2017 S60 2.0 Turbo

[1989XJS]

Thank you for letting me join! I'm stumped on this one. My pastor asked me to look at his 2017 Volvo S60. He took it to a local oil change place and after the work the car wouldn't start. They said he needed a new starter, $1300. He had it towed to my shop as we felt the starter could be replaced for much less. I found that the fusible link to the starter was blown and that the starter had suffered some significant hammer blows. Evidently an attempt by the other shop to get it started. I got a new starter and fusible link and installed them. I checked resistance through the cable to the starter and found it to be less than 1 ohm. I also checked all connections and battery condition. Attempting to start, the engine turns over briefly, maybe one revolution, but then stalls. After several attempts, the starter gets hot and the fusible link blows. I've put the vehicle on my lift to look around underneath for a grounding issue but see nothing evident. I've gone over the wiring several times and notice no open insulation or evidence of grounding. I'm beginning to believe the engine is binding as the starter is trying to turn it over but stalls resulting in the heat and ultimate blowing of the fuse. Any advice on what/how to check further. Thanks!

[abscate]

You cannot really measure resistance on big wires without expensive equipment.

It sounds like you have a poor cranking or no cranking issue, engine isn’t spinning fast enough to start.

You can measure starter draw in amps with a clamp on ammeter. Don’t assume a “ new one” is good, there are a lot of junk parts sold new

Check the battery voltage at the battery clamp, should be 12.7 volts , now swing down to the big terminal on the starter , it should also be 12.7 volts. A 0.1 volt difference here is big.

[jonesg]

try turn the engine by hand, 32mm nut on the crank pulley.

[1989XJS]

Did that, although I didn't turn it over two complete revolutions, it turned over relatively easy.

[jonesg]

Did that, although I didn't turn it over two complete revolutions, it turned over relatively easy.

then I would swap the starter, it fails to crank, starter gets hot but engine isn't stuck.