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Service ManualTrucks

Group 82

HoodVN

PV776-TSP138123

Foreword

The descriptions and service procedures contained in this manual are based on de-signs and methods studies carried out up to March 00.

The products are under continuous development. Vehicles and components producedafter the above date may therefore have different specifications and repair methods.When this is believed to have a significant bearing on this manual, supplementary ser-vice 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 refer-ence to an S.R.T. (Standard Repair Time).

Service procedures which do not include an operation number in the title are for gen-eral information and no reference is made to an S.R.T.

The following levels of observations, cautions and warnings are used in this ServiceDocumentation:

Note: Indicates a procedure, practice, or condition that must be followed in order tohave 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 theproduct could occur.

Danger: Indicates an unsafe practice where serious personal injury or death could oc-cur.

Volvo Trucks North America, Inc.Greensboro, NC USA

Order number: PV776-TSP138123

© 2000 Volvo Trucks North America, Inc., Greensboro, NC USA

All rights reserved. No part of this publication may be reproduced, stored inretrieval system, or transmitted in any forms by any means, electronic, me-chanical, photocopying, recording or otherwise, without the prior writtenpermission of Volvo Trucks North America, Inc..

ContentsSpecifications ......................................................................................... 3

Hood Torque Values .............................................................................. 3Hood Dimensions & Alignment ............................................................. 3

Tools ........................................................................................................ 5Special Tools ......................................................................................... 5

Design and Function ............................................................................. 9Hood ........................................................................................................ 9

General .................................................................................................. 9Hood Mounting .................................................................................... 10Hood Latch .......................................................................................... 12Engine Air Intake ................................................................................. 14Front Grille ........................................................................................... 15Headlights ............................................................................................ 15Miscellaneous Components ................................................................ 16

Service Procedures ............................................................................. 17Hood, Replacement ............................................................................. 17Hood, Adjustment ................................................................................ 19Torsion Rod Assembly, Replacement .................................................. 23Hood Restraint Cylinder, Replacement ............................................... 26Hood Latch, Replacement ................................................................... 28Hood Latch Stud, Replacement .......................................................... 29Hood Latch Arm, Replacement ........................................................... 29Hood Release Cable, Replacement .................................................... 30Grille, Replacement ............................................................................. 32Grille Slash, Replacement ................................................................... 33Air Intake Grille, Replacement ............................................................ 34Air Intake Bellows, Replacement ......................................................... 34Headlamp Lens, Replacement ............................................................ 36Headlamp, Adjustment ........................................................................ 37Turn Signal Lens, Replacement .......................................................... 44Hood Insulation, Replacement ............................................................ 45Hood Rivet Nut, Replacement ............................................................. 46Hood Fender and Headlamp Bucket, Replacement ........................... 47SMC Panel, Repair .............................................................................. 53

Feedback

Operation Numbers

1

Group 82 Hood Specifications

SpecificationsHood Torque Values

J-bracket mounting bolts ........................................................................................................ 56 ± 10 Nm (41 ± 7 ft-lb)

Restraint cylinder mounting bolts .............................................................................................. 30 ± 4 Nm (22 ± 3 ft-lb)

Pivot bracket nuts .................................................................................................................... 56 ± 10 Nm (41 ± 7 ft-lb)

Latch assembly mounting bolts ............................................................................................... 28 ± 5 Nm (21 ± 4 ft-lb)

Latch stud mounting bolts ....................................................................................................... 28 ± 5 Nm (21 ± 4 ft-lb)

Latch arm mounting bolts ............................................................................................... 200 ± 33 Nm (148 ± 24 ft-lb)

Grille mounting screws ......................................................................................................................... 2 Nm (1.5 in-lb)

Hood Dimensions & Alignment

Width across fenders (outside to outside) .................................................................... 2405 ± 3 mm (94.685 ± 0.1 in.)

Hood to cowl gap ................................................................................................ maximum 6 mm greater than gap tool

Allowable difference between upper and lower gap ............................................................................ maximum 4 mm

3

Group 82 Hood Tools

ToolsSpecial ToolsNote: The gap gauge and gauge blocks may be orderedindividually or as a Hood Alignment Kit, which containsboth tools. The part number for the kit is 3946180.

3945528 Hood gap gauge

W0001375

3945529 Hood gauge blocks (2)(includes long screws,part no. 969603)

The following alignment kit is required to adjust the VNSeries hood and the bumper to the hood. To order, con-tact Kent-Moore at 1–800–328–6657.

J-42764 Front bumper/hood alignment kit.

The kit contains the following:

J–42884 Hood Alignment Tool (2 required)

J-42764–1 Alignment Block for VNL/VNM truckswith painted bumpers

J-42207–A Alignment Block for VNL trucks withSMC or bright bumpers

W0001507

5

Group 82 Hood Tools

J-25300–D Headlight aiming equipmentKent-Moore (1–800–328–6657)

W8001100

J-42405 Rivet nut insertion tool kitKent-Moore (1–800–328–6657)

An inverted torx socket is needed for adjustment ofthe VN headlamp.

Inverted Torx Socket: Size E7

P/N ME7 Available from Mac Tools

P/N IMTLE70 Available from Snap-On

W3002352

6

Group 82 Hood Tools

The following items may be necessary for repair of theVN Series hood. They are available from Precision Prod-ucts & Services, Inc. (1–800–993–8767).

P/N 301 300 mL manual dispenser

W8002291

P/N 304 300 mL pneumatic dispenser

W8002290

For repair and maintenance of the VN Series hood,Volvo recommends the use of Fusor® 1 Bonding and Re-pair Materials. These are available from PrecisionProducts & Services, Inc. (1–800–993–8767).

FUSOR® T-22 Fast Set Adhesive

FUSOR® T-23 Medium Set Adhesive

FUSOR® TF-24 Slow Set Adhesive

W8002616

1Fusor® is a registered trademark of Lord Repair Adhesives.

7

Group 82 Hood Tools

The following tools are required for doing the procedure:“Hood Fender and Headlamp Bucket, Replacement”page 47.

