Service Manual Trucks

Service Manual Trucks Group 8 Hood VN PV776-TSP383

Foreword The descriptions and service procedures contained in this manual are based on designs and methods studies carried out up to March 00. The products are under continuous development. Vehicles and components produced after the above date may therefore have different specifications and repair methods. When this is believed to have a significant bearing on this manual, supplementary service bulletins will be issued to cover the changes. The new edition of this manual will update the changes. In service procedures where the title incorporates an operation number, this is a reference to an S.R.T. (Standard Repair Time). Service procedures which do not include an operation number in the title are for general information and no reference is made to an S.R.T. The following levels of observations, cautions and warnings are used in this Service Documentation: Note: Indicates a procedure, practice, or condition that must be followed in order to have the vehicle or component function in the manner intended. Caution: Indicates an unsafe practice where damage to the product could occur. Warning: Indicates an unsafe practice where personal injury or severe damage to the product could occur. Danger: Indicates an unsafe practice where serious personal injury or death could occur. Volvo Trucks North America, Inc. Greensboro, NC USA Order number: PV776-TSP383 000 Volvo Trucks North America, Inc., Greensboro, NC USA All rights reserved. No part of this publication may be reproduced, stored in retrieval system, or transmitted in any forms by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Volvo Trucks North America, Inc..

Contents Specifications... 3 Hood Torque Values... 3 Hood Dimensions & Alignment... 3 Tools... 5 Special Tools... 5 Design and Function... 9 Hood... 9 General... 9 Hood Mounting... 0 Hood Latch... Engine Air Intake... 4 Front Grille... 5 Headlights... 5 Miscellaneous Components... 6... 7 Hood, Replacement... 7 Hood, Adjustment... 9 Torsion Rod Assembly, Replacement... 3 Hood Restraint Cylinder, Replacement... 6 Hood Latch, Replacement... 8 Hood Latch Stud, Replacement... 9 Hood Latch Arm, Replacement... 9 Hood Release Cable, Replacement... 30 Grille, Replacement... 3 Grille Slash, Replacement... 33 Air Intake Grille, Replacement... 34 Air Intake Bellows, Replacement... 34 Headlamp Lens, Replacement... 36 Headlamp, Adjustment... 37 Turn Signal Lens, Replacement... 44 Hood Insulation, Replacement... 45 Hood Rivet Nut, Replacement... 46 Hood Fender and Headlamp Bucket, Replacement... 47 SMC Panel, Repair... 53 Feedback Operation Numbers

Specifications Hood Torque Values Specifications J-bracket mounting bolts... 56 ± 0 Nm (4 ± 7 ft-lb) Restraint cylinder mounting bolts... 30 ± 4 Nm ( ± 3 ft-lb) Pivot bracket nuts... 56 ± 0 Nm (4 ± 7 ft-lb) Latch assembly mounting bolts... 8 ± 5 Nm ( ± 4 ft-lb) Latch stud mounting bolts... 8 ± 5 Nm ( ± 4 ft-lb) Latch arm mounting bolts... 00 ± 33 Nm (48 ± 4 ft-lb) Grille mounting screws... Nm (.5 in-lb) Hood Dimensions & Alignment Width across fenders (outside to outside)... 405 ± 3 mm (94.685 ± 0. in.) Hood to cowl gap... maximum 6 mm greater than gap tool Allowable difference between upper and lower gap... maximum 4 mm 3

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Tools Special Tools Note: The gap gauge and gauge blocks may be ordered individually or as a Hood Alignment Kit, which contains both tools. The part number for the kit is 394680. Tools 394558 Hood gap gauge 394559 Hood gauge blocks () (includes long screws, part no. 969603) W000375 The following alignment kit is required to adjust the VN Series hood and the bumper to the hood. To order, contact Kent-Moore at 800 38 6657. J-4764 Front bumper/hood alignment kit. The kit contains the following: J 4884 Hood Alignment Tool ( required) J-4764 J-407 A Alignment Block for VNL/VNM trucks with painted bumpers Alignment Block for VNL trucks with SMC or bright bumpers W000507 5

Tools J-5300 D Headlight aiming equipment Kent-Moore ( 800 38 6657) W80000 J-4405 Rivet nut insertion tool kit Kent-Moore ( 800 38 6657) An inverted torx socket is needed for adjustment of the VN headlamp. Inverted Torx Socket: Size E7 P/N ME7 P/N IMTLE70 Available from Mac Tools Available from Snap-On W30035 6

Tools The following items may be necessary for repair of the VN Series hood. They are available from Precision Products & Services, Inc. ( 800 993 8767). P/N 30 300 ml manual dispenser W8009 P/N 304 300 ml pneumatic dispenser For repair and maintenance of the VN Series hood, Volvo recommends the use of Fusor Bonding and Repair Materials. These are available from Precision Products & Services, Inc. ( 800 993 8767). W80090 FUSOR T- Fast Set Adhesive FUSOR T-3 Medium Set Adhesive FUSOR TF-4 Slow Set Adhesive W80066 Fusor is a registered trademark of Lord Repair Adhesives. 7

Tools The following tools are required for doing the procedure: Hood Fender and Headlamp Bucket, Replacement page 47. Extra Large Vise-Grip Locking C Clamps (Vise-Grip #4R) Large Vise - Grip Locking C Clamps (Vise-Grip #8R) 3 Medium Vise - Grip Locking C Clamps (Vise-Grip #R) 4 Small Vise - Grip Locking C Clamps (Vise-Grip #6R) 5 Regular Vise - Grip Locking Pliers (Vise-Grip #0R) 6 Air Reciprocating Saw (CP-880) 7 Heat Temperature Strips 8 Heat Lamp (Speedray SRU-65) 9 Pneumatic Application Gun (Fusor #304) 0 Fusor T- Fast Set Adhesive Fusor T-3 Medium Set Adhesive Fusor TF-4 Slow Set Adhesive 3 Heat Gun Kit (Milwaukee #8977) W800689 8

