I was driving my car home (2004.5) a couple of weeks ago and came to a red light. As I started slowing down the car died. Now it won't start. All I'm getting is a single click from the starter and then the lights dim if I keep the key turned. As soon as I let off, everything is back to normal brightness. Everything else works as normal.

Here's what I have done so far:

-Changed starters (had an extra one laying around)
-Tried starting the car with a known good battery
-Inspected battery cables
-Turned the engine by hand to make sure it's not seized (it's not)
-Pulled starter relay, nothing happens with it removed but clicks when inserted

I'm out of ideas...am I missing something? I haven't checked the alternator, but I would assume the car would crank even if the alternator was bad.

 

what year (S40??). It could be the ignition switch or the immobilizer. What's the voltage at the battery when key is in position 2 and when you turn to start? Also try doing the shifter row thing... wondering if the PNP switch is telling the car your not in park or neutral???

 

It's a 2004.5. Forgot to mention I've tried rowing the shifter. If the ignition switch is bad, I would think nothing would happen instead of just one click? I'll have to check voltages and report back.

 

the solenoid click sure makes it sound like either a bad cable (or connection) from the battery to the starter, a weak battery or bad starter... I agree that with an immobilizer, PNP or ignition switch problem you wouldn't expect a click... Regarding the alternator, it is conceivable that a bad voltage regulator could be draining the battery... I presume your lights and accessories work?

 

Yes all accessories and lights work. Battery cable looked ok but I'll check voltage at the starter tomorrow. Maybe there is some oxidation inside the cable that I can't see

 

Update.....checked the voltage drop from the battery to the starter while trying to crank. Voltage at battery is 12.71 and drops almost 3.5 volts by the time it gets to the starter...ugh. So even though the cable looks ok, I think I've found the culprit. I'll replace the cable sometime this week and hopefully this will take care of the no start issue.

This should also explain why the car died suddenly as the alternator is not able to charge the battery through a bad cable and the car was running of the battery until it finally discharged.

Volvo wants a ridiculous amount for new cables, so I'll be making my own. I'll report back with results.

 

Replaced positive battery cable. Found that the fuse on the cable itself had popped. New cable and the car fired right up.

 

Thank you for posting the fix.

 

Fuse on the cable? Does this require a new cable to fix?


Also, did you take the time to check and clean your ground connections?

 

It would require a new cable if you are keeping the same fuse in place. I made my own cable from stuff I already had laying around. I did check all other connections with a voltmeter and they all checked out.

The reason the fuse popped is because the cable wore through in one spot and shorted out against the starter.