Service Manual

Trucks
Group 820–500
Hood
VHD

PV776-TSP141953
 Foreword
The descriptions and service procedures contained in this manual are based on de-
signs and methods studies carried out up to August 2000.

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 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 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 oc-
cur.

Volvo Trucks North America, Inc.

Greensboro, NC USA

Order number: PV776-TSP141953

© 2000 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, me-
chanical, photocopying, recording or otherwise, without the prior written
permission of Volvo Trucks North America, Inc..
 Contents
Tools ........................................................................................................ 3
Special Tools ......................................................................................... 3

Design and Function ............................................................................. 5

Hood ........................................................................................................ 5
General .................................................................................................. 5
Hood Mounting ...................................................................................... 6
Hood Latch ............................................................................................ 8
Engine Air Intake ................................................................................. 10
Front Grille ........................................................................................... 11
Headlights ............................................................................................ 11
Miscellaneous Components ................................................................ 12

Service Procedures ............................................................................. 15

Hood, Replacement ............................................................................. 15
Hood, Adjustment ................................................................................ 19
Hood Restraint Cylinder, Replacement ............................................... 22
Hood Latch, Replacement ................................................................... 23
Hood Latch Stud, Replacement .......................................................... 24
Hood Latch Arm, Replacement ........................................................... 25
Hood Release Cable, Replacement .................................................... 27
Grille, Replacement (Hood Mounted) .................................................. 29
Air Intake Grille, Replacement ............................................................ 32
Air Intake Bellows, Replacement ......................................................... 33
Headlamp Bezel, Replacement ........................................................... 34
Headlamp Assembly, Replacement ..................................................... 36
Headlamp Lens, Replacement ............................................................ 37
Turn Signal Lens, Replacement .......................................................... 38
Hood Insulation, Replacement ............................................................ 39

Feedback

Operation Numbers

1
2
Group 82 Hood Tools

Tools
Special Tools
Following tools are available from Volvo Parts.

Note: The gap gauge may be ordered individually or as

a Hood Alignment Kit, which contains the gap gauge and
gauge blocks. The part number for the kit is 3946180.

3945528 Hood gap gauge

3
4
Group 82 Hood Design and Function

Design and Function

Hood
General

W8002712

The hood on the VHD is the covering for the engine The hood is made of Sheet Molded Compound (SMC), a
compartment. It houses a grille which covers the vehicle composite material which is exceptionally strong and
radiator, a grille for the engine air intake on both sides, lightweight. The hood is manufactured in several sec-
and the vehicle headlight and turn signal light assem- tions, which are then bonded together to form the entire
blies. It is shaped to smoothly transition from the front unit. SMC appears similar to fiberglass. However, con-
bumper to the cowl and wheel openings. ventional fiberglass repair materials, such as fiberglass
resin and other polyester-based materials, should not be
The hood is connected to the frame by a pivot assembly. used in repairing the hood. In time, the adhesion for
The pivot assembly allows the hood to tilt forward to pro- these materials will be lost and the repair will fail. Only
vide access to the engine compartment. The pivot Fusor repair adhesives are approved and recommended
assembly consists of several brackets which reduce the for the bonding and repair of SMC.
impact on the hood and its latch upon closing. Restraint
cylinders and a tension spring limit the speed of the hood The hood is hinged at the lower front edge. It has the

opening as and well as, the opening angle, to prevent ability to open a full 55 of tilt, providing full access to all
damage to the pivot assembly and hood components. engine compartment components. An integral hand hold
is provided in the top of the hood near the front to allow
The hood is held closed by a latching assembly on each it to be pulled open. Once the hood begins to open, its
side, similar to a hood latch found on automobiles. Latch acceleration is limited by a tension spring mounted
assemblies under the hood reduce aerodynamic drag between the hood and the radiator bracket, and the re-
and increase the security of the vehicle. A handle, lo- straint cylinders.
cated in the cab, controls the latch, and is connected to
the latch via a cable.

5
Group 82 Hood 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 adjust-
ment of the hood.

W8002740

J-bracket
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.

W8002728

6
Group 82 Hood Design and Function

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 or-
der to reduce the chance of damage to the hood and the
mounting system.

W8002751

Tension Spring
The tension spring is mounted between the hood and
the radiator bracket. The spring controls the rate of
W8002780
opening of the hood in order to reduce the chance of
damage to the hood and the mounting system.