Design and Function Hood General Design and Function The hood on the VNL and VNM is the covering for the engine compartment. It houses a grille which covers the vehicle radiator, a grille for the engine air intake, and the vehicle headlight and turn signal light assemblies. It is aerodynamically shaped to smoothly transition from the front bumper to the cowl and wheel openings. The hood is connected to the frame by a pivot assembly. The pivot assembly allows the hood to tilt forward to provide access to the engine compartment. The pivot assembly consists of several brackets and a set of torsion bars that reduce the force required to open the hood and, reduce the impact on the hood and its latch upon closing. Restraint cylinders limit the speed of the hood opening, as well as the opening angle, to prevent damage to the pivot assembly and hood components. The hood is held closed by a latching assembly on each side, similar to a hood latch found on automobiles. Latch assemblies under the hood reduce aerodynamic drag and increase the security of the vehicle. A handle located in the cab controls the latch, and is connected to the latch via a cable. W8000907 The hood is made of Sheet Molded Compound (SMC), a composite material which is exceptionally strong and lightweight. The hood is manufactured in several sections, which are then bonded together to form the entire unit. SMC appears similar to fiberglass. However, conventional fiberglass repair materials, such as fiberglass resin and other polyester-based materials, should not be used in repairing the hood. In time, the adhesion for these materials will be lost and the repair will fail. Only Fusor repair adhesives are approved and recommended for the bonding and repair of SMC. There is a physical difference between the hood for the VNL and the hood for the VNM. The VNM hood is shorter than the VNL hood. As a result, the grille for the VNM is larger in order to maintain the aerodynamic design. The hood is hinged at the lower front edge. It has the ability to open a full 55 of tilt, providing full access to all engine compartment components. An integral hand hold is provided in the top of the hood near the front to allow it to be pulled open. The hood is also light enough that it can be pushed open from the rear on either side. Once the hood begins to open, its acceleration is limited by the torsion bar system and the restraint cylinders. 9

Design and Function Hood Mounting Pivot Block The pivot block serves as the connection point between the hood and the frame. The pivot block is mounted with studs through slotted holes in the front of each tow-eye bracket. The slotted brackets allow for vertical adjustment of the hood. The pivot block holds the pivot and torsion rod systems together. J-brackets The hood is connected to the vehicle by a J-bracket that is bolted to the inside front of the hood. The J-bracket has a pin at its lower end which is the pivot point of the hood. The pivot pin fits into the hood pivot bracket that is mounted to the tow-eye bracket on the front edge of the frame. W800300 J-Bracket for Operation Class only (with tooling hole) W80007 0 J-Bracket for Operation Class only (without tooling hole) W80030

Design and Function Torsion Rods The torsion rods aid in reducing the force required to open the hood, and also help limit the closing speed. The rods are hexagonal bars that are twisted as the hood is closed. Some of the kinetic energy of the closing hood is transferred into the torsion bars to cause them to twist when the hood is closing. When the hood is being opened, the torsion bars release the energy retained. That energy is added to the energy applied to open the hood. The torsion rods mount in the hood pivot block which is connected to the tow-eye brackets. W800064 Restraint Cylinder There are two restraint cylinders connected to the hood, just behind each upper corner of the front grille down to each tow-eye bracket. The cylinders are single-acting oil shocks that control the rate of opening of the hood in order to reduce the chance of damage to the hood and the mounting system. W80099

Design and Function Hood Latch The hood on the VN series is held closed by an automotive type latch mechanism. The latch points for the hood are on each side of the hood directly above the front wheels. The latch is released by a pull handle inside the cab on the dash. Latch Mounting Arm The latch mounting arm connects to the frame and supports the receiver cup latch mechanism. It is constructed of a steel tube and has a bracket on the top. The bracket has slotted bolt holes to allow mounting and adjustment of the latch mechanism. Latch Mechanism The latch mechanism is an automotive type hood latch. When the hood is closed the hood mounted latch studs are inserted into the latch receiver cup. When the stud is in the receiver far enough the latch lever snaps into a slot above the stud to keep it from pulling out. The latch lever is a spring loaded lever that pivots at one end. The other end is connected to the release cable. When the hood release is pulled the latch lever is pulled out of the slot in the latch studs and a spring above the latch stud pushes the hood up so that the slots clear the lever. W800059 W800069

Design and Function Latch Stud The latch stud is a pin that inserts into the latch mechanism. The pin is covered by a spring loaded shield. When the shield contacts the latch mechanism ring during hood closing, the latch ring forces the shield back against its spring, exposing the pin. The pin is forced into the ring by the momentum of the hood. As the pin enters the latch receiver, it moves the latch lever to the side. When the head of the pin has completely traveled past the latch lever, the lever snaps into place above the pin, preventing the pin from retracting out of the latch receiver. The spring loaded shield also functions to reduce the transmission of frame vibrations to the hood. Hood Release The hood release is a pull handle mounted in the vehicle dash. The cables that pull the latch lever back during hood latch release are attached to the hood release handle. As the handle is pulled, both release cables are pulled. This moves the latch levers away from the top of the latch stud, allowing the latch stud to pop out of the latch receiver cup. When the hood release is let go, the springs in the latch arms pull the latch levers back into place, which in turn pulls the hood release handle back to its normal position. W80006 Cable The hood release cables connect between the latch lever and the hood release handle. The cables are braided steel cables that are covered by a plastic jacket. The latch mechanism end of the cable has a ball that fits into a slot in the latch arm. This end is held in place by a jam nut. The other end has a barrel that fits into a slot in the hood release handle. The cables pass through the bulkhead directly above the engine. A rubber grommet protects each cable from chafing at the pass through. W8000986 W800060 3

