Starter Motor Removal Tips Volvo V60 2.0L 2016 Diesel 140kW/190BHP D4204T Engine Topic is solved

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To anyone who this might help.




Starter Motor Removal Tips Volvo V60 2.0L 2016 Diesel 140kW/190BHP D4204T Engine

I used a 3/8” socket set and needed deep sockets, a universal joint and some socket extensions. An 8mm open-ended or ring spanner for the bolt on the underside of the starter motor (ring ratchet is better). Torx for the engine cover, airbox cover and MAF sensor. Torch and mirror.

I would suggest looking at an image of a replacement starter before you start to see what to expect. Mine was volvo part number 31419530.


1. Remove battery negative terminal
2. Remove engine top cover.
3. Loosen air box cover (torx, they are captive), remove MAF (two torx screws) from the air duct, undo worm drive on air duct and remove airbox cover and filter.
4. Push prong fixing in bottom of the airbox with an 8mm socket and simultaneously lift bottom of air box free. Leave wires attached if you want and hang against wing/fender
5. Undo 2 no. nuts holding starter cable bracket onto starter motor.
6. Undo 3 no. bolts holding starter to bell housing (2 no. bolts/studs, and a single bolt at the top (the forward one of the two black headed bolts).
7. Remove intercooler air duct (worm drive at one end and spring clips at the other). Gently lever out the two spring clips with two screwdrivers simultaneously. Stuff lower opening with a clean rag to stop bits falling in once hose removed.
8. Undo fourth bolt holding starter on place (underneath, at the arse end). Use 8mm spanner. Torch and mirror may be needed, as well as tiny fingers.
9. Wiggle the starter free and remove tie holding a cable to the starter. Remove the two connections to the solenoid.
10. Carefully manoeuvre the starter free.


I didn’t remove any coolant hoses, just tucked/tied them out of the way.
Took me 2 hrs to swap the starter as unfamiliar. Next time would be well under 1hr.

Refitting Notes
1. Hold nuts into sockets with blue tack. If using universal joints on sockets, put some duct tape around the outside to keep them straight if required.
2. Reinstalling intercooler hose – face worm clip so screw is upwards (easier to do up)
3. The intercooler hose clips upwards in to place
4. Lightly grease guide pin of starter to make installation/removal easier
5. Loosely fit the three starter bellhousing bolts before finally tightening.

For anyone interested, when I tested the starter out of the car, it ran when +12V was applied to the motor connection, but not when applied to the solenoid stud that the same wire was connected to. The lug was dirty from overheating (I had suffered a failed clutch and the garage had driven the car around their yard on the starter motor). A quick clean up of all connections and the starter tested fine out of the car and was a successful repair once installed. Garage quote was £400 so I am having some beers tonight.