W8002689

1 Extra Large Vise-Grip Locking C Clamps(Vise-Grip #24R)

2 Large Vise - Grip Locking C Clamps(Vise-Grip #18R)

3 Medium Vise - Grip Locking C Clamps(Vise-Grip #11R)

4 Small Vise - Grip Locking C Clamps (Vise-Grip #6R)

5 Regular Vise - Grip Locking Pliers (Vise-Grip #10R)

6 Air Reciprocating Saw (CP-880)

7 Heat Temperature Strips

8 Heat Lamp (Speedray SRU-1615)

9 Pneumatic Application Gun (Fusor #304)

10 Fusor® T-22 Fast Set Adhesive

11 Fusor® T-23 Medium Set Adhesive

12 Fusor® TF-24 Slow Set Adhesive

13 Heat Gun Kit (Milwaukee #8977)

8

Group 82 Hood Design and Function

Design and FunctionHoodGeneral

W8000907

The hood on the VNL and VNM is the covering for theengine compartment. It houses a grille which covers thevehicle radiator, a grille for the engine air intake, and thevehicle headlight and turn signal light assemblies. It isaerodynamically shaped to smoothly transition from thefront 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 pro-vide access to the engine compartment. The pivotassembly consists of several brackets and a set of tor-sion bars that reduce the force required to open thehood and, reduce the impact on the hood and its latchupon closing. Restraint cylinders limit the speed of thehood opening, as well as the opening angle, to preventdamage to the pivot assembly and hood components.

The hood is held closed by a latching assembly on eachside, similar to a hood latch found on automobiles. Latchassemblies under the hood reduce aerodynamic dragand increase the security of the vehicle. A handle lo-cated in the cab controls the latch, and is connected tothe latch via a cable.

The hood is made of Sheet Molded Compound (SMC), acomposite material which is exceptionally strong andlightweight. The hood is manufactured in several sec-tions, which are then bonded together to form the entireunit. SMC appears similar to fiberglass. However, con-ventional fiberglass repair materials, such as fiberglassresin and other polyester-based materials, should not beused in repairing the hood. In time, the adhesion forthese materials will be lost and the repair will fail. OnlyFusor repair adhesives are approved and recommendedfor the bonding and repair of SMC.

There is a physical difference between the hood for theVNL and the hood for the VNM. The VNM hood is shorterthan the VNL hood. As a result, the grille for the VNM islarger in order to maintain the aerodynamic design.

The hood is hinged at the lower front edge. It has theability to open a full 55� of tilt, providing full access to allengine compartment components. An integral hand holdis provided in the top of the hood near the front to allowit to be pulled open. The hood is also light enough that itcan be pushed open from the rear on either side. Oncethe hood begins to open, its acceleration is limited by thetorsion bar system and the restraint cylinders.

9


Hood MountingPivot BlockThe pivot block serves as the connection point betweenthe hood and the frame. The pivot block is mounted withstuds through slotted holes in the front of each tow-eyebracket. The slotted brackets allow for vertical adjust-ment of the hood. The pivot block holds the pivot andtorsion rod systems together.

W8002300

J-bracketsThe hood is connected to the vehicle by a J-bracket thatis bolted to the inside front of the hood. The J-brackethas a pin at its lower end which is the pivot point of thehood. The pivot pin fits into the hood pivot bracket that ismounted to the tow-eye bracket on the front edge of theframe.

W8001071

J-Bracket for Operation Class 1 only(with tooling hole)

W8002301

J-Bracket for Operation Class 2 only(without tooling hole)

10


Torsion RodsThe torsion rods aid in reducing the force required toopen the hood, and also help limit the closing speed.The rods are hexagonal bars that are twisted as thehood is closed. Some of the kinetic energy of the closinghood is transferred into the torsion bars to cause them totwist when the hood is closing. When the hood is beingopened, the torsion bars release the energy retained.That energy is added to the energy applied to open thehood. The torsion rods mount in the hood pivot blockwhich is connected to the tow-eye brackets.

W8001064

Restraint CylinderThere are two restraint cylinders connected to the hood,just behind each upper corner of the front grille down toeach tow-eye bracket. The cylinders are single-acting oilshocks that control the rate of opening of the hood in or-der to reduce the chance of damage to the hood and themounting system.

W8002299

11


Hood LatchThe hood on the VN series is held closed by an automo-tive type latch mechanism. The latch points for the hoodare on each side of the hood directly above the frontwheels. The latch is released by a pull handle inside thecab on the dash.

Latch Mounting ArmThe latch mounting arm connects to the frame and sup-ports the receiver cup latch mechanism. It is constructedof a steel tube and has a bracket on the top. The brackethas slotted bolt holes to allow mounting and adjustmentof the latch mechanism.

W8001059

Latch MechanismThe latch mechanism is an automotive type hood latch.When the hood is closed the hood mounted latch studsare inserted into the latch receiver cup. When the stud isin the receiver far enough the latch lever snaps into aslot above the stud to keep it from pulling out. The latchlever is a spring loaded lever that pivots at one end. Theother end is connected to the release cable. When thehood release is pulled the latch lever is pulled out of theslot in the latch studs and a spring above the latch studpushes the hood up so that the slots clear the lever.

W8001069

12


Latch StudThe latch stud is a pin that inserts into the latch mecha-nism. The pin is covered by a spring loaded shield. Whenthe shield contacts the latch mechanism ring during hoodclosing, the latch ring forces the shield back against itsspring, exposing the pin. The pin is forced into the ringby the momentum of the hood. As the pin enters thelatch receiver, it moves the latch lever to the side. Whenthe head of the pin has completely traveled past thelatch lever, the lever snaps into place above the pin, pre-venting the pin from retracting out of the latch receiver.

The spring loaded shield also functions to reduce thetransmission of frame vibrations to the hood.

W8001061

Hood ReleaseThe hood release is a pull handle mounted in the vehicledash. The cables that pull the latch lever back duringhood latch release are attached to the hood release han-dle. As the handle is pulled, both release cables arepulled. This moves the latch levers away from the top ofthe latch stud, allowing the latch stud to pop out of thelatch receiver cup. When the hood release is let go, thesprings in the latch arms pull the latch levers back intoplace, which in turn pulls the hood release handle backto its normal position.

W8000986

CableThe hood release cables connect between the latchlever and the hood release handle. The cables arebraided steel cables that are covered by a plastic jacket.The latch mechanism end of the cable has a ball that fitsinto a slot in the latch arm. This end is held in place by ajam nut. The other end has a barrel that fits into a slot inthe hood release handle. The cables pass through thebulkhead directly above the engine. A rubber grommetprotects each cable from chafing at the pass through.

W8001060

13


Engine Air IntakeThe engine air intake is mounted in the side of the hoodon the passenger’s side. A water collection channel is in-corporated around the air intake grille. This channelforces any water away from the engine air cleaner open-ing and into the integral drains.

GrilleA plastic grille is installed in the air intake on the passen-ger’s side of the hood. The grille prevents large objectsfrom being drawn into the air intake plenum that couldreduce air flow and cause eventual blockage. The lou-vers on the grille are angled to channel rain and roadspray down away from the air intake.

The grille can be removed by prying up the clips thathold it in the hood. Installation requires only pressing thegrille until it snaps into place.