7
Group 82 Hood Design and Function

Hood Latch
The hood on the VHD 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 sup-
ports 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.

W8002752

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.

W8002749

8
Group 82 Hood Design and Function

Latch Stud
The latch stud is a pin that inserts into the latch mecha-
nism. 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, pre-
venting 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.

W8002739

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 han-
dle. 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.

W8002715

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.

W8002750

9
Group 82 Hood 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 in-
corporated around the air intake grille. This channel
forces any water away from the engine air cleaner open-
ing and into the integral drains.

Grille
A rubber grille is installed in the air intake on both sides
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 grille can be removed by pulling it out by hand. In-

stallation requires only pressing the grille until it snaps
into place.
W8002746

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 en-
gine to the hood.

W8002738

10
Group 82 Hood Design and Function

Front Grille
The front grille is smoothly fitted into the hood. The grille
assembly consists of the grille, the grille bezel, the
VOLVO slash, the VOLVO emblem, and an insect net.
The grille is bolted to the hood, the hood needs to be
raised before the grille can be removed. Once the grille
assembly is removed, the emblem and slash can each
be removed from it, if replacement is required.

W8002727

Headlights
The headlights and turn signal lights are integrally
mounted in the front of the hood. The headlight assem-
bly mounting bolts are accessible from inside the engine
compartment when the hood is raised. The headlights
are sealed beam units. An assembly consists of two
headlights that mount to the outside of the hood, the
turn signal light assembly and the chrome trim bezel.
The headlight positioning adjustments are external to the
cover panel.

W8002711

11
Group 82 Hood 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 contact-
ing the cowl and to help reduce noise and vibration
transmitted to the cab.

W8002737

Insulation
The insulation is attached to the under side of the hood.
This insulation reduces the engine noise transmitted out-
side the engine compartment. The insulation is required
on vehicles with high rpm engines.

W8002722

12
Group 82 Hood Design and Function

Splash Shields
A system of splash shields protects the engine compart-
ment 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.

The lower splash shields are grooved to reduce the im-

pact of spray from other vehicles. They also have an
access cover that is directly below the hood latch mech-
anism. 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.

W8002765

13
14
Group 82 Hood Service Procedures

Service Procedures
8211-03-02-01 2
Hood, Replacement

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 ve-
hicle movement and cause serious personal injury or
death.

WARNING
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 personal W8002691
injury and/or vehicle damage. Remove the hood tension spring.

Removal
1

W8002690

(Headlight/turn signal wiring connector)

Locate and disconnect the wiring con-

nector for the headlight/turn signal
assembly and the wiring connector for
the fog lamps (if equipped). These
connectors are located near the front
of the hood at the J-brackets.

15
Group 82 Hood Service Procedures

3 4

W8002692

With a technician supporting the hood,

remove the hood restraint cylinders.

5
W8002693

(Axle forward)

W8002747

(Axle back)

Remove the left and right side hood

splash shield.

W8002694

With a technician on each side of the


hood, tilt the hood up to about a 55
angle.

16
Group 82 Hood Service Procedures

6 Installation
1

W8002695

Remove the four nuts that attach the

hood pivot brackets to the chassis.

7
With a technician on each side, care-
fully remove the hood from the vehicle.

W8002694

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.

17
Group 82 Hood Service Procedures

2 5

W8002695 W8002690

Install the four nuts onto the hood 56 ± 10 Nm (headlight/turn signal wiring connector)
pivot bracket studs and torque the nuts (41 ± 7 ft-lb)
Reconnect the headlight/turn signal
to 56 ± 10 Nm (41 ± 7 ft-lb).
wiring connector and, if equipped, the
fog light wiring connector.
3
6

W8002692 W8002691

With one technician supporting the 30 ± 4 Nm Hook up the hood tension spring.
hood, reinstall the hood restraint cylin- (22 ± 3 ft-lb)
ders and tighten the bolts. Torque the 7
bolts to 30 ± 4 Nm (22 ± 3 ft-lb).
Check the hood adjustment and adjust
the hood as necessary. Refer to
“Hood, Adjustment” page 19 for de-
4 tailed instructions on adjusting the
Install the hood splash shields. Torque 10 ± 1.5 Nm hood.
the bolts to 10 ± 1.5 Nm (7 ± 1 ft-lb). (7 ± 1 ft-lb)

18
Group 82 Hood Service Procedures

8211-05-03-01 3

Hood, Adjustment
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.

