I know this issue has been posted numerous times out there but I'm curious which of the following might be temperature related (engine bay or cabin) when the issue is not the starter. The problem is you turn the key and get full power, lights, etc. but the starter won't crank.

As the temps reach 90 and above around us, the no crank issue crops up more and more. During a recent overhaul (HG,timing belt, water pump, etc) I decided to have the starter rebuilt as this problem existed before that work. I'm positive the starter is good as it was rebuilt by a specialist with a good reputation -also new solenoid.

I'm told this can now either be a faulty ignition switch or neutral safety switch. Would any of these begin to react poorly as temperatures increase? There is a nice troubleshooting article here, but I've not yet had the opportunity to try this: Intermittent no start on 2000 Volvo S40. (Electrical Ignition Volvo S40 Engine No start)

Could anything else come into play that might be related to rising temps? I drove the car for a week trouble free when temps were in the 70s.

Thanks in advance guys!

 

I'd say the neutral starting switch, replaced mine (2002 S40 110k miles) from Rockauto.com for $75 and the random no crank issue was resolved. Took about 30-45 minutes to change-out. You can try shifting through all gears quickly a few times then try again. If you intentionally put the gear in D and try to start you should get the same effect. Wouldn't hurt to check to see if everything is tight and check the connector near the brake master cylinder.

 

Oh, I think the 2000 model has a different switch and connector type, more money also to buy.

2002
http://www.rockauto.com/catalog/more...355&cc=1431486

2000
http://www.rockauto.com/catalog/more...063&cc=1434041
http://www.partsgeek.com/catalog/200...on_sensor.html

 

Correct, the 2000 is different from 01-04 and is more money. I actually found the best price for this one through NAPA at around $170.

Can you tell me exactly where it is located? The parts diagram shows on top of tranny but I'm not sure - not near shifter? (automatic trans)

 

This link will help you, although the connector is likely different. My 2002 connector is below the engine fuse box. Note I didn't have to remove the battery or air filter box to change mine out. Make sure car is in neutral before starting the swap, switch alignment is important.

Volvo Performance Repairs And Modifications

 

Thanks for the link, those instructions look quite helpful. If the switch is set in neutral prior to making the swap, do we negate the need for yet another special Volvo tool as long as the new switch is put in at the same adjustment, or is also using that tool necessary? Thanks again!

 

Either the transmission stud or the switch will likely move during the process. The switch comes set for neutral. I used a hairpin to help with positioning, after installation, open end at the stud, scribe line if the switch centered. Also, if you note the spacing in the bolt holes and repeat after the exchange you should be OK.