 285k
'06 S60 R, 165k
'99 Camry V6 :shock: 125k
gone: '96 NA 850 210k, '98 NA V70 182k

xHeart
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xHeart

Re: upgrade charging system?

Post by xHeart » Thu Jan 02, 2020 11:35 am

The FEDEx will bring the new battery cable today so I took few more voltage readings while idling and loading with headlights, warning lights, radio, wiper, heater and fan, all cabin lights with door and trunk open, and iPhone charging at the cig. lighter, the reading were:
- Alternator output at B+ post/– housing: 14.02v
- Battery charge rate at the terminals +/–: 13.12v
- Voltage reader device at cig. lighter: 12.9v

Now battery is out and cooling fan removed, I can see the cable routing. The battery cable's other end connects to the starter, and a second cable connects alternator and starter.

What to check at the starter before disconnecting cables?
--
Golden Retriever | 2014D VIDA DiCE | 2013A XC90 +144mi/231km | 2001 V70XC 1st Owner +196mi/ +315km | 1997 Volvo 850 NA 1st Owner +180mi/ +289km
Past: German Shepherd | 1989 Volvo 740 GL | 1979 Volvo 240

xHeart
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xHeart

Re: upgrade charging system?

Post by xHeart » Fri Jan 03, 2020 8:19 am

erikv11 wrote: ↑
Thu Jan 02, 2020 8:55 am
This is a low quality, thin gauge, cable. Same if you buy it from Volvo or from aftermarket suppliers. I've put in a couple of these cables but much prefer to build my own with heavier gauge cable where I have the time.

When using this cable I've also run the new cable in parallel with the old cable, since you have to just leave the old one there. It can only help. Yes there is room at the starter for both lugs.
+1
AND not a direct fit battery terminal. The 1" long 1/4 24 screw for connecting 2 red leads is an insert -- crooked thread -- will loosen and fail. Throwing good money after bad.

It is a critical cable therefore stick with Volvo.
--
Golden Retriever | 2014D VIDA DiCE | 2013A XC90 +144mi/231km | 2001 V70XC 1st Owner +196mi/ +315km | 1997 Volvo 850 NA 1st Owner +180mi/ +289km
Past: German Shepherd | 1989 Volvo 740 GL | 1979 Volvo 240

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erikv11
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erikv11

Re: upgrade charging system?

Post by erikv11 » Fri Jan 03, 2020 12:15 pm

You can't buy anything better or different from Volvo, that is the crux of the problem here. Volvo sells the exact same cable!

Building a new cable is the way to go if you want it done well.
'95 854 T5-R, Motronic 4.4, 185k
'96 855 NA, 145k
'98 S70 NA, 220k (living out west)
'98 V70, T5 tune-injectors-turbo, LPT engine, 285k
'06 S60 R, 165k
'99 Camry V6 :shock: 125k
gone: '96 NA 850 210k, '98 NA V70 182k

xHeart
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xHeart

Re: upgrade charging system?

Post by xHeart » Fri Jan 03, 2020 12:18 pm

The battery charging is now restored with ECONOMY replacement cable. Old Volvo terminal is designed to fit various wires. I was able to modify and add square port like original.

The replacement cable terminal arm is short, and the ring is hard to fit over battery terminal -- simply pia!

Here is the pix of old terminal:
MVS_terminal_0641.jpg
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--
Golden Retriever | 2014D VIDA DiCE | 2013A XC90 +144mi/231km | 2001 V70XC 1st Owner +196mi/ +315km | 1997 Volvo 850 NA 1st Owner +180mi/ +289km
Past: German Shepherd | 1989 Volvo 740 GL | 1979 Volvo 240

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misha
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misha

Re: upgrade charging system?

Post by misha » Fri Jan 03, 2020 1:23 pm

Now get your battery fully re-charged with a charger and check it periodically.
If sulphating process started because it was always undercharged it will never have full capacity like it should...but it will last longer now when charging issues are solved.

The old clamp was soldered with big soldering iron....how did you just transfer the old clamp on new cable?
'97 850 2.5 20v / fully equipped / Motronic 4.4 from the factory / upgraded with S,V,C,XC70 instrument cluster / polar white wagon
'91 Citroen XM 2.0 SI /fully equipped/mandarine red metallic
History of Volvos in the family:
'71 144 S
'73 144 De Luxe
'78 244 DL
'78 244 DL
'79 244 GLE
'85 340 GLS

xHeart
Posts: 2581
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xHeart

Re: upgrade charging system?

Post by xHeart » Sat Jan 04, 2020 8:13 am

misha wrote: ↑
Fri Jan 03, 2020 1:23 pm
Now get your battery fully re-charged with a charger and check it periodically.
If sulphating process started because it was always undercharged it will never have full capacity like it should...but it will last longer now when charging issues are solved.

The old clamp was soldered with big soldering iron....how did you just transfer the old clamp on new cable?
The battery is new, replacement under warranty, so there is no sulphate build up and charge was 12.65v. The idle charge is 13.8-13.9v at the battery terminals under load, i.e headlights, warning lights, radio, wiper, heater and fan, all cabin lights with door and trunk open, and iPhone charging at the cig. lighter.

No, I did not transfer the old original terminal clamp to new cable. However, the new cable is long enough to be cut off at the clamp and put on the original -- original clamp is WAY BETTER! Can the original camp be reconditioned for the new cable -- like the challenge?
--
Golden Retriever | 2014D VIDA DiCE | 2013A XC90 +144mi/231km | 2001 V70XC 1st Owner +196mi/ +315km | 1997 Volvo 850 NA 1st Owner +180mi/ +289km
Past: German Shepherd | 1989 Volvo 740 GL | 1979 Volvo 240

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misha
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misha

Re: upgrade charging system?

Post by misha » Sat Jan 04, 2020 10:57 am

Charging results are excellent!
It can,but you will need a BIG industrial soldering iron to remove the remainings of the old cable from it and to re-solder a new one.

I wouldn't bother with it unless i have that soldering iron.
Clamps are clamps....cables are those which fails.
'97 850 2.5 20v / fully equipped / Motronic 4.4 from the factory / upgraded with S,V,C,XC70 instrument cluster / polar white wagon
'91 Citroen XM 2.0 SI /fully equipped/mandarine red metallic
History of Volvos in the family:
'71 144 S
'73 144 De Luxe
'78 244 DL
'78 244 DL
'79 244 GLE
'85 340 GLS

xHeart
Posts: 2581
Joined: Sat Dec 03, 2011 8:05 am
Year and Model: 13XC90/01V70X/97N854
Location: Great Lakes - USA
Has thanked: 18 times
Been thanked: 33 times
United States of America
xHeart

Re: upgrade charging system?

Post by xHeart » Sun Jan 19, 2020 9:03 am

New cable is working -- ample battery charge for a cold start after overnight temps dropping in single digits. The trickle charger may loose its job this winter.
--
Golden Retriever | 2014D VIDA DiCE | 2013A XC90 +144mi/231km | 2001 V70XC 1st Owner +196mi/ +315km | 1997 Volvo 850 NA 1st Owner +180mi/ +289km
Past: German Shepherd | 1989 Volvo 740 GL | 1979 Volvo 240

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abscate
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abscate

Re: upgrade charging system?

Post by abscate » Sun Jan 19, 2020 10:32 am

A solid 10 -amp battery charger in the garage or in your local club inventory is pretty mandatory in the cold climates
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