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 ve-
hicle movement and cause serious personal injury or W8002297
death. Remove the inner fender access
plates.

CAUTION 4

Possible component damage. If the hood was re-

placed 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.

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

2
Remove the front bumper.
For front bumper replacement proce-
dure, see service information in group
86. W8002696

Disconnect the hood latch release ca-

bles.

19
Group 82 Hood Service Procedures

5 •
Loosen all of the adjustment points:

W8002695

Pivot blocks (2 nuts on each side)

W8002697

Cup latch (4 bolts on each side)

W8002714

J-brackets (6 bolts on each side)

6
Position the 2 pivot blocks at the top or
bottom of their slots and tighten.

W8002713

Latch mount assembly (3 bolts on 7

each side) Raise the latch mounting bracket
assembly until it is level with the sta-
tionary mount bracket that is mounted
to the framerail and tighten.

Note: The use of visegrips could aid

in holding this bracket in place tem-
porarily because it will be moved
before the adjustment is complete.

8
Gently lower the hood to determine in
which direction it needs to be shifted
(left or right).

20
Group 82 Hood Service Procedures

9 14
Raise the hood and adjust the cup Tighten the 5 remaining J-bracket
latches accordingly. bolts on either side of the hood.

Note: Slide the cup latch 12 of the de-

sired distance in the direction needed 15
and tighten. Connect the 2 hood latch release ca-
bles and adjust if necessary.

10
Gently lower the hood to assure that 16
the latch studs will align with their Torque the latch mounting bracket bolt 56 ± 10 Nm
latches, then latch the hood. on each side to 56 ± 10 Nm (41 ± 7 ft-lb)
(41 ± 7 ft-lb).

11
Loosen the latch mounting bracket as- 17
sembly. Torque the 6 J-bracket bolts on each 56 ± 10 Nm
side to 56 ± 10 Nm (41 ± 7 ft-lb). (41 ± 7 ft-lb)
Note: If visegrips were used, remove
them instead of having to loosen the
mount bolt. 18
Torque the 2 pivot block nuts on each 56 ± 10 Nm
side to 56 ± 10 Nm (41 ± 7 ft-lb). (41 ± 7 ft-lb)
12

19
Torque the 4 cup latch bracket bolts on 28 ± 5 Nm
each side to 28 ± 5 Nm (21 ± 4 ft-lb). (21 ± 4 ft-lb)

20

W8001101

Adjust the hood for proper height, 3945528

depth, and clearance using tool
3945528. Check the gap at two places
(approx. 340 mm (13 in.) apart) along
the cowl on each side. W8002297

Manually adjust the hood by pushing Install the inner fender access plates.
up or down on the fender and either
pushing and/or pulling on the front
portion of the hood. When the hood 21
has reached the correct clearances, Close the hood and ensure it latches
tighten the latch mounting bracket as- properly.
sembly on either side and tighten the
2 accessible J-bracket bolts.
22
Install the front bumper.
13 For front bumper replacement proce-
Unlatch and raise the hood from un- dure, see service information in group
derneath, through the splash shield 86.
access hole.

21
Group 82 Hood Service Procedures

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

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 ve-
hicle movement and cause serious personal injury or
death.

Removal
1
W8002747

(Axle back)

Remove the bolts and the studs from

the hood splash shield. Remove the
splash shield.

W8002693

(Axle forward)

W8002692

With a technician supporting the hood,

remove the two nuts from the hood re-
straint cylinder. Remove the cylinder.

22
Group 82 Hood Service Procedures

Installation 8213-03-02-01
1 Hood Latch, Replacement

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 ve-
hicle movement and cause serious personal injury or
death.

Removal
1
Unlatch and raise the hood.
Note: If the hood will not release from
inside the vehicle, the splash shield
access panel will need to be removed.
Then the latch will need to be re-
W8002692
leased manually.
With a technician supporting the hood,
install the new hood restraint cylinder
and nuts. 2
Mark the exact location of the latch
and disconnect the latch release cable.
2
Torque the nuts to 30 ± 4 Nm 30 ± 4 Nm
(22 ± 3 ft-lb). (22 ± 3 ft-lb) 3

3
Install the hood splash shield and 10 ± 1.5 Nm
tighten the bolt and the 2 studs. (7 ± 1 ft-lb)
Torque to 10 ± 1.5 Nm (7 ± 1 ft-lb).

