MAINTENANCE
INFORMATION
DATE :
SUBJECT :

FEBRUARY 2016

MI16-16
SECTION : 01 - Engine

VOLVO D13 ENGINE –
STARTER REMOVAL AND INSTALLATION

DESCRIPTION
This procedure applies to current Melco 105P70 starter part number #21212425.

REQUIRED TOOLS
RATCHET EXTENSION BAR

RATCHET AND SOCKET SET – METRIC

CORDLESS DRILL

BRASS WIRE CUP BRUSH

TORQUE WRENCH

CUTTING PLIERS

VOLTMETER / MULTIMETER

METRIC OPEN END WRENCH SET

MI16-16 / Page 2 / 6

PROCEDURE – STARTER REMOVAL AND INSTALLATION

DANGER
Park vehicle safely, apply parking brake, stop engine. Prior to working on the vehicle, set the ignition
switch to the OFF position, the battery master switch to the OFF position and trip the main circuit
breakers equipped with a trip button.

RISK OF ELECTRICAL SHOCK
1. The starter is connected to the batteries through master relay R1. If the ignition switch is in the OFF
position and the battery master switch (master cut-out) is set to the OFF position, there should not
be electrical power to the starter B (batt) terminal. However, a faulty master relay R1 could
eventually leave the battery power circuit closed, thus electrical power would be present at the
starter B terminal.
2. Using a voltmeter or multimeter, probe the starter B terminal and the ground terminal. Make sure
that the voltage reading is 0 volt prior disconnecting the starter cables (FIGURE 2).

STARTER REMOVAL
3. While proceeding from under the vehicle,
gain access to the starter (item 29 on
FIGURE 1) on the turbocharger side (street
side).

FIGURE 1: D13H ENGINE OVERVIEW, TURBO SIDE

4. On the starter, disconnect circuits 0C, 101
and 101B (see FIGURE 2). Properly clean
cable lugs as applicable using a brass
wire cup brush, a Scotch-Brite pad or an
emery cloth. Remove old Color Guard
Rubber Coating as much as possible.
IMPORTANT: keep hardware for later
use

FIGURE 2

MI16-16 / Page 3 / 6

5. Using a 18mm socket, unscrew three bolts
fastening the starter to the flywheel
housing (FIGURE 3).
6. Detach the starter from the flywheel
housing.

FIGURE 3

STARTER INSTALLATION
1. If the starter is replaced with a brand new
starter, prepare the new starter as follows
(refer to FIGURE 5).
a) Remove the second nut on the ground
terminal (FIGURE 5). Keep for later use.
b) Remove the jumper cable connected
to the ground terminal (FIGURE 5).
c) Make sure that the three nuts
identified on FIGURE 5 are tightened to
a torque of 22 lbf-ft.
d) Reinstall the jumper cable to the
ground terminal.
e) Install a nylon tie mount p/n 504013 on
the starter. Refer to FIGURE 6 for
proper location. Secure the nylon tie
mount with one screw p/n 502817
(FIGURE 7).

FIGURE 4 : TERMINAL IDENTIFICATION

MI16-16 / Page 4 / 6

FIGURE 6

FIGURE 5

FIGURE 7

2. Install the replacement starter with the
solenoid located on the underside of the
starter motor as shown on FIGURE 8.
3. Hand tighten the three mounting nut.
Flange nut M12 p/n 990942 qty: 3
4. Once the starter is properly seated on the
flywheel housing, torque the three
mounting nuts to al torque of 44 lbf-ft.

FIGURE 8

INSTALLATION OF CIRCUIT 0C
5. Connect the ground cable (circuit 0C) to
the ground terminal first. Make sure the
ground cable extends vertically downward
from the terminal as shown on FIGURE 9.
6. Secure the ground cable lug with the nut
previously removed at step 1-a. Tighten to
a torque of 22 lbf-ft.
M12 hex nut p/n 983717

FIGURE 9

MI16-16 / Page 5 / 6

INSTALLATION OF CIRCUIT 101
7. Connect circuit 101 to B terminal (FIGURE 4
& FIGURE 5). Position circuit 101 cable to
be in line with the nylon tie mount on the
starter.
8. Place the washer against circuit 101 cable
lug and secure cable lug and washer with
the nut. Tighten the nut to a torque of 22
lbf-ft.
washer p/n 500958 qty:1

FIGURE 10

nut p/n 5001761 qty:1
INSTALLATION OF CIRCUIT 101B
9. If not already done, remove the nut and
washer provided with the brand new
alternator on S terminal (FIGURE 4).
10. Connect circuit 101B to S terminal.
Position circuit 101B cable to be in line
with the nylon tie mount on the starter.
11. Place the provided washer against circuit
101 cable lug and then secure cable lug
and washer with the nut provided. Tighten
the nut to 35 lbf-in.

FIGURE 11

12. Secure circuit 101 and 101B to the tie
mount using one nylon tie p/n 504016.
13. Tie circuit 101 and 101B together using
one nylon tie p/n 504637 as shown on
FIGURE 12.

FIGURE 12

14. Apply anti-corrosion compound or Color
Guard
Rubber
Coating
(Prevost
p/n 684013) on starter terminals, cable
lugs and nuts (see FIGURE 13 to FIGURE 15).

FIGURE 13

MI16-16 / Page 6 / 6

FIGURE 14

FIGURE 15

FUNCTIONAL TEST
1. Reset main circuit breakers if applicable. Set the battery master switch (master cut-out) to the ON
position and start the engine.

PARTS / WASTE DISPOSAL
Discard according to applicable environmental regulations (Municipal/State[Prov.]/ Federal)

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