A couple nights agoI had the following sequence of events (2002 Volvo S60 AWD, 90K miles).
1. Dash lights got suddenly brighter for a split second.
2. Headlights went to high beams, message said low-beam failure.
3. Dash lights went dim about the same time I flipped back down to low beams. Message came up voltage overload, pull over safely.
4. I was in taffic and it seemed to be running ok so I limped home, and could tell the battery was draining.
5. As the battery drained the computer started shedding non-essentials so I pulled over, jumped it for a while with my wifes car and limped the remainder of the way home.

Voltage tests results: After charging the battery and restarting, the voltage reading at the fuse block is less than 12V. So, I'm thinking it's either the alternator, or voltage regulator.

Questions:
1. I searched the archives and didn't come across this "Voltage Overload" problem. Is this a common voltage regulator issue?

2. Do all the S60's have removable regulators? I havn't started exploratory wrenching yet.

3. If the alternator must be liberated from the vehicle, what parts usually come off first?

4. Finally, are there trouble codes that need to be cleared or that can be pulled down to help in the problem solving?

Thanks in advance

 

A good battery should read over 12 volts after charged. You should test it while disconnected. You may have blown some fuses with the brief current overload. I would start with the alternator. I have not removed one YET, so I cannot help there.

 

Thanks. I should have been more specific. The voltage readings at the fuse block were taken while the engine was idling, suggesting no-chargefrom the alternator.

 

Here's closure to this post. I pulled the alternator and had it bench tested. Very goodwebpagebelow on how to get to it and remove it from the car. In addition (not noted in this write up I don't think), you'll need to loosen the radiator top hose at the radiator and push the hose to the side for clearance.

http://turbobil.com/SMF/index.php?topic=37.0

When tested at the local auto shop it flipped their braker on the bench and then put out about 11 volts. I replaced the VR with a new one from a local import parts shop, reassembled, and all is good again. Just need to replace a hi and low beam headlight that did not survive the incedent.

 

Glad it worked out.