Design and Function Engine Air Intake The engine air intake is mounted in the side of the hood on the passenger s side. A water collection channel is incorporated around the air intake grille. This channel forces any water away from the engine air cleaner opening and into the integral drains. Grille A plastic grille is installed in the air intake on the passenger s side of the hood. The grille prevents large objects from being drawn into the air intake plenum that could reduce air flow and cause eventual blockage. The louvers on the grille are angled to channel rain and road spray down away from the air intake. The grille can be removed by prying up the clips that hold it in the hood. Installation requires only pressing the grille until it snaps into place. Bellows A bellows assembly is incorporated in the air intake path, between the hood and the air cleaner. This bellows expands and contracts with the relative motions of the hood and the engine air cleaner, so that no additional stresses are placed on the air cleaner mounting. It also reduces transmission of noise and vibration from the engine to the hood. W800066 W800065 4

Design and Function Front Grille The front grille is fitted into the hood to maintain the aerodynamic design. The grille assembly consists of the grille, the VOLVO slash, the VOLVO emblem, and an insect net. The grille is bolted to the hood and can be removed without opening the hood. Once the grille assembly is removed, the emblem and slash can each be removed from it if replacement is required. Headlights The headlights and turn signal lights are integrally mounted in the front of the hood to reduce aerodynamic drag. They are accessible from inside the engine compartment when the hood is raised. The headlights are not sealed beam units. An assembly consists of a headlight lens that mounts to the outside of the hood and a bulb and socket that insert into the lens housing with a twist. The turn signal light assembly is similar. There is a seal and a cover panel that mounts over the opening for the light assemblies. Spring clips hold the cover tight enough to prevent water and debris from entering the lens housings, while still allowing easy access to the bulbs for replacement. The headlight positioning adjustments are external to the cover panel. W800058 W3000953 5

Design and Function Miscellaneous Components Wear Block The upper corners of the cowl have a rubber wear block. This block is designed to prevent the hood from contacting the cowl and to help reduce noise and vibration transmitted to the cab. Insulation A two piece insulation is attached to the under side of the hood. This insulation reduces the engine noise transmitted outside the engine compartment. The insulation is required on vehicles with high rpm engines. W800070 Splash Shields A system of splash shields protects the engine compartment and bulkhead from tire spray and road dirt. The splash shields are constructed of molded plastic and consist of two pieces on each side of the vehicle. The upper pieces are attached to the hood and the lower pieces are attached to the cab. When the hood is closed, the upper shields overlap the lower shields to form a barrier against water and dirt from the road. When the hood is open the upper shields are out of the way of the engine compartment to provide easier engine access. W800068 The lower splash shields are grooved to reduce the impact of spray from other vehicles. They also have an access cover that is directly below the hood latch mechanism. This allows for maintenance on the latch mechanism without removing the entire splash shield. It also allows access to the latch lever in the event the latch is disabled and access to the engine compartment is required. 6

8-03-0-0 Hood, Replacement Remove the front bumper. Note: See bumper replacement procedures in: PERSONAL INJURY HAZARD! Before working on the vehicle, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or death. Service Manual Group 86 Front Bumper, VNL, VNM TSP0376/ IMPACT Function Group 86 Information Type: Repair WARNING The VN Series hood weighs approximately 86 kg (90 lb). Never remove or replace the hood without assistance. Use a second person and a lifting device. Failure to follow this warning could result in personal injury and/or vehicle damage. 3 Removal Support the hood and then remove the nuts to the hood restraint cylinders. W80083 4 Locate and disconnect the wiring connectors for the headlight/turn signal assemblies and the wiring connectors for the fog lamps and driving lights. These connectors are located near the front of the hood at the J-brackets. W8008 Remove the four nuts that attach the hood pivot brackets to the chassis. W80084 7

5 Reinstall the hood restraint cylinders and tighten the bolts. Torque the bolts to 30 ± 4 Nm ( ± 3 ft-lb). W80086 30 ± 4 Nm ( ± 3 ft-lb) With a technician on each side of the hood, tilt the hood up to about a 55 angle to relieve the pressure on the torsion rod assembly. Carefully remove the hood from the vehicle and set aside. W80044 Note: On VNL, the restraint cylinder is bolted to the inner face of the crossmember bracket. On VNM, the restraint cylinder is bolted to the outer face of the crossmember bracket. 3 Installation Reconnect the headlight and fog light wiring connectors. W8008 With a technician on each side, lift the hood and tilt it to approximately a 55 angle. Align the studs from the hood pivot bracket and install the hood. Install the four nuts onto the hood pivot bracket studs and torque the nuts to 56 ± 0 Nm (4 ± 7 ft-lb). W80044 56 ± 0 Nm (4 ± 7 ft-lb) 4 Check the hood adjustment and adjust the hood as necessary. Refer to Hood, Adjustment page 9 for detailed instructions on adjusting the hood. 5 Reinstall the bumper, and make the necessary side to side adjustments to center the bumper. 8