W8001066

BellowsA bellows assembly is incorporated in the air intakepath, between the hood and the air cleaner. This bellowsexpands and contracts with the relative motions of thehood and the engine air cleaner, so that no additionalstresses are placed on the air cleaner mounting. It alsoreduces transmission of noise and vibration from the en-gine to the hood.

W8001065

14


Front GrilleThe front grille is fitted into the hood to maintain theaerodynamic design. The grille assembly consists of thegrille, the VOLVO slash, the VOLVO emblem, and an in-sect net. The grille is bolted to the hood and can beremoved without opening the hood. Once the grille as-sembly is removed, the emblem and slash can each beremoved from it if replacement is required.

W8001058

HeadlightsThe headlights and turn signal lights are integrallymounted in the front of the hood to reduce aerodynamicdrag. They are accessible from inside the engine com-partment when the hood is raised. The headlights arenot sealed beam units. An assembly consists of a head-light lens that mounts to the outside of the hood and abulb and socket that insert into the lens housing with atwist. The turn signal light assembly is similar. There is aseal and a cover panel that mounts over the opening forthe light assemblies. Spring clips hold the cover tightenough to prevent water and debris from entering thelens housings, while still allowing easy access to thebulbs for replacement. The headlight positioning adjust-ments are external to the cover panel.

W3000953

15


Miscellaneous Components

Wear BlockThe upper corners of the cowl have a rubber wear block.This block is designed to prevent the hood from contact-ing the cowl and to help reduce noise and vibrationtransmitted to the cab.

W8001070

InsulationA two piece insulation is attached to the under side ofthe hood. This insulation reduces the engine noise trans-mitted outside the engine compartment. The insulation isrequired on vehicles with high rpm engines.

W8001068

Splash ShieldsA system of splash shields protects the engine compart-ment and bulkhead from tire spray and road dirt. Thesplash shields are constructed of molded plastic andconsist of two pieces on each side of the vehicle. Theupper pieces are attached to the hood and the lowerpieces are attached to the cab. When the hood is closed,the upper shields overlap the lower shields to form abarrier against water and dirt from the road. When thehood is open the upper shields are out of the way of theengine compartment to provide easier engine access.

The lower splash shields are grooved to reduce the im-pact of spray from other vehicles. They also have anaccess cover that is directly below the hood latch mech-anism. This allows for maintenance on the latchmechanism without removing the entire splash shield. Italso allows access to the latch lever in the event thelatch is disabled and access to the engine compartmentis required.

16

Group 82 Hood Service Procedures

Service Procedures8211-03-02-01Hood, Replacement

PERSONAL INJURY HAZARD! Before working on thevehicle, set the parking brakes, place the transmissionin neutral, and block the wheels. Failure to do so canresult in unexpected vehicle movement and cause se-rious personal injury or death.

WARNING

The VN Series hood weighs approximately 86 kg (190lb). Never remove or replace the hood without assis-tance. Use a second person and a lifting device.Failure to follow this warning could result in personalinjury and/or vehicle damage.

Removal1

W8002282

Locate and disconnect the wiring con-nectors for the headlight/turn signalassemblies and the wiring connectorsfor the fog lamps and driving lights.These connectors are located near thefront of the hood at the J-brackets.

2Remove the front bumper.

Note: See bumper replacement proce-dures in:

ServiceManual

Group 86Front Bumper, VNL, VNMService ProceduresTSP103726/1

IMPACT Function Group 8611Information Type: Repair

3

W8002283

Support the hood and then remove thenuts to the hood restraint cylinders.

4

W8002284

Remove the four nuts that attach thehood pivot brackets to the chassis.

17


5

W8001144

With a technician on each side of thehood, tilt the hood up to about a 55�

angle to relieve the pressure on thetorsion rod assembly. Carefully removethe hood from the vehicle and setaside.

Installation

1

W8001144

With a technician on each side, lift thehood and tilt it to approximately a 55�

angle. Align the studs from the hoodpivot bracket and install the hood. In-stall the four nuts onto the hood pivotbracket studs and torque the nuts to56 ± 10 Nm (41 ± 7 ft-lb).

56 ± 10 Nm(41 ± 7 ft-lb)

2

W8002286

Reinstall the hood restraint cylindersand tighten the bolts. Torque the boltsto 30 ± 4 Nm (22 ± 3 ft-lb).

Note: On VNL, the restraint cylinder isbolted to the inner face of the cross-member bracket. On VNM, therestraint cylinder is bolted to the outerface of the crossmember bracket.

30 ± 4 Nm(22 ± 3 ft-lb)

3

W8002282

Reconnect the headlight and fog lightwiring connectors.

4Check the hood adjustment and adjustthe hood as necessary. Refer to“Hood, Adjustment” page 19 for de-tailed instructions on adjusting thehood.

5Reinstall the bumper, and make thenecessary side to side adjustments tocenter the bumper.

18


8211-05-03-01Hood, AdjustmentNote: This adjustment procedure should be performed ifthe hood has been replaced or if other repairs havebeen made that would affect the proper alignment of thehood. It should also be performed if the hood appearsout of adjustment, or if it takes excessive force to causethe hood to latch.


1If the vehicle is equipped with air sus-pension, build the pressure in the airsystem to 827 kPa (120 psi).

2Measure the rear cab height to ensureit is adjusted to the proper specifica-tion. The cab must be square on thechassis. If cab height is incorrect orthe cab is not square on the chassis,then make the necessary adjustmentsto bring them to the proper specifica-tions before continuing the hoodadjustment procedure.

Note: Cab height measured at therear of the cab is174 ± 4 mm (6.850 ± .157).This measurement is taken from thetop of the spring plates to the top ofthe cab suspension crossmember.

3Remove the splash shield supportbracket on both sides of the vehicle.

4

W8002297

Remove the access panels from un-derneath the right and left splashshields to access the hood latch as-semblies.

5

W8001132

Push the latch lever back and removethe latch release cable end from thelatch lever on both sides of the vehicle.

6Close the hood and ensure it latches.

CAUTION

Possible component damage. If the hood was re-placed or repairs were performed that could cause thehood to be misadjusted, it MUST be adjusted. DoNOT leave the hood latched without ensuring properadjustment. Operation of the vehicle without properhood adjustment could result in damage to the hoodand its latching components.

19


7

W8002298

Remove the four latch receiver cupmounting screws from both sides ofthe vehicle.

WARNING

Personal injury hazard. Do NOT unlatch the hood af-ter the four receiver cup mounting screws have beenremoved. Unlatching the hood with the receiver cupmounting screws removed could cause the receiver tobe ejected from the latch stud resulting in personal in-jury.