W8002697

Remove the 4 hood latch mechanism

mounting bolts. Remove the hood
latch.

23
Group 82 Hood Service Procedures

Installation 8213-03-02-02
1 Hood Latch Stud, Replacement
Install the hood latch and the hood 28 ± 5 Nm
latch mounting bolts. Torque the hood (21 ± 4 ft-lb)
latch mounting bolts to 28 ± 5 Nm
(21 ± 4 ft-lb).
Before working on the vehicle, set the parking brakes,
2 place the transmission in neutral, and block the
Push the hood latch lever back and in- wheels. Failure to do so can result in unexpected ve-
stall the ball end of the hood release hicle movement and cause serious personal injury or
cable. death.

Note: Check the release cable adjust-

ment and readjust if necessary. Removal
1
3 Access the hood latch stud by raising
Close the hood. the hood or by removing the access
cover underneath the splash shield.

2
Mark the exact location of the latch
stud on the hood.

Note: If the receiver cup bracket bolts

have been loosened, then the hood
adjustment procedure must be per-
formed after replacement of the latch
mechanism is complete. See “Hood,
Adjustment” page 19.

W8001117

Remove the four bolts from the stud

and remove the stud.

24
Group 82 Hood Service Procedures

Installation 8214-03-02-02
1 Hood Latch Arm, Replacement
Install the new hood latch stud using 28 ± 5 Nm
the four bolts. Torque the bolts to (21 ± 3.7 ft-lb)
28 ± 5 Nm (21 ± 3.7 ft-lb).

2 Before working on the vehicle, set the parking brakes,

Close the hood and verify it is properly place the transmission in neutral, and block the
aligned. Perform the adjustment pro- wheels. Failure to do so can result in unexpected ve-
cedure if necessary. See “Hood, hicle movement and cause serious personal injury or
Adjustment” page 19. death.

3 Removal
If removed, install the access cover
underneath the splash shield. 1

W8002764

Remove the splash shield on the side

that the hood latch arm is to be re-
placed.

25
Group 82 Hood Service Procedures

2 Installation
1
Install the new hood latch arm, bolts 200 ± 33 Nm
and nuts to the frame rail. Torque to (148 ± 24 ft-lb)
200 ± 33 Nm (148 ± 24 ft-lb).

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

3
Reinstall the splash shield. Torque to 24 ± 4 Nm
24 ± 4 Nm (18 ± 3 ft-lb). (18 ± 3 ft-lb)

4
Adjust the hood using the Hood ad-
justment procedure. See “Hood,
W8002697
Adjustment” page 19.
Remove the four bolts that attach the
hood latch assembly to the hood latch
arm.

W8001139

Remove the four bolts and nuts that

attach the hood latch arm to the vehi-
cle chassis.

26
Group 82 Hood Service Procedures

8214-03-02-03 4
Raise the hood or remove the access
Hood Release Cable, Replace- cover underneath the splash shield.
ment
5

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 ve-
hicle movement and cause serious personal injury or
death.

Removal
1

W8002696

Loosen the jam nuts at the hood latch

assembly and remove the cable.

Installation
W8001131
Remove the passenger side and cen- 1
ter lower dash panels. Remove the rubber grommet from the
bulkhead and slide the new cable into
the rubber grommet.
2

W8002748
Remove the hood release cable from
the hood release handle.

3 W8001120

Cut the tie straps. Remove the hood Begin installing the cable by pushing it
release cable from the cab by pulling through the hole in the bulkhead from
the cable through the bulkhead from the outside. Push the grommet into
outside the cab. place on the bulkhead.

27
Group 82 Hood Service Procedures

3 5

W8001131

Reinstall the passenger side and cen-

ter dash panels.

6
Close the hood or if removed, install
the access cover underneath the
splash shield.
W8001121

Attach the cable end to the hood re-

lease handle inside the cab.

W8002696

Attach the other end of the cable to

the hood latch assembly. Adjust the
cable and tighten the two jam nuts.

28
Group 82 Hood Service Procedures

8231-03-02-06
Grille, Replacement (Hood
Mounted)

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 ve-
hicle movement and cause serious personal injury or
death.