8-05-03-0 Hood, Adjustment 4 Note: This adjustment procedure should be performed if the hood has been replaced or if other repairs have been made that would affect the proper alignment of the hood. It should also be performed if the hood appears out of adjustment, or if it takes excessive force to cause the hood to latch. PERSONAL INJURY HAZARD! Before working on the vehicle, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or death. If the vehicle is equipped with air suspension, build the pressure in the air system to 87 kpa (0 psi). Measure the rear cab height to ensure it is adjusted to the proper specification. The cab must be square on the chassis. If cab height is incorrect or the cab is not square on the chassis, then make the necessary adjustments to bring them to the proper specifications before continuing the hood adjustment procedure. Remove the access panels from underneath the right and left splash shields to access the hood latch assemblies. 5 W80097 Note: Cab height measured at the rear of the cab is 74 ± 4 mm (6.850 ±.57). This measurement is taken from the top of the spring plates to the top of the cab suspension crossmember. 3 Remove the splash shield support bracket on both sides of the vehicle. Push the latch lever back and remove the latch release cable end from the latch lever on both sides of the vehicle. 6 Close the hood and ensure it latches. W8003 CAUTION Possible component damage. If the hood was replaced or repairs were performed that could cause the hood to be misadjusted, it MUST be adjusted. Do NOT leave the hood latched without ensuring proper adjustment. Operation of the vehicle without proper hood adjustment could result in damage to the hood and its latching components. 9

7 0 Remove the four latch receiver cup mounting screws from both sides of the vehicle. W80098 Loosen the three vertical adjustment bolts and the four horizontal adjustment bolts on the latch adjustment brackets on both sides of the vehicle. W800303 WARNING Personal injury hazard. Do NOT unlatch the hood after the four receiver cup mounting screws have been removed. Unlatching the hood with the receiver cup mounting screws removed could cause the receiver to be ejected from the latch stud resulting in personal injury. Slide the adjustment brackets down to their lowest position. Loosen the five bolts on both hood J-brackets. 8 Raise the hood by pushing it open. 3 Gently lower the hood so that it rests on the gauge blocks. 9 4 Measure the gap between the inside edge of each J-bracket and the outer edge of each pivot bracket. Measurements should be within 3 mm (0. in.) of each other. 5 If J-bracket to hood pivot brackets are not within 3 mm (0. in.) of one another, loosen the locking collar socket screws on each side and move the hood right or left to make the measurements within 3 mm (0. in.). Then torque the locking collar socket screws to ± Nm (9 ±.5 ft-lb). ± Nm (9 ±.5 ft-lb) Install the hood gauge blocks 394559 by removing the two torx screws in the upper left and right sides of the cowl. Install the hood gauge blocks with the long screws provided. W8003 0

6 8 Move the hood pivot bracket up or down to make the gap parallel. Tighten the bottom pivot bracket nut from under the vehicle. 9 Use hood gap gauge 394558 to check the gaps between the hood and the cowl. Check the gap at two places (approximately 340 mm, or 3 in. apart) along the cowl on each side. Note the size of the gap at all points. W8000 Note: The hood gap is the distance from the forward edge of the hood gap gauge to the rear edge of the hood. 7 Install the hood alignment tool, J-4884. Attach the tool to the existing hole in the J-bracket and bolt to the hood with the clip bolt provided. Recheck the hood gap using the adjuster tool. If the gap is more than 8 mm (.3 in.), turn the nut on the hood adjuster to slide the hood rearward to make the gap 8 mm (.3 in.). W80087 0 On both sides of the vehicle, slide the adjustment brackets up to the receiver cup. Line up the bracket and receiver cup holes and install the four screws. If there is more than 4 mm (0.6 in.) difference between the upper and lower gap on either side, then loosen the hood pivot bracket nuts at the front of the chassis just enough to be able to slide the bracket up or down. W80084 Tighten one vertical adjustment bolt and one horizontal adjustment bolt on each side of the vehicle. Release the hood latch and open the hood.

3 6 Torque the horizontal adjustment bracket bolts to 8 ± 5 Nm ( ± 4 ft-lb). W8004 8 ± 5 Nm ( ± 4 ft-lb) Torque the pivot bracket nuts to 56 ± 0 Nm (4 ± 7 ft-lb). 4 Torque the J-bracket bolts to 56 ± 0 Nm (4 ± 7 ft-lb). 5 W80084 56 ± 0 Nm (4 ± 7 ft-lb) 56 ± 0 Nm (4 ± 7 ft-lb) 7 Install the splash shield support bracket. 8 Install the latch release cable end onto the latch lever. 9 Reinstall the access panels in the splash shields. 30 Remove the gauge blocks from the cowl and install the original screws. 3 Remove the hood adjuster tool from the hood. If the wiring harness bracket has been removed, be sure to reinstall it to the hood by tightening the screw on the top hole. Torque the vertical adjustment bracket bolts to 8 ± 5 Nm ( ± 4 ft-lb). W8008 8 ± 5 Nm ( ± 4 ft-lb) 3 Close the hood and ensure it latches properly.