8Raise the hood by pushing it open.

9

W8001312

Install the hood gauge blocks 3945529by removing the two torx screws in theupper left and right sides of the cowl.Install the hood gauge blocks with thelong screws provided.

10

W8002303

Loosen the three vertical adjustmentbolts and the four horizontal adjust-ment bolts on the latch adjustmentbrackets on both sides of the vehicle.

11Slide the adjustment brackets down totheir lowest position.

12Loosen the five bolts on both hoodJ-brackets.

13Gently lower the hood so that it restson the gauge blocks.

14Measure the gap between the insideedge of each J-bracket and the outeredge of each pivot bracket. Measure-ments should be within 3 mm(0.12 in.) of each other.

15If J-bracket to hood pivot brackets arenot within 3 mm (0.12 in.) of one an-other, loosen the locking collar socketscrews on each side and move thehood right or left to make the mea-surements within 3 mm (0.12 in.).Then torque the locking collar socketscrews to 12 ± 2 Nm (9 ± 1.5 ft-lb).

12 ± 2 Nm(9 ± 1.5 ft-lb)

20


16

W8001101

Use hood gap gauge 3945528 tocheck the gaps between the hood andthe cowl. Check the gap at two places(approximately 340 mm, or 13 in.apart) along the cowl on each side.Note the size of the gap at all points.

Note: The hood gap is the distancefrom the forward edge of the hood gapgauge to the rear edge of the hood.

17

W8002284

If there is more than 4 mm (0.16 in.)difference between the upper andlower gap on either side, then loosenthe hood pivot bracket nuts at the frontof the chassis just enough to be ableto slide the bracket up or down.

18Move the hood pivot bracket up ordown to make the gap parallel.Tighten the bottom pivot bracket nutfrom under the vehicle.

19

W8002287

Install the hood alignment tool,J-42884. Attach the tool to the existinghole in the J-bracket and bolt to thehood with the clip bolt provided.Recheck the hood gap using the ad-juster tool. If the gap is more than 8mm (.32 in.), turn the nut on the hoodadjuster to slide the hood rearward tomake the gap 8 mm (.32 in.).

20On both sides of the vehicle, slide theadjustment brackets up to the receivercup. Line up the bracket and receivercup holes and install the four screws.

21Tighten one vertical adjustment boltand one horizontal adjustment bolt oneach side of the vehicle.

22Release the hood latch and open thehood.

21


23

W8002284

Torque the pivot bracket nuts to56 ± 10 Nm (41 ± 7 ft-lb).

56 ± 10 Nm(41 ± 7 ft-lb)

24Torque the J-bracket bolts to56 ± 10 Nm (41 ± 7 ft-lb).

56 ± 10 Nm(41 ± 7 ft-lb)

25

W8001118

Torque the vertical adjustment bracketbolts to 28 ± 5 Nm (21 ± 4 ft-lb).

28 ± 5 Nm(21 ± 4 ft-lb)

26

W8001141

Torque the horizontal adjustmentbracket bolts to 28 ± 5 Nm(21 ± 4 ft-lb).

28 ± 5 Nm(21 ± 4 ft-lb)

27Install the splash shield supportbracket.

28Install the latch release cable end ontothe latch lever.

29Reinstall the access panels in thesplash shields.

30Remove the gauge blocks from thecowl and install the original screws.

31Remove the hood adjuster tool fromthe hood. If the wiring harness brackethas been removed, be sure to reinstallit to the hood by tightening the screwon the top hole.

32Close the hood and ensure it latchesproperly.

22


8212-03-02-01Torsion Rod Assembly, Re-placement


Removal1

W8002282

Locate and disconnect the wiring con-nectors for the headlight/turn signalassemblies, and disconnect the wiringconnectors for the fog lamps anddriving lights. These connectors are lo-cated near the front of the hoodJ-brackets.

2Remove the front bumper.


ServiceManual



3If the entire torsion rod assembly mustbe replaced, skip Steps 4 through 7and resume at Step 8.

4Open the hood to the neutral position(approximately 55�) to relieve tensionon the torsion springs.

5To replace the torsion spring, removethe six point socket screw from thebottom of the hood pivot bracket.

6Slide the torsion spring out of thehood pivot bracket.

7Skip the remainder of the torsion rodassembly removal steps and install thenew torsion spring using the installa-tion procedure.

8

W8002283

Support the hood and then remove thenuts to the hood restraint cylinders.

9

W8002284

Remove the four nuts that attach thehood pivot bracket to the chassis.

23


10

W8001144

WARNING

The VN Series hood weighs approximately 86 kg (190lbs). Never remove or replace the hood without assis-tance. Use a second person and a lifting device.Failure to follow this warning could result in personalinjury and/or vehicle damage.

With a technician on each side of thehood, tilt the hood up to about a 55�

angle to relieve the pressure on thetorsion rod assembly. Carefully set thehood off of the vehicle.

11

W8002288

Loosen and remove the five bolts thathold each J-bracket to the hood. Re-move the J-brackets and torsion barsas an assembly.

Installation1If only a torsion spring was removed,skip Steps 2 through 7 and resume atStep 8.

2

W8002288

Install the torsion rod assembly backonto the hood by installing the fivebolts on each J-bracket.

Note: For the torsion rod assembly tobe adjusted, install the bolts to thehood, but do not tighten.

24


3

W8001144

WARNING

The VN Series hood weighs approximately 86 kg (190lbs). Never remove or replace the hood without assis-tance. Use a second person and a lifting device.Failure to follow this warning could result in personalinjury and/or vehicle damage.

With a technician on each side lift thehood and tilt it to approximately a 55�

angle. Align the studs from the hoodpivot bracket and install the hood. In-stall the four nuts onto the hood pivotbracket studs and torque the nuts to56 ± 10 Nm (41 ± 7 ft-lb).

4

W8002286

Reinstall the hood restraint cylindersand tighten the bolts. Torque the boltsto 30 ± 4 Nm (22 ± 3 ft-lb).

Note: On VNL, the restraint cylinder isbolted to the inner face of the cross-member bracket. On VNM, therestraint cylinder is bolted to the outerface of the crossmember bracket.

30 ± 4 Nm(22 ± 3 ft-lb)

5

W8002285

Reconnect the headlight and fog lampwiring connectors.

6Check the hood adjustment and adjustthe hood as necessary. See “Hood,Adjustment” page 19.

7If the entire torsion rod assembly wasreplaced, skip Steps 8 and 9 and re-sume at Step 10.

25


8Insert the new spring through thehood pivot bracket hole and the springbushing, and into the slot in the otherside pivot bracket.

