upgrade charging system?

[erikv11]

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

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.

[xHeart]

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?

[xHeart]

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.

[erikv11]

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.

[xHeart]

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 (86.72 KiB) Viewed 136 times

[misha]

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?

[xHeart]

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?

[misha]

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.

[xHeart]

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.

[abscate]

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