8-03-0-0 Torsion Rod Assembly, Replacement PERSONAL INJURY HAZARD! Before working on the vehicle, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or death. Removal 4 Open the hood to the neutral position (approximately 55 ) to relieve tension on the torsion springs. 5 To replace the torsion spring, remove the six point socket screw from the bottom of the hood pivot bracket. 6 Slide the torsion spring out of the hood pivot bracket. 7 Skip the remainder of the torsion rod assembly removal steps and install the new torsion spring using the installation procedure. 8 Locate and disconnect the wiring connectors for the headlight/turn signal assemblies, and disconnect the wiring connectors for the fog lamps and driving lights. These connectors are located near the front of the hood J-brackets. W8008 Support the hood and then remove the nuts to the hood restraint cylinders. 9 W80083 Remove the front bumper. Note: See bumper replacement procedures in: Service Manual Group 86 Front Bumper, VNL, VNM TSP0376/ IMPACT Function Group 86 Information Type: Repair 3 If the entire torsion rod assembly must be replaced, skip Steps 4 through 7 and resume at Step 8. Remove the four nuts that attach the hood pivot bracket to the chassis. W80084 3

0 Installation If only a torsion spring was removed, skip Steps through 7 and resume at Step 8. Install the torsion rod assembly back onto the hood by installing the five bolts on each J-bracket. W80088 WARNING W80044 Note: For the torsion rod assembly to be adjusted, install the bolts to the hood, but do not tighten. The VN Series hood weighs approximately 86 kg (90 lbs). Never remove or replace the hood without assistance. Use a second person and a lifting device. Failure to follow this warning could result in personal injury and/or vehicle damage. With a technician on each side of the hood, tilt the hood up to about a 55 angle to relieve the pressure on the torsion rod assembly. Carefully set the hood off of the vehicle. Loosen and remove the five bolts that hold each J-bracket to the hood. Remove the J-brackets and torsion bars as an assembly. W80088 4

3 4 Reinstall the hood restraint cylinders and tighten the bolts. Torque the bolts to 30 ± 4 Nm ( ± 3 ft-lb). W80086 30 ± 4 Nm ( ± 3 ft-lb) W80044 Note: On VNL, the restraint cylinder is bolted to the inner face of the crossmember bracket. On VNM, the restraint cylinder is bolted to the outer face of the crossmember bracket. WARNING 5 The VN Series hood weighs approximately 86 kg (90 lbs). Never remove or replace the hood without assistance. Use a second person and a lifting device. Failure to follow this warning could result in personal injury and/or vehicle damage. With a technician on each side lift the hood and tilt it to approximately a 55 angle. Align the studs from the hood pivot bracket and install the hood. Install the four nuts onto the hood pivot bracket studs and torque the nuts to 56 ± 0 Nm (4 ± 7 ft-lb). Reconnect the headlight and fog lamp wiring connectors. W80085 6 Check the hood adjustment and adjust the hood as necessary. See Hood, Adjustment page 9. 7 If the entire torsion rod assembly was replaced, skip Steps 8 and 9 and resume at Step 0. 5

8 Insert the new spring through the hood pivot bracket hole and the spring bushing, and into the slot in the other side pivot bracket. 84-03-0-0 Hood Restraint Cylinder, Replacement 9 Install the six point socket screw and torque to ± Nm (9 ±.5 ft-lb). 0 Reinstall the bumper and make the necessary side to side adjustments to center the bumper. Note: See bumper replacement procedures in: Service Manual Group 86 Front Bumper, VNL, VNM TSP0376/ ± Nm (9 ±.5 ft-lb) PERSONAL INJURY HAZARD! Before working on the vehicle, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or death. Removal IMPACT Function Group 86 Information Type: Repair Remove the six bolts from the splash shield. W80030 6

Installation Install the new hood restraint cylinder and nuts. Note: On VNL models, the restraint cylinder must be bolted to the inner face of the crossmember bracket. On VNM models, the restraint cylinder must be bolted to the outer face of the crossmember bracket. Torque the nuts to 30 ± 4 Nm ( ± 3 ft-lb). 30 ± 4 Nm ( ± 3 ft-lb) VNL Hood Restraint Removal W80083 3 Install the splash shield and tighten the bolts. VNM Hood Restraint Removal Remove the two nuts from the hood restraint cylinder and remove the cylinder. Note: On VNL models, the restraint cylinder is bolted to the inner face of the crossmember bracket. On VNM models, the restraint cylinder is bolted to the outer face of the crossmember bracket. See the corresponding illustrations. W80089 7

83-03-0-0 Hood Latch, Replacement 4 PERSONAL INJURY HAZARD! Before working on the vehicle, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or death. Removal Remove the four hood latch mechanism mounting bolts through the access in the splash shield. Remove the hood latch. W80098 Installation Install the hood latch and the hood latch mounting bolts. Torque the hood latch mounting bolts to 8 ± 5 Nm ( ± 4 ft-lb). 8 ± 5 Nm ( ± 4 ft-lb) Remove the access cover underneath the splash shield. Push the hood latch lever back and pull the ball end of the cable out of the lever. 3 Mark the exact location of the receiver cup on the adjustment bracket. Note: If the bracket bolts are loosened then the hood adjustment procedure must be performed after replacement of the latch mechanism is complete. See Hood, Adjustment page 9. W80097 Push the hood latch lever back and install the ball end of the hood release cable. Note: Check the release cable adjustment and readjust if necessary. 3 Reinstall the splash shield access cover. 8

