Volvo VNL Service Manual Download Page 67

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Group 30 Electrical System—VNL, VNM

Service Procedures

W3000812

Use a rag and a pair of pliers to
remove the rheostat knob. Then dis-
connect the terminal connectors on
the switch.

W3000798

Use the rheostat removal tool (Kent—
Moore P/N J–42395) to remove the
shaft nut from the rheostat.

Installation

1
Install the new rheostat into panel. In-
stall the nut on the rheostat shaft.
Connect the terminal connectors and
install the knob.

W3000647

Install panel by inserting tips on right
side and pushing the panel into posi-
tion. The clips will snap in place on the
left side.

Summary of Contents for VNL

Page 1: ...Service Manual Trucks Group 30 New Features Electrical General VNL VNM PV776 TSP23760 1 ...

Page 2: ...ference 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 ...

Page 3: ...r Suspension Cab Unloader Control Valve Replacement 66 Lift Axle Control Valve Replacement 66 Fifth Wheel Slider Valve Replacement 66 Differential Lockout Valve Replacement 66 Axle Lock Control Valve Replacement 66 Dash Air Switch Replacement 66 Cigar Lighter Replacement 68 Hazard Lamp Switch Replacement 69 Auxiliary Light Switch Replacement 69 Dash Left Side Switch Replacement 69 Marker Interrupt...

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Page 5: ...n on new components circuit types controls connectors and the tools commonly used for maintenance The electrical systems of VOLVO trucks are designed to withstand the demands of a heavy duty motor truck under all types of operation Every effort has been made to provide trouble free operation easy maintenance and service and to provide maximum life of the system and its components For more informat...

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Page 7: ... rating column The point where the line crosses the wire size column is the size of the wire required If the line crosses the wire size column between gauge sizes round up to the next larger size If replacing a wire and the amperage of the circuit is not known it can be measured using a digital multimeter placed in series in the circuit EXAMPLE A 12 volt hydraulic pump motor is rated at 20 amps Th...

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Page 9: ...sted is unknown always use the highest scale first and work down to a mid scale reading whenever possible This will avoid damage to the instrument Before using the DMM to measure resistance check its calibration by touching the leads together If there is a reading other than zero subtract it from measurements made with the DMM The following tests can be performed with a DMM Current amperage check ...

Page 10: ... and wrist strap W3000704 Full Size Type 8501 Static Dissipative Grounding Kit Available from Newark P N 46F7444 Call 1 910 292 7240 Rheostat Removal Tool The rheostat removal tool is used when removing the dash rheostat see Service Procedures W3000799 Rheostat Removal Tool Available from Kent Moore P N J 42395 Call 1 800 328 6657 Window Mirror Switch Removal Tool The window mirror switch removal ...

Page 11: ...d cranking motor through another wire to ground and back to the source A break anywhere along this route results in an open circuit and the complete loss of power In a sense the break is a very high resistance in the circuit However the symptoms will appear somewhat different than the typical high resistance because there is no current flow An ammeter will not register at all because there cannot ...

Page 12: ...lt in blown fuses open circuit breakers wiring or component overheat burned parts and insulation and of course non working components Hot smelly insulation is always a sign of trouble If the wire melts through there is no electrical path so the circuit then becomes open W3000490 Grounded Circuit A grounded circuit is similar to a short circuit in that the current bypasses part of the normal circui...

Page 13: ...rent will decrease Series Circuits In series circuits each electrical device is connected to other electrical devices in such a way that there is only one path for the current to follow as it flows from the battery through the circuit and back to the battery W3000492 Typical Series Circuit Ohm s Law in Series Circuits In a series circuit the total circuit resistance is the sum of all the resistors...

Page 14: ...uits is less than any of the individual resistances W3000494 Typical Parallel Circuit Ohm s Law in parallel circuits In the circuit below one resistor is 2 and the other is 4 The source voltage is 12 volts Current must be found for each path individually as follows Apply Ohm s Law to find current across the first resistor I V 4 R I 12 volts 4 2 6 amps And for the second resistor I 12 volts 4 4 3 a...

Page 15: ...e below first find the resistance in each branch The two 2 and 4 resistors add to give a resistance of 6 for this part of the circuit For the other 2 resistors 2 1 3 To simplify the circuit think of it as a parallel circuit having a 6 and 3 resistor So 6 x 3 4 6 3 18 4 9 2 total resistance The total circuit current therefore is I V 4 R I 12 volts 4 2 6 amps The current through each branch can also...

Page 16: ...oads circuit protectors such as fuses circuit breakers or fusible links are used WARNING Failure to use proper circuit protection devices in the vehicle can result in personal injury or damage to the vehicle Replace blown fuses only with fuses of the same rating Replace fusible links only with proper replacement parts of the exact gauge and length Failure to use proper circuit protection could ove...

Page 17: ...ff Diodes allow voltage to flow in one direction only like a one way check valve Circuit breakers Circuit breakers are optional equipment SAE Type 2 modified reset circuit breakers are the only type of circuit breakers approved for use in VNL or VNM vehicles They may be used on accessory and ignition circuits only Circuit breakers protect a circuit from overload When an overload high current flow ...

Page 18: ...lling the dome light completes the circuit to ground Relays are remotely controlled switches They use a low current signal through a coil to control larger currents conducted through their contacts A new feature used in the VN Series vehicle is the micro relay The micro relay is smaller in size than a conventional relay and the pin arrangement is different see illustration W3000777 Relay Pin Arran...

Page 19: ...he engine ECU An Anti lock Brake System ABS wheel speed sensor is mounted in each monitored wheel As the wheel spins the sensor sends a fluctuating signal to the ABS ECU which the ECU interprets as wheel speed W5000602 Anti lock Brake Wheel Speed Sensor The transmission oil temperature sender shown in the illustration senses the temperature of the transmission oil creating a resistance and sending...

Page 20: ...use bus bar for fuse positions 17 20 Another Battery Maxi fuse feeds 1 C to the fuse bus bar for fuse positions 25 32 Also from stud 1 wire 1 E goes to the Accessory Power Relay From stud 2 wire 1 A goes to the Ignition Power Relay From wire 1 A 1 B sends battery power to bus bar fuse positions 41 48 W3000827 A Pass through for main cab wiring Main Cab Electrical Pass Through and Ground Studs driv...

Page 21: ...on wire 284 provides power from the ignition switch to energize the starter relay coil This completes the circuit from the battery to the starter solenoid stud The solenoid is grounded directly to the starter System Ground The engine ground is the common ground location on the vehicle The main cab ground stud 1 and the frame rail ground meet at the engine ground stud Current is then carried throug...

Page 22: ...Group 30 Electrical System VNL VNM Design and Function Starting and Charging System Logic Diagram W3000772 20 ...

Page 23: ...h of a new double contact design there is no separate start button The chart below gives the pin and circuit description Pin Circuit No Description R 195 To accessory power relay B 243 12V Battery supply 50 284 Starter relay feed P Not used 30 243A 12V Battery supply 19 Engine dependent VOLVO 245 Detroit Diesel 591 VOLVO Preheat request Detroit Diesel Shutdown override relay feed 15 196 To ignitio...

Page 24: ...ood Both pass throughs consist of a protective outer housing and an attachment plate which holds the connectors in position The pass through covers can be opened from the outside The cab main power studs are located at the left hand side pass through Ground studs are located on the left and right side bulkhead on both the inside and outside Each stud has a unique identity number which is used for ...

Page 25: ...F of electrical devices Note Switches are illustrated from insertion side view The switch for the engine brake is different depending on which engine brake is installed With the Volvo or Cummins M11 engine brake there is a single switch with 3 positions OFF LOW and HIGH With other engine brakes there are two switches one with 2 positions ON and OFF and another with 3 positions LOW MED HIGH Switch ...

Page 26: ... Logic Hazard Warning W3000579 W3000577 W3000585 Back of Cab Lamp Heated Mir ror Auxiliary Lamps Traction Control System W3000579 W3000577 W3000588 Power Take Off W3000579 W3000577 W3000587 Marker Interrupter W3000578 