9Install the six point socket screw andtorque to 12 ± 2 Nm (9 ± 1.5 ft-lb).

12 ± 2 Nm(9 ± 1.5 ft-lb)

10Reinstall the bumper and make thenecessary side to side adjustments tocenter the bumper.


ServiceManual



8214-03-02-01Hood Restraint Cylinder, Re-placement


Removal1

W8001130

Remove the six bolts from the splashshield.

26


2

W8002283

VNL Hood Restraint Removal

W8002289

VNM Hood Restraint Removal

Remove the two nuts from the hoodrestraint cylinder and remove the cylin-der.

Note: On VNL models, the restraintcylinder is bolted to the inner face ofthe crossmember bracket. On VNMmodels, the restraint cylinder is boltedto the outer face of the crossmemberbracket. See the corresponding illus-trations.

Installation1Install the new hood restraint cylinderand nuts.

Note: On VNL models, the restraintcylinder must be bolted to the innerface of the crossmember bracket. OnVNM models, the restraint cylindermust be bolted to the outer face of thecrossmember bracket.

2Torque the nuts to 30 ± 4 Nm(22 ± 3 ft-lb).

30 ± 4 Nm(22 ± 3 ft-lb)

3Install the splash shield and tightenthe bolts.

27


8213-03-02-01Hood Latch, Replacement


Removal1

W8002297

Remove the access cover underneaththe splash shield.

2Push the hood latch lever back andpull the ball end of the cable out of thelever.

3Mark the exact location of the receivercup on the adjustment bracket.

Note: If the bracket bolts are loosenedthen the hood adjustment proceduremust be performed after replacementof the latch mechanism is complete.See “Hood, Adjustment” page 19.

4

W8002298

Remove the four hood latch mecha-nism mounting bolts through theaccess in the splash shield. Removethe hood latch.

Installation1Install the hood latch and the hoodlatch mounting bolts. Torque the hoodlatch mounting bolts to 28 ± 5 Nm(21 ± 4 ft-lb).

28 ± 5 Nm(21 ± 4 ft-lb)

2Push the hood latch lever back and in-stall the ball end of the hood releasecable.

Note: Check the release cable adjust-ment and readjust if necessary.

3Reinstall the splash shield accesscover.

28


8213-03-02-02Hood Latch Stud, Replacement


Removal1Mark the exact location of the latchstud on the hood.

Note: If the receiver cup bracket boltshave been loosened, then the hoodadjustment procedure must be per-formed after replacement of the latchmechanism is complete. See “Hood,Adjustment” page 19.

2

W8001117

Remove the four bolts from the studand remove the stud.

Installation1Install the new hood latch stud usingthe four bolts. Torque the bolts to28 ± 5 Nm (21 ± 3.7 ft-lb).

28 ± 5 Nm(21 ± 3.7 ft-lb)

2Close the hood and verify it is properlyaligned. Perform the adjustment pro-cedure if necessary. See “Hood,Adjustment” page 19.

8214-03-02-02Hood Latch Arm, Replacement


Removal1

W8001137

Remove the splash shield on the sidethat the hood latch arm is to be re-placed.

2

W8001141

Remove the four bolts that attach thehood latch assembly to the hood latcharm.

29


3

W8001139

Remove the four bolts and nuts thatattach the hood latch arm to the vehi-cle chassis.

Installation1Install the new hood latch arm, boltsand nuts to the frame rail. Torque to200 ± 33 Nm (148 ± 24 ft-lb).

200 ± 33 Nm(148 ± 24 ft-lb)

2Reinstall the hood latch assembly andmounting bolts. Torque to 28 ± 5 Nm(21 ± 4 ft-lb).

28 ± 5 Nm(21 ± 4 ft-lb)

3Reinstall the splash shield.

4Adjust the hood using the Hood ad-justment procedure. See “Hood,Adjustment” page 19.

8214-03-02-03Hood Release Cable, Replace-ment


Removal1

W8001131

Remove the passenger side and cen-ter dash panels.

30


2

W8001121

Remove the hood release cable fromthe hood release handle.

3Cut the tie straps. Remove the hoodrelease cable from the cab by pullingthe cable through the bulkhead fromoutside the cab.

4

W8001132

Loosen the jam nuts at the hood latchassembly and remove the cable.

Installation1Remove the rubber grommet from thebulkhead and slide the new cable intothe rubber grommet.

2

W8001120

Begin installing the cable by pushing itthrough the hole in the bulkhead fromthe outside. Push the grommet intoplace on the bulkhead.

3

W8001121

Attach the cable end to the hood re-lease handle inside the cab.

31


4

W8001129

Attach the other end of the cable tothe hood latch assembly. Adjust thecable and tighten the two jam nuts

5Reinstall the passenger side and cen-ter dash panels.

8231-03-02-01Grille, Replacement


Removal1Remove the screws around the out-side of the grille and remove the grille.

Installation1Hold the grille in place and install thescrews.

2Note: Grille mounting screws shouldbe tightened so that the rubber mountextends from 6.5 to 8 mm (approxi-mately 1/4 in.) past the inside edge ofthe hood, and so that the rubbermount has a visible outward bow.

Torque the screws to 2 Nm (1.5 in-lb).

2 Nm(1.5 in-lb)

32


8231-03-02-02Grille Slash, Replacement


Removal1Remove the screws around the out-side of the grille and remove the grilleassembly.

2Remove the two screws that attach thebug screen to the inside of the grilleassembly. Remove the insect net.

3

W8001110

Remove the emblem by placing a10 mm socket over the retaining clipsand striking the back of the socket.This will flatten out the clips, causingthem to release.

4Note: The retaining clips are NOTreusable. Once they have been re-moved, they must be replaced withnew clips.

Discard the old clips.

Installation1

W8001108

Install the new emblem onto the grille.Lay the grille front side down. Installthe clips by using a 7 mm socket andpressing them on by hand.

Note: New retaining clips must beused when replacing the VOLVO em-blem.

2Reinstall the bug screen.

3Hold the grille in place and insert thescrews.

4Note: Grille mounting screws shouldbe tightened so that the rubber mountextends from 6.5 to 8 mm (approxi-mately 1/4 in.) past the inside edge ofthe hood, and so that the rubbermount has a visible outward bow.

Torque the screws to 2 Nm (1.5 in-lb).

2 Nm(1.5 in-lb)

33


2563-03-02-01Air Intake Grille, Replacement


Removal1

W8001134

Using a small flat blade screwdriverand working through the outside lou-vers in the grille, pry the clips up whilepulling out on the grille. When all of theclips are loosened, remove the grille.

Installation1Check to be sure there are no foreignobjects in the hood intake or behindthe grille.