83-03-0-0 Hood Latch Stud, Replacement 84-03-0-0 Hood Latch Arm, Replacement PERSONAL INJURY HAZARD! Before working on the vehicle, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or death. Removal Mark the exact location of the latch stud on the hood. PERSONAL INJURY HAZARD! Before working on the vehicle, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or death. Removal Note: If the receiver cup bracket bolts have been loosened, then the hood adjustment procedure must be performed after replacement of the latch mechanism is complete. See Hood, Adjustment page 9. Remove the splash shield on the side that the hood latch arm is to be replaced. W80037 Remove the four bolts from the stud and remove the stud. W8007 Installation Install the new hood latch stud using the four bolts. Torque the bolts to 8 ± 5 Nm ( ± 3.7 ft-lb). Close the hood and verify it is properly aligned. Perform the adjustment procedure if necessary. See Hood, Adjustment page 9. 8 ± 5 Nm ( ± 3.7 ft-lb) Remove the four bolts that attach the hood latch assembly to the hood latch arm. W8004 9

3 84-03-0-03 Hood Release Cable, Replacement PERSONAL INJURY HAZARD! Before working on the vehicle, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or death. Remove the four bolts and nuts that attach the hood latch arm to the vehicle chassis. W80039 Removal Installation Install the new hood latch arm, bolts and nuts to the frame rail. Torque to 00 ± 33 Nm (48 ± 4 ft-lb). 00 ± 33 Nm (48 ± 4 ft-lb) Reinstall the hood latch assembly and mounting bolts. Torque to 8 ± 5 Nm ( ± 4 ft-lb). 3 Reinstall the splash shield. 8 ± 5 Nm ( ± 4 ft-lb) Remove the passenger side and center dash panels. W8003 4 Adjust the hood using the Hood adjustment procedure. See Hood, Adjustment page 9. 30

Installation Remove the rubber grommet from the bulkhead and slide the new cable into the rubber grommet. Remove the hood release cable from the hood release handle. W800 Begin installing the cable by pushing it through the hole in the bulkhead from the outside. Push the grommet into place on the bulkhead. W8000 3 Cut the tie straps. Remove the hood release cable from the cab by pulling the cable through the bulkhead from outside the cab. 3 4 Loosen the jam nuts at the hood latch assembly and remove the cable. W8003 Attach the cable end to the hood release handle inside the cab. W800 3

4 83-03-0-0 Grille, Replacement PERSONAL INJURY HAZARD! Before working on the vehicle, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or death. Attach the other end of the cable to the hood latch assembly. Adjust the cable and tighten the two jam nuts 5 Reinstall the passenger side and center dash panels. W8009 Removal Remove the screws around the outside of the grille and remove the grille. Installation Hold the grille in place and install the screws. Note: Grille mounting screws should be tightened so that the rubber mount extends from 6.5 to 8 mm (approximately /4 in.) past the inside edge of the hood, and so that the rubber mount has a visible outward bow. Nm (.5 in-lb) Torque the screws to Nm (.5 in-lb). 3

83-03-0-0 Grille Slash, Replacement Installation PERSONAL INJURY HAZARD! Before working on the vehicle, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or death. Removal Remove the screws around the outside of the grille and remove the grille assembly. Remove the two screws that attach the bug screen to the inside of the grille assembly. Remove the insect net. 3 Install the new emblem onto the grille. Lay the grille front side down. Install the clips by using a 7 mm socket and pressing them on by hand. Note: New retaining clips must be used when replacing the VOLVO emblem. Reinstall the bug screen. W80008 3 Hold the grille in place and insert the screws. Remove the emblem by placing a 0 mm socket over the retaining clips and striking the back of the socket. This will flatten out the clips, causing them to release. W8000 4 Note: Grille mounting screws should be tightened so that the rubber mount extends from 6.5 to 8 mm (approximately /4 in.) past the inside edge of the hood, and so that the rubber mount has a visible outward bow. Torque the screws to Nm (.5 in-lb). Nm (.5 in-lb) 4 Note: The retaining clips are NOT reusable. Once they have been removed, they must be replaced with new clips. Discard the old clips. 33

563-03-0-0 Air Intake Grille, Replacement 564-03-0-0 Air Intake Bellows, Replacement PERSONAL INJURY HAZARD! Before working on the vehicle, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or death. Removal PERSONAL INJURY HAZARD! Before working on the vehicle, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or death. Removal Using a small flat blade screwdriver and working through the outside louvers in the grille, pry the clips up while pulling out on the grille. When all of the clips are loosened, remove the grille. Installation W80034 Open the hood and reach into the bellows through the bellows guide. Pull the metal retaining ring out of its groove in the bellows. Remove the bellows from the hood. W80006 Check to be sure there are no foreign objects in the hood intake or behind the grille. Install a new seal around the inner edge of the grille. 3 Place the grille in position (in its hole) and press it until it snaps into place. 34

Installation 3 Air intake bellows Retaining ring W80007 Note: The bellows must be installed in the air intake in the first groove in the bellows. The retaining ring must also be installed in the first groove and should be in place prior to installation of the bellows assembly. Install the retaining ring in the first groove of the bellows. Install the lower side of the bellows, and as much as possible of one end into the air duct of the hood. Bow the center of the retaining ring away from the hood, and push the upper edge of the bellows down into the air intake. Begin working the remaining portion of the bellows into its proper location inside the air intake. 4 Make sure the retaining ring is fully seated in the groove. W8008 Apply a soapy solution to the outside of the end groove of the bellows. W800 35

35-03-0-0 Headlamp Lens, Replacement PERSONAL INJURY HAZARD! Before working on the vehicle, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or death. Installation Install the new headlight lens assembly into the hood, and align the adjuster screws through the hood. Install and tighten the nine retaining screws. Install the headlight bulb socket assembly and reinstall the dust cover. Removal Remove the dust cover from the headlight assembly. W80004 Remove the headlight bulb socket from the headlight lens assembly. W8006 3 Remove the nine headlight retaining screws and the headlight lens assembly. 36

