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I recently had a no-start with my 760. Got all the dash lights, no sounds, but the no-start was intermittent. Visual examination of the starter/solenoid showed a flattened edge of the starter. This was a recently installed Bosch rebuilt. Couldn't get the shop to get interested in the notion that this starter may have been dropped. Nor could they diagnose my problem connected to the starter/solenoid. My no-starts correlated to temperature, as temperature rose above 110 F a no-start condition prevailed. This was confirmed with a remote IR temperature sensor aimed at the starter. A quick stream of water on the starter, cooling it to ambient air, and I got it started every time.
Further, I measured nominal volts at the wire that would connect to solenoid T50. Always got battery voltage. This easily eliminated ignition switch, NSS, etc. All battery and cable checks passed. I did this over and over with the same outcome. With this data, I returned to the shop. The warranty Bosch unit was replaced - no questions asked and at none of my expense. These were very simple tests to do. It cut out the shotgun approach and expense. I concluded I had a damaged unit.
For the fun of Volvos,
Mike
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'92 245DL, '90 760 GLT
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