Removal
1
Raise the hood. W8002747

(Axle back)

2 Remove the left and right hood splash

shield.

W8002693

(Axle forward)

29
Group 82 Hood Service Procedures

3 4
Remove the top center grille chrome
trim bezel.

5
Close the hood.

W8002770

W8002771

Remove the 8 mounting screws

around the outside of the grille.

7
W8002754
Remove the self tapping screw from
the lower crossbar that connects to
rubber strap.

8
Remove the grille from the hood.

W8002755

Remove the left and right side grille

chrome trim bezel.
Remove the top and bottom screws
from the backside of the grille then re-
move the middle screw from the front.

30
Group 82 Hood Service Procedures

Installation 4

W8002770

Install the top center grille chrome trim 10 ± 1.5 Nm

W8002771 bezel. (7 ± 1 ft-lb)
Hold the grille in place and install the 24 ± 4 Nm Install the left and right side grille
8 mounting screws. (18 ± 4 ft-lb) chrome trim bezel.
Torque the screws to 24 ± 4 Nm Torque the screws to 10 ± 1.5 Nm
(18 ± 3 ft-lb). (7 ± 1 ft-lb).

2
Raise the hood.

3
Install the screw into the lower cross-
bar that connects to the rubber strap.

31
Group 82 Hood Service Procedures

5 2563-03-02-01
Air Intake Grille, Replacement

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 ve-
hicle movement and cause serious personal injury or
death.

Removal
1

W8002693

(Axle forward)

W8002725

Pull out the grille.

Installation
1
Check to be sure there are no foreign
objects in the hood intake or behind
the grille.

2
Place the grille in position and press it
until it snaps into place.
Make sure that the grille is fully seated
in the groove.
W8002747

(Axle back)

Install the left and right side hood 10 ± 1.5 Nm

splash shields. (7 ± ft-lb)
Torque the screws to 10 ± 1.5 Nm
(7 ± 1 ft-lb).

32
Group 82 Hood Service Procedures

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

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 ve-
hicle movement and cause serious personal injury or
death.

Removal W8001107

1 1 Air intake bellows

2 Retaining ring

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.

1
Install the retaining ring in the first
groove of the bellows.

W8001106

Open the hood and reach into the bel-

lows through the bellows guide. Pull
the metal retaining ring out of its
groove in the bellows.

2
Remove the bellows from the hood.

W8001111

Apply a soapy solution to the outside

of the end groove of the bellows.

33
Group 82 Hood Service Procedures

3 3523-03-02-02
Headlamp Bezel, Replacement

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 ve-
hicle movement and cause serious personal injury or
death.

Removal
1
W8001128

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 in-
side the air intake.

4
Make sure the retaining ring is fully
seated in the groove.

W8002698

Remove the 2 mounting screws that

mount the turn signal assembly.

2
Pull the turn signal assembly straight
out to the side. Twist the turn signal
light socket until unlocked. Remove
the turn signal assembly.

34
Group 82 Hood Service Procedures

3 4

W8002699

Remove the 2 trim bezel mounting

screws.

4
W8002700

Slide the turn signal assembly, from

the side, onto the housing tabs.

5
Tighten the 2 mounting screws.

W8002716

Grab the side close to the grill and the

center and pull the trim bezel straight
out.

Installation
1
Position the bezel into place and push
until the bezel tabs snap into position.

2
Tighten the 2 mounting screws.

3
Install the light socket into the turn sig-
nal assembly. Twist the light socket
until it locks in place.

35
Group 82 Hood Service Procedures

3521-03-02-01 3

Headlamp Assembly, Replace-

ment

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 ve-
hicle movement and cause serious personal injury or
death.

Removal
1 W8002701

Secure the headlamp assembly from

the front side and remove the 4
mounting nuts on the back side.

4
Pull the headlamp assembly straight
forward from the bucket.

W8002690

Remove the headlight/turn signal

wiring connector.

2
Remove the cover over the back side
of the headlamp bucket.

36
Group 82 Hood Service Procedures

Installation 3522-03-02-01
1 Headlamp Lens, Replacement

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 ve-
hicle movement and cause serious personal injury or
death.