2Install a new seal around the inneredge of the grille.

3Place the grille in position (in its hole)and press it until it snaps into place.

2564-03-02-01Air Intake Bellows, Replace-ment


Removal1

W8001106

Open the hood and reach into the bel-lows through the bellows guide. Pullthe metal retaining ring out of itsgroove in the bellows.

2Remove the bellows from the hood.

34


Installation

W8001107

1 Air intake bellows2 Retaining ring

Note: The bellows must be installed in the air intake inthe first groove in the bellows. The retaining ring mustalso be installed in the first groove and should be inplace prior to installation of the bellows assembly.

1Install the retaining ring in the firstgroove of the bellows.

2

W8001111

Apply a soapy solution to the outsideof the end groove of the bellows.

3

W8001128

Install the lower side of the bellows,and as much as possible of one endinto the air duct of the hood. Bow thecenter of the retaining ring away fromthe hood, and push the upper edge ofthe bellows down into the air intake.Begin working the remaining portion ofthe bellows into its proper location in-side the air intake.

4Make sure the retaining ring is fullyseated in the groove.

35


3522-03-02-01Headlamp Lens, Replacement


Removal1

W8001104

Remove the dust cover from the head-light assembly.

2

W8001126

Remove the headlight bulb socketfrom the headlight lens assembly.

3Remove the nine headlight retainingscrews and the headlight lens assem-bly.

Installation1Install the new headlight lens assemblyinto the hood, and align the adjusterscrews through the hood. Install andtighten the nine retaining screws.

2Install the headlight bulb socket as-sembly and reinstall the dust cover.

36


3521-05-03-01Headlamp, AdjustmentNote: The following procedure describes headlamp ad-justment using the Hoppy B4A Suction Cup HeadlampAiming Kit. Use of the Hoppy Headlamp Aiming Kit is theONLY method recommended for aligning VNL and VNMheadlamps.

Vehicle PreparationBefore beginning the headlamp aiming process, preparethe vehicle as follows:


1Drive the vehicle onto a flat surface. Itis not necessary that this surface beexactly level.

2Remove any large amounts of mud orice from the underside of the fenders.

3Check whether tires are noticeably de-flated and inflate if necessary.

4See that there is no load in the vehicleother than the driver.

5Rock the vehicle to equalize thesprings. Check them for sag or brokenleaves.

6Make sure the cab suspension andthe Volvo air suspension are fully in-flated and that the air system pressureis 620 kPa (90 psi) or higher.

37


7Clean the headlamp lenses and aim-ing pads.

CAUTION

Some solvents and cleaners will attack and/or weakenthe components of the B4A aimer. Thoroughly dry anyobject which has been cleaned with a solvent beforeattaching an aimer to it.

8Check for bulb burnout, broken aimingpads, and proper beam switching.

9Check to ensure that the hood isclosed completely, and latched on bothsides.

Floor Slope CalibrationNote: The headlamp aimers will not work correctly un-less floor slope is taken into account. Calibration of floorslope should be done prior to aiming. However, if youregularly use one area to aim headlamps, recheckingfloor slope is unnecessary. Permanently mark the area,calibrate slope for that area, and mark the setting for fu-ture reference.

W3002348

B4A Aimer Unit

1 Piston Handle2 Level Vial Bubble3 Top Port Hole4 Unit Identification5 Horizontal Aim Port Hole6 Horizontal Aim Knob7 Vertical Aim Knob8 Vertical Aim Vial9 Floor Level Dial

1

W3002349

1 Thumb Adjusting Screw

Attach Calibration Fixtures to aimers.The fixtures will easily snap into placewhen properly positioned.

38


2

W3002350

Fig. 1: Floor Calibration (on passenger side only)

1 Unit A (rear tire)2 Unit B (front tire)3 Calibration Fixture4 Thumb Adjusting Screws5 Level Vial Bubble6 Top Port Hole7 Horizontal Knob8 Floor Level Dial

Place aimers at the center line of eachwheel on the passenger side of thevehicle.Unit B must be placed at the frontwheel on the passenger side with thetarget facing to the rear. Unit A mustbe placed at the rear wheel on thepassenger side with the target facingfront.

3Level each unit by turning the thumbadjusting screw on each calibration fix-ture. Turn the screw either clockwiseor counter-clockwise until the level vialbubble registers in a centered, levelposition.

39


4

W3002344

Look into the top port hole of Unit A.Turn horizontal knob until the split im-age is aligned.

5

W3002359

1 Horizontal Dial2 Floor Level Dial

Transfer the plus or minus reading in-dicated on the horizontal dial to theFLOOR LEVEL DIAL on each aimer(press floor level dial inward to setreading).

6Remove calibration fixtures from theaimers.

Adaptor Assembly1

W3002345

1 Articulating Vacuum Cup Assembly2 O-Rings3 Extension Studs4 Vacuum Extension Plate5 Large Universal Adaptor6 Fixed Vacuum Cup7 B4A Aimer

Locate the correct parts needed to as-semble the aimer for use on VNheadlamps. For aiming headlamps ona VN series truck, always use thelarge adjustable black adaptors sup-plied with the Headlamp Aiming Kit.The adaptors will be attached last.

2

W3002347

Attach the vacuum extension plate as-sembly (1) to the fixed vacuum cup (2)on the B4A aimer. The fixed cupshould be fully extended.

40


3

W3002395

1 Vacuum Extension Plate2 Fixed Vacuum Cup

Squeegee the fixed cup into the roundhole in the back of the vacuum exten-sion plate.

4

W3002351

1 Articulating Vacuum Cup2 O-rings3 Extension Stud4 Vacuum Cup Extension Plate5 Fixed Vacuum Cup

Attach an extension stud (3) to thevacuum cup assembly. The threadedstud fastens between the vacuum cupextension plate (4) and the articulatingvacuum cup assembly (1). The studmust be seated firmly against theO-ring (2) in the vacuum cup exten-sion plate.

Note: The B4A aimer kit includes 2extension studs that can be placed be-tween the vacuum cup extension plateand the articulating cup assembly.When using the aimer on the head-lamps of the VN Series trucks, onlyone extension is needed.

5Install the articulating vacuum cup as-sembly onto the extension stud,making sure the O-ring is seatedfirmly against the vacuum cup.

6Attach the large black adaptor to theB4A assembly.

Attaching the Aimer1

W3002361

Fig. 2: Attaching the B4A aimer

Note: For aiming headlamps on a VNseries truck, always use the large ad-justable black adaptors supplied withthe Headlamp Aiming Kit.

