jdlc Posted July 9, 2008 Report Share Posted July 9, 2008 Need to replace the starter on my 850, got a lower-mileage, used starter from a member.I wonder what needs to come out to access the starter - would not want to remove the intake manifold if I can help it.Fan & shroud enough to give room?Also, any pitfalls? Link to comment Share on other sites More sharing options...
copycat923 Posted July 9, 2008 Report Share Posted July 9, 2008 I googled and found these directions, no pix though. http://en.allexperts.com/q/Volvo-802/95-Vo...850-Starter.htm This does seem to do it without removing the intake manifold.Taking off the intake manifold is really not that difficult though, I did it three times one day due to some pcv posts on this web page that confused me. Anyways, you can leave the fuel rail on, just disconnect the lines at the top. You only need to remove the top 3 manifold bolts, and just loosen the bottom 4 bolts like 1/2 inch, if the come out, put them back in before you put the intake manifold back on.You'll probably want some sort of magnetic tool retrieval device because bolts will fall if you aren't very very careful. I actually put a magnet on the side of my socket to hold the bolts in as I put them back on.Leave the throttle body on and just remove the throttle cable assembly, do remove the intake pipe from the throttle body. You could also leave the throttle cable attached and just flip the intake manifold over and set around the intake/battery area.Just take off the two 12 mm bolts under the mani, one on oil dipstick one about 4 inches behind that and the manifold will be able to pull up and out. You will need to release the vac lines that are connected in order to pull the manifold all the way out.If you have EGR (94-95) you will need to take that off (22mm wrench). You will also need a 1/4 inch driver with extensions and elbow to get to the bottom passenger side bolt on the intake. Really if done right it should only take about half an hour to get off, and it will make replacing the starter much easier.When I did this 3 times in one day ~5 hrs for pcv servicing ( Thought I was wrong first time, made it wrong second time, back to good third time...) I actually had radiator out already so the amount of space I had was much much more than normal. I think removal of fan and shroud would make job a lot easier and it is only 4 bolts and a few wire connectors. Just be sure to get it to slip into the radiator on the bottom when you put it back in. I believe there is a post about intake removal with pics in the pinned threads, check it if you are confused.If you don't have one, a haynes owner manual is pretty good for little common jobs like these. According to some people I think this is attemptable without removing intake, I guess it depends how much time you have. I would probably just take the intake off because I've done it a few times now and it wouldn't be a big deal. If you have never done a pcv service, it would be a great time for one as well. Link to comment Share on other sites More sharing options...
Ozark Lee Posted July 9, 2008 Report Share Posted July 9, 2008 I changed one out without taking the intake manifold off (Ironically a week after I serviced the PCV) but that was on an N/A model. It was very very tight but I did get it done. On a turbo I'm not sure what else will be in the way - I would think that the intercooler line will need to come of for sure....Lee Link to comment Share on other sites More sharing options...
7 VII 7 Posted July 9, 2008 Report Share Posted July 9, 2008 take off the fan shroud... you will have so much more room. Link to comment Share on other sites More sharing options...
jdlc Posted July 9, 2008 Author Report Share Posted July 9, 2008 Thanks guys, looks like cc923's find is the way to go.I will try to document with pics my progress, maybe do a write-up of some kind. Link to comment Share on other sites More sharing options...
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