Removal
1
Remove the chrome trim bezel, see
“Headlamp Bezel, Replacement” page
W8002701
34.
Position the headlamp assembly into 3.5 ± 0.5 Nm
the headlamp bucket. Install all the 4 (31 ± 4 in-lb)
2
nuts on the studs and tighten.
Torque to 3.5 ± 0.5 Nm (31 ± 4 in-lb).

2
Install the cover on the back side of
the headlamp bucket.

3
Connect the wiring connector.

Note: For headlamp adjustment refer

to service information in group 35.

W8002702

Remove the 3 screws from the metal

ring that holds the headlamp in place.
Pull the headlamp straight forward.

3
Disconnect the wiring connector on
the rear of the lamp and remove the
headlamp.

37
Group 82 Hood Service Procedures

Installation 3527-03-02-01
1 Turn Signal Lens, Replacement
Connect the wiring connector and po-
sition the headlamp.

2
Install the mounting metal ring and Before working on the vehicle, set the parking brakes,
tighten the 3 mounting screws. place the transmission in neutral, and block the
wheels. Failure to do so can result in unexpected ve-
hicle movement and cause serious personal injury or
3 death.
Install the chrome trim bezel, see
“Headlamp Bezel, Replacement” page
34. Removal
Note: For headlamp adjustment refer 1
to service information in group 35.

W8002698

Remove the 2 mounting screws that

mount the turn signal assembly.

2
Pull the turn signal assembly straight
out to the side. Twist the turn signal
light socket until unlocked. Remove
the turn signal assembly.

38
Group 82 Hood Service Procedures

Installation 8211-03-02-04
1 Hood Insulation, Replacement
Install the light socket into the turn sig-
nal assembly. Twist the light socket
until it locks in place.

2 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 ve-
hicle movement and cause serious personal injury or
death.

Removal
1
Unlatch and raise the hood.

2
Remove the grille assembly, see
“Grille, Replacement (Hood Mounted)”
page 29.

W8002700

Slide the turn signal assembly, from

the side, onto the housing tabs.

3
Tighten the 2 mounting screws.

W8002721

Remove the 2 center hood stud nuts

(2) and washers (1).

39
Group 82 Hood Service Procedures

4 3

W8002772

WARNING
W8002772
Always wear appropriate eye protection to prevent risk
Align the rivet holes and install new
of eye injury due to contact with debris or fluids.
rivets (1) around the outside edge of
the insulation sections.
Remove the 20 trim panel rivets (1)
using the special tool J-38778.
4
Install the grille assembly, see “Grille,
5 Replacement (Hood Mounted)” page
Remove the 2 pieces of the hood insu- 29.
lation from the vehicle.

5
6 Shut and latch the hood.
Using a small center punch, push the
remains of the trim panel retainers
through the retaining holes.

Installation
1
Install the replacement insulation pan-
els.

W8002721
Install the 2 center hood stud nuts (2)
and washers (1).

40
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when using this manual would be greatly appreciated.
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To From

Volvo Trucks North America, Inc. ..........................................................................

Dept. 516 Service Publications ..........................................................................

7825 National Service Road ..........................................................................

P.O. Box 26115 ..........................................................................

Greensboro, NC 27402-6115 ..........................................................................

USA ..........................................................................

(336) 393-3170 ..........................................................................

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

 Operation Numbers

2563-03-02-01 Air Intake Grille, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2564-03-02-01 Air Intake Bellows, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 33
3521-03-02-01 Headlamp Assembly, Replacement . . . . . . . . . . . . . . . . . . . . . . . . 36
3522-03-02-01 Headlamp Lens, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3523-03-02-02 Headlamp Bezel, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 34
3527-03-02-01 Turn Signal Lens, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 38
8211-03-02-01 Hood, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8211-03-02-04 Hood Insulation, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8211-05-03-01 Hood, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8213-03-02-01 Hood Latch, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8213-03-02-02 Hood Latch Stud, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 24
8214-03-02-01 Hood Restraint Cylinder, Replacement . . . . . . . . . . . . . . . . . . . . . . 22
8214-03-02-02 Hood Latch Arm, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 25
8214-03-02-03 Hood Release Cable, Replacement . . . . . . . . . . . . . . . . . . . . . . . 27
8231-03-02-06 Grille, Replacement (Hood Mounted) . . . . . . . . . . . . . . . . . . . . . . . 29
 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-TSP141953 (1000) 8.00 © Volvo Trucks North America, Inc., 2000