2Align the large universal adaptor to theaiming pads on the lens (as shown inFigure 2). Note the numbers locatedon the pads of the lens. Move the ad-justment rod for each pad until itagrees with the number located nextto the pad. This procedure should befollowed for the passenger side anddriver side adaptors.

41


3

W3002346

1 Neutral Position2 Odd Number3 Even Number

To adjust the adaptor rods to the re-quired position, turn the rods to theneutral position and slide in or out tothe proper setting.

4Turn the rod clockwise to lock in anodd number, and counter clockwise tolock in an even number.

5

W3002354

1 Piston Handle2 Vacuum Release Button

Attach each aimer to the headlampsby pushing the piston handle forward,engaging the rubber suction cup. Im-mediately pull back the piston handleuntil it locks in place.

6

W3002372

1 Unit B2 Unit A3 Sight Openings4 Viewing Port5 Horizontal Dial6 Vertical Dial7 Level Bubble

Unit A should be attached to thedriver’s side headlamp, and Unit B tothe passenger side. The sight open-ings on each aimer must face eachother.

Adjusting Headlamp AimHorizontal Aim

1

W3002343

Note: For the VN Series trucks, thehorizontal and vertical headlampscrews must be adjusted from behindthe headlamp. Due to the sensitivity ofthe aimer, adjustments must be madewith the hood closed and secured. Ad-justments to the headlamp screwsmust be made from under the hood. Itis recommended that one personcheck alignment of the split imagewhile another makes adjustments tothe headlamp screws.

42


2

W3002371

1 Viewing Port2 Horizontal Dial

To set the horizontal aim (side to side),the horizontal dial should be set atzero.

3Check to see that the split image tar-get lines are visible in the viewingport. If necessary, rotate each aimerslightly to locate the target.

4

W3002352

Using an inverted torx socket, size E7,turn the horizontal adjusting screw lo-cated on the back of the headlamp.

5

W3002370

Turn the horizontal screw until the splitimage of the target line appears inmirrors as one solid line. To remove“backlash,” make final adjustment byturning screw clockwise.

6Repeat these steps with the oppositeaimer and headlamp.

Vertical Aim

7

W3002360

1 Level Bubble2 Vertical Dial

The vertical dial should be set at zero.

43


8

W3002369

Turn the vertical adjusting screw be-hind the headlamp until the level of thebubble is centered between the lines.To remove “backlash,” make final ad-justments by turning the screwclockwise.

9Repeat the last two steps with the op-posite aimer and headlamp.

10Recheck target alignment on bothaimers and readjust horizontal aim ifnecessary.

11

W3002354

1 Piston Handle2 Vacuum Release Button

Remove the aimer by holding it se-curely and pressing the “VacuumRelease” button located on the pistonhandle.

3527-03-02-01Turn Signal Lens, Replacement


Removal1

W8001104

Remove the dust cover from the head-light assembly.

2

W8001125

Remove the bulb socket assemblyfrom the lens.

3Remove the three screws and the turnsignal light assembly.

44


Installation1Install the turn signal lens assemblyand reinstall the three screws.

2Install the bulb socket assembly andreinstall the dust cover.

8211-03-02-04Hood Insulation, Replacement


Removal

W8001122

1Using a center punch, knock out thecenter of each rivet on the hood insu-lation.

2Mark the drill bit at 8 mm (0.32 in.) toprevent drilling through the outer hoodmaterial.

3Drill out each rivet.

Note: Drill rivets slowly so the head ofthe rivet does not turn and tear the in-sulation and the drill does not contactthe hood material.

4Remove the three nuts in the center ofthe hood and remove the insulation.

Installation1Align the small section of insulation tothe three studs in the center of thehood, and then align and install thelarge insulation section.

45


2Reinstall the three nuts onto the studsand tighten.

3Align the rivet holes and install newrivets around the outside edge of theinsulation sections.

8219-03-02-06Hood Rivet Nut, Replacement


Special tools: Rivet nut insertion toolkit J-42405

1Grind off the head of the rivet nut tobe replaced.

Note: Be careful when grinding therivet nut out to prevent distorting themounting hole.

2Push the body of the rivet nut throughits mounting hole.

3Check the fit of the new rivet nut in themounting hole. Drill the hole out to fitthe new rivet nut if necessary.

4Set up the new rivet nut in the inser-tion tool. Verify the mandrel is thecorrect size for the rivet nut that will beinstalled.

5

W8001127

Install the rivet nut using the insertiontool.

46


Hood Fender and HeadlampBucket, Replacement

WARNING

Always wear safety goggles while using a heat gun.Failure to wear safety goggles could result in damageto the eyes.

WARNING

Commercial cleaning solvents can be toxic and causeskin irritation, they may also be considered firehazards. When using solvents follow the safety pre-cautions recommended by the solvent manufacture.

WARNING

When a heat lamp and/or heat gun is used to heat awork area do not touch that area. Risk of burns orother personal injury.

Removal1

W8002597

Use a heat lamp and heat the workarea before starting the repair.

2

W8002598

Use a heat gun and heat the workarea to 204� C (400� F) until the adhe-sive starts to break loose. Heat shouldbe directed towards the panel that isbeing removed, be careful not to dam-age the inner supports.Use a pry bar or screwdriver to sepa-rate the top edge of the fender loosefrom the center panel.

CAUTION

Use a heat strip to monitor the temperature. Exces-sive heat will break down the SMC material.

WARNING

Always wear appropriate eye protection to prevent therisk of eye injury due to contact with debris or fluids.

WARNING

Use a respirator when sanding to protect lungs fromforeign matter. Failure to follow these recommenda-tions may result in injury.

47


3

W8002615

W8002599

Use an air reciprocating saw and cutsections of the fender away from theinner supports. Most of the cuttingshould be done from the inside of thefender well. Cut 1 in. away from the in-ner supports.

WARNING

Personal injury hazard. Always wear safety gogglesand a respirator while using a reciprocating saw. Fail-ure to use safety goggles could result in damage tothe eyes. Failure to use a respirator could result in for-eign material in the lungs.

4

W8002613

Locate the bracket support behind therear of the headlamp bucket. Heat thebracket and remove.

CAUTION

Be careful not to damage this part as it will be rein-stalled on the new fender.

5After sections of the fender has beencut away you can use an air chisel toseparate the sections of the fenderthat remains.

48


Installation1

W8002600

W8002601

Position the headlamp bucket in placeon the backside of the new fender andtrace out the edges with a blackmarker.

2

W8002602

Use 80 grit sandpaper and scuff upthe mating surface of the fender paneland the headlamp bucket.

3

W8002603

Position the headlamp bucket in placeand adjust the vise-grip locking Cclamps.

49


4

W8002604

Remove end cap and dispense a small amount topurge out air and level the plungers.

W8002614

Put mixing tip on and dispense a bead of adhesiveabout the length of the mixing tip.

W8002605

Apply adhesive on the mating surfaceof the headlamp bucket. Use T-22(fast set) or T-23 (medium set).

Note: Read the Fusor warnings andtechnical data sheet for informationabout how to apply.

5

W8002606

Position the headlamp bucket to thepanel. Use a heat lamp and a temper-ature strip and heat to 60� C (140� F)for 15 minutes if T-22 is used or 22minutes if T-23 is used.

6Sand and remove any remaining ad-hesive from the inner supports.

WARNING

Always wear safety goggles and a respirator while us-ing a disc sander. Failure to use safety goggles couldresult in damage to the eyes. Failure to use a respira-tor could result in foreign material in the lungs.

50


7

W8002608

Pre-fit the fender on the hood. Pre-adjust the locking C clamps. Use ablack marker to mark out where the in-ner supports are located.

8

W8002609

Remove the fender and place it on aworkbench. Sand by hand with 80 gritsandpaper where the adhesive will beapplied. Sand a 1 in. area in from themarker lines.

9

W8002610

W8002611

Apply adhesive to the inner supportson the hood. Use T-23 (medium set)or T-24 (slow set).

51


10

W8002612

W8002608

Set the fender in place and clamp.Using T-24, leave fender clamped atroom temperature for 4 hours or 30minutes at 60� C (140� F) with heatlamp and heat strip.

11Apply adhesive to the L-bracket innersupport. Use T-22 (fast set) or T-23(medium set). Set the L-bracket inplace and leave clamped for:

At room temperature

T-22 1 hourT-23 2 hours

At 60� C (140� F) with heat lamp andheat strips

T-22 15 minutesT-23 22 minutes

52


SMC Panel, RepairSMC, although its appearance is similar to fiberglass, isnot a conventional fiberglass panel. The repair tech-niques may be similar, but the composition of SMC andthe materials used to repair it are quite different. At thistime, only Fusor bonding materials have been approvedand recommended for panel bonding, structural repairsand cosmetic repairs on the Volvo SMC, metton and te-lene panels. Fiberglass resin and ordinary polyesterfillers should not be used. In time, the adhesion ofthese materials is lost and the repair will fail.


For information about recommended repair materials,see “Special Tools” page 5.

1

W8001815

Inspect the damaged area and cleanout loose material. If damage extendscompletely through the panel, abacker panel will be necessary.

WARNING

Always wear appropriate eye protection to prevent therisk of eye injury due to contact with engine debris orfluids.

2

W8001816

WARNING

Use a respirator when sanding to protect lungs fromforeign matter. Failure to follow these recommenda-tions may result in personal injury.

Prepare for bonding the backer panelby scuffing the back side of the dam-aged area using a No. 80 disc on asander.

3

W8001817

The backer panel can be fabricatedfrom a scrap piece of SMC, or somefiberglass reinforcement cloth satu-rated with Fusor adhesive. See“Special Tools” page 5 for informationon recommended adhesive. The panelshould be large enough to cover thedamage and approximately 50 mm (2in.) to the sides of the damage. ApplyFusor repair adhesive to the backerpanel.

53


4

W8001818

Secure the backer panel on the re-verse side of the damage. Allow theadhesive to set before continuingwork. At room temperature, the adhe-sive will set in approximately 1 hour,and will totally cure in 24 hours. Forfaster set, use a heat lamp or heatgun to set the adhesive.

5

W8001819

WARNING


On the outer surface, bevel the paneldown on both sides of the damagedarea using a No. 50 grit disc.

6

W8001820

Remove paint from the area surround-ing the damage and feather outseveral inches.

54


7

W8001821

Apply a light coat of Fusor repair ad-hesive. Spread out the adhesive.

8

W8001822

Place a pre-cut piece of fiberglass re-inforcement cloth onto the adhesive.

55


9

W8001823

Apply a second coat of Fusor repairadhesive. Use the applicator to workthe adhesive into the cloth to removeall trapped air.

10

W8001824

Lay a second layer of reinforcementcloth over the second coat of Fusoradhesive. Work the air out, and coverthe area again with bonding adhesive.At room temperature, the new bondwill set in approximately 1 hour andwill totally cure in 24 hours. For betterand faster curing, use a heat lamp andheat the bond to 80 �C (180 �F) for 60minutes, then allow the bond to coolcompletely before working with it.

11

W8001825

WARNING


Rough sand the area with a No. 80grit disc and a sander.

12

W8001826

Finish with block sanding for a smoothsurface with No. 220 to 320 grit paper.

56

Feedback

One of our objectives is that workshop personnel should have access to correct andappropriate service manuals where it concerns fault tracing, repairs and maintenanceof Volvo trucks.In order to maintain the high standards of our literature, your opinions and experiencewhen using this manual would be greatly appreciated.If you have any comments or suggestions, make a copy of this page, write down yourcomments and send them to us, either via telefax or mailing directly to the addresslisted below.

To

Volvo Trucks North America, Inc.

Dept. 516 Service Publications

7825 National Service Road

P.O. Box 26115

Greensboro, NC 27402-6115

USA

Fax (336) 393-3170

From

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Concerns Service Manual: ...............................................................................................................................

Operation Numbers

2563-03-02-01 Air Intake Grille, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 342564-03-02-01 Air Intake Bellows, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 343521-05-03-01 Headlamp, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373522-03-02-01 Headlamp Lens, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 363527-03-02-01 Turn Signal Lens, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 448211-03-02-01 Hood, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178211-03-02-04 Hood Insulation, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 458211-05-03-01 Hood, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198212-03-02-01 Torsion Rod Assembly, Replacement . . . . . . . . . . . . . . . . . . . . . . . 238213-03-02-01 Hood Latch, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288213-03-02-02 Hood Latch Stud, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 298214-03-02-01 Hood Restraint Cylinder, Replacement . . . . . . . . . . . . . . . . . . . . . . 268214-03-02-02 Hood Latch Arm, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 298214-03-02-03 Hood Release Cable, Replacement . . . . . . . . . . . . . . . . . . . . . . . 308219-03-02-06 Hood Rivet Nut, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 468231-03-02-01 Grille, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328231-03-02-02 Grille Slash, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Volvo Trucks North America, Inc.P.O. Box 26115, Greensboro, NC 27402-6115

Volvo Trucks Canada, Ltd.6490 Vipond Drive, Mississauga, Ontario L5T 1W8

http://www.volvotrucks.volvo.com

PV776-TSP138123 (1000) 3.2000 © Volvo Trucks North America, Inc., 2000

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