35-05-03-0 Headlamp, Adjustment Note: The following procedure describes headlamp adjustment using the Hoppy B4A Suction Cup Headlamp Aiming Kit. Use of the Hoppy Headlamp Aiming Kit is the ONLY method recommended for aligning VNL and VNM headlamps. Vehicle Preparation Before beginning the headlamp aiming process, prepare the vehicle as follows: PERSONAL INJURY HAZARD! Before working on the vehicle, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or death. Drive the vehicle onto a flat surface. It is not necessary that this surface be exactly level. Remove any large amounts of mud or ice from the underside of the fenders. 3 Check whether tires are noticeably deflated and inflate if necessary. 4 See that there is no load in the vehicle other than the driver. 5 Rock the vehicle to equalize the springs. Check them for sag or broken leaves. 6 Make sure the cab suspension and the Volvo air suspension are fully inflated and that the air system pressure is 60 kpa (90 psi) or higher. 37

7 Clean the headlamp lenses and aiming pads. CAUTION Some solvents and cleaners will attack and/or weaken the components of the B4A aimer. Thoroughly dry any object which has been cleaned with a solvent before attaching an aimer to it. Floor Slope Calibration Note: The headlamp aimers will not work correctly unless floor slope is taken into account. Calibration of floor slope should be done prior to aiming. However, if you regularly use one area to aim headlamps, rechecking floor slope is unnecessary. Permanently mark the area, calibrate slope for that area, and mark the setting for future reference. 8 Check for bulb burnout, broken aiming pads, and proper beam switching. 9 Check to ensure that the hood is closed completely, and latched on both sides. B4A Aimer Unit Piston Handle Level Vial Bubble 3 Top Port Hole 4 Unit Identification 5 Horizontal Aim Port Hole 6 Horizontal Aim Knob 7 Vertical Aim Knob 8 Vertical Aim Vial 9 Floor Level Dial W300348 W300349 Thumb Adjusting Screw Attach Calibration Fixtures to aimers. The fixtures will easily snap into place when properly positioned. 38

Fig. : Floor Calibration (on passenger side only) W300350 Unit A (rear tire) Unit B (front tire) 3 Calibration Fixture 4 Thumb Adjusting Screws 5 Level Vial Bubble 6 Top Port Hole 7 Horizontal Knob 8 Floor Level Dial Place aimers at the center line of each wheel on the passenger side of the vehicle. Unit B must be placed at the front wheel on the passenger side with the target facing to the rear. Unit A must be placed at the rear wheel on the passenger side with the target facing front. 3 Level each unit by turning the thumb adjusting screw on each calibration fixture. Turn the screw either clockwise or counter-clockwise until the level vial bubble registers in a centered, level position. 39

4 Adaptor Assembly Look into the top port hole of Unit A. Turn horizontal knob until the split image is aligned. W300344 5 Horizontal Dial Floor Level Dial Transfer the plus or minus reading indicated on the horizontal dial to the FLOOR LEVEL DIAL on each aimer (press floor level dial inward to set reading). W300359 Articulating Vacuum Cup Assembly O-Rings 3 Extension Studs 4 Vacuum Extension Plate 5 Large Universal Adaptor 6 Fixed Vacuum Cup 7 B4A Aimer W300345 6 Remove calibration fixtures from the aimers. Locate the correct parts needed to assemble the aimer for use on VN headlamps. For aiming headlamps on a VN series truck, always use the large adjustable black adaptors supplied with the Headlamp Aiming Kit. The adaptors will be attached last. W300347 Attach the vacuum extension plate assembly () to the fixed vacuum cup () on the B4A aimer. The fixed cup should be fully extended. 40

3 5 Install the articulating vacuum cup assembly onto the extension stud, making sure the O-ring is seated firmly against the vacuum cup. 6 Attach the large black adaptor to the B4A assembly. Vacuum Extension Plate Fixed Vacuum Cup Squeegee the fixed cup into the round hole in the back of the vacuum extension plate. W300395 Attaching the Aimer 4 Articulating Vacuum Cup O-rings 3 Extension Stud 4 Vacuum Cup Extension Plate 5 Fixed Vacuum Cup Attach an extension stud (3) to the vacuum cup assembly. The threaded stud fastens between the vacuum cup extension plate (4) and the articulating vacuum cup assembly (). The stud must be seated firmly against the O-ring () in the vacuum cup extension plate. Note: The B4A aimer kit includes extension studs that can be placed between the vacuum cup extension plate and the articulating cup assembly. When using the aimer on the headlamps of the VN Series trucks, only one extension is needed. W30035 Fig. : Attaching the B4A aimer Note: For aiming headlamps on a VN series truck, always use the large adjustable black adaptors supplied with the Headlamp Aiming Kit. Align the large universal adaptor to the aiming pads on the lens (as shown in Figure ). Note the numbers located on the pads of the lens. Move the adjustment rod for each pad until it agrees with the number located next to the pad. This procedure should be followed for the passenger side and driver side adaptors. W30036 4

