Service Manual Trucks: Hood VHD
Service Manual Trucks: Hood VHD
Service Manual Trucks: Hood VHD
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.
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:
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.
Feedback
Operation Numbers
1
2
Group 82 Hood Tools
Tools
Special Tools
Following tools are available from Volvo Parts.
3
4
Group 82 Hood Design and Function
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.
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.
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
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.
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.
W8002765
13
14
Group 82 Hood Service Procedures
Service Procedures
8211-03-02-01 2
Hood, Replacement
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
15
Group 82 Hood Service Procedures
3 4
W8002692
5
W8002693
(Axle forward)
W8002747
(Axle back)
W8002694
16
Group 82 Hood Service Procedures
6 Installation
1
W8002695
7
With a technician on each side, care-
fully remove the hood from the vehicle.
W8002694
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.
CAUTION 4
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
19
Group 82 Hood Service Procedures
5 •
Loosen all of the adjustment points:
W8002695
W8002697
W8002714
6
Position the 2 pivot blocks at the top or
bottom of their slots and tighten.
W8002713
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.
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
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
Removal
1
W8002747
(Axle back)
W8002693
(Axle forward)
W8002692
22
Group 82 Hood Service Procedures
Installation 8213-03-02-01
1 Hood Latch, Replacement
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
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.
2
Mark the exact location of the latch
stud on the hood.
W8001117
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).
3 Removal
If removed, install the access cover
underneath the splash shield. 1
W8002764
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
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
Removal
1
W8002696
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
6
Close the hood or if removed, install
the access cover underneath the
splash shield.
W8001121
W8002696
28
Group 82 Hood Service Procedures
8231-03-02-06
Grille, Replacement (Hood
Mounted)
Removal
1
Raise the hood. W8002747
(Axle back)
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
7
W8002754
Remove the self tapping screw from
the lower crossbar that connects to
rubber strap.
8
Remove the grille from the hood.
W8002755
30
Group 82 Hood Service Procedures
Installation 4
W8002770
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
Removal
1
W8002693
(Axle forward)
W8002725
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)
32
Group 82 Hood Service Procedures
2564-03-02-01 Installation
Air Intake Bellows, Replace-
ment
Removal W8001107
1
Install the retaining ring in the first
groove of the bellows.
W8001106
2
Remove the bellows from the hood.
W8001111
33
Group 82 Hood Service Procedures
3 3523-03-02-02
Headlamp Bezel, Replacement
Removal
1
W8001128
4
Make sure the retaining ring is fully
seated in the groove.
W8002698
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
4
W8002700
5
Tighten the 2 mounting screws.
W8002716
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
Removal
1 W8002701
4
Pull the headlamp assembly straight
forward from the bucket.
W8002690
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
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.
W8002702
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
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.
Removal
1
Unlatch and raise the hood.
2
Remove the grille assembly, see
“Grille, Replacement (Hood Mounted)”
page 29.
W8002700
3
Tighten the 2 mounting screws.
W8002721
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
Feedback
One of our objectives is that workshop personnel should have access to correct and
appropriate service manuals where it concerns fault tracing, repairs and maintenance
of Volvo trucks.
In order to maintain the high standards of our literature, your opinions and experience
when using this manual would be greatly appreciated.
If you have any comments or suggestions, make a copy of this page, write down your
comments and send them to us, either via telefax or mailing directly to the address
listed below.
To From
USA ..........................................................................
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