3 6 Neutral Position Odd Number 3 Even Number To adjust the adaptor rods to the required position, turn the rods to the neutral position and slide in or out to the proper setting. 4 Turn the rod clockwise to lock in an odd number, and counter clockwise to lock in an even number. W300346 Unit B Unit A 3 Sight Openings 4 Viewing Port 5 Horizontal Dial 6 Vertical Dial 7 Level Bubble Unit A should be attached to the driver s side headlamp, and Unit B to the passenger side. The sight openings on each aimer must face each other. Adjusting Headlamp Aim Horizontal Aim W30037 5 Piston Handle Vacuum Release Button Attach each aimer to the headlamps by pushing the piston handle forward, engaging the rubber suction cup. Immediately pull back the piston handle until it locks in place. W300354 Note: For the VN Series trucks, the horizontal and vertical headlamp screws must be adjusted from behind the headlamp. Due to the sensitivity of the aimer, adjustments must be made with the hood closed and secured. Adjustments to the headlamp screws must be made from under the hood. It is recommended that one person check alignment of the split image while another makes adjustments to the headlamp screws. W300343 4

5 Viewing Port Horizontal Dial W30037 To set the horizontal aim (side to side), the horizontal dial should be set at zero. 3 Check to see that the split image target lines are visible in the viewing port. If necessary, rotate each aimer slightly to locate the target. 4 Turn the horizontal screw until the split image of the target line appears in mirrors as one solid line. To remove backlash, make final adjustment by turning screw clockwise. 6 Repeat these steps with the opposite aimer and headlamp. W300370 W30035 Using an inverted torx socket, size E7, turn the horizontal adjusting screw located on the back of the headlamp. Vertical Aim 7 Level Bubble Vertical Dial The vertical dial should be set at zero. W300360 43

8 357-03-0-0 Turn Signal Lens, Replacement PERSONAL INJURY HAZARD! Before working on the vehicle, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or death. Removal Turn the vertical adjusting screw behind the headlamp until the level of the bubble is centered between the lines. To remove backlash, make final adjustments by turning the screw clockwise. W300369 9 Repeat the last two steps with the opposite aimer and headlamp. 0 Recheck target alignment on both aimers and readjust horizontal aim if necessary. Remove the dust cover from the headlight assembly. W80004 W300354 Piston Handle Vacuum Release Button Remove the aimer by holding it securely and pressing the Vacuum Release button located on the piston handle. Remove the bulb socket assembly from the lens. 3 Remove the three screws and the turn signal light assembly. W8005 44

Installation Install the turn signal lens assembly and reinstall the three screws. 8-03-0-04 Hood Insulation, Replacement Install the bulb socket assembly and reinstall the dust cover. PERSONAL INJURY HAZARD! Before working on the vehicle, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or death. Removal Using a center punch, knock out the center of each rivet on the hood insulation. W800 Mark the drill bit at 8 mm (0.3 in.) to prevent drilling through the outer hood material. 3 Drill out each rivet. Note: Drill rivets slowly so the head of the rivet does not turn and tear the insulation and the drill does not contact the hood material. 4 Remove the three nuts in the center of the hood and remove the insulation. Installation Align the small section of insulation to the three studs in the center of the hood, and then align and install the large insulation section. 45

Reinstall the three nuts onto the studs and tighten. 89-03-0-06 Hood Rivet Nut, Replacement 3 Align the rivet holes and install new rivets around the outside edge of the insulation sections. PERSONAL INJURY HAZARD! Before working on the vehicle, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and cause serious personal injury or death. Special tools: Rivet nut insertion tool kit J-4405 Grind off the head of the rivet nut to be replaced. Note: Be careful when grinding the rivet nut out to prevent distorting the mounting hole. Push the body of the rivet nut through its mounting hole. 3 Check the fit of the new rivet nut in the mounting hole. Drill the hole out to fit the new rivet nut if necessary. 4 Set up the new rivet nut in the insertion tool. Verify the mandrel is the correct size for the rivet nut that will be installed. 5 Install the rivet nut using the insertion tool. W8007 46

Hood Fender and Headlamp Bucket, Replacement WARNING Always wear safety goggles while using a heat gun. Failure to wear safety goggles could result in damage to the eyes. WARNING Commercial cleaning solvents can be toxic and cause skin irritation, they may also be considered fire hazards. When using solvents follow the safety precautions recommended by the solvent manufacture. WARNING When a heat lamp and/or heat gun is used to heat a work area do not touch that area. Risk of burns or other personal injury. Removal Use a heat gun and heat the work area to 04 C (400 F) until the adhesive starts to break loose. Heat should be directed towards the panel that is being removed, be careful not to damage the inner supports. Use a pry bar or screwdriver to separate the top edge of the fender loose from the center panel. CAUTION W800598 Use a heat strip to monitor the temperature. Excessive heat will break down the SMC material. WARNING Always wear appropriate eye protection to prevent the risk of eye injury due to contact with debris or fluids. WARNING Use a respirator when sanding to protect lungs from foreign matter. Failure to follow these recommendations may result in injury. Use a heat lamp and heat the work area before starting the repair. W800597 47

3 WARNING Personal injury hazard. Always wear safety goggles and a respirator while using a reciprocating saw. Failure to use safety goggles could result in damage to the eyes. Failure to use a respirator could result in foreign material in the lungs. 4 W80065 Locate the bracket support behind the rear of the headlamp bucket. Heat the bracket and remove. W80063 CAUTION Be careful not to damage this part as it will be reinstalled on the new fender. Use an air reciprocating saw and cut sections of the fender away from the inner supports. Most of the cutting should be done from the inside of the fender well. Cut in. away from the inner supports. W800599 5 After sections of the fender has been cut away you can use an air chisel to separate the sections of the fender that remains. 48

Installation W800600 Use 80 grit sandpaper and scuff up the mating surface of the fender panel and the headlamp bucket. W80060 3 Position the headlamp bucket in place on the backside of the new fender and trace out the edges with a black marker. W80060 Position the headlamp bucket in place and adjust the vise-grip locking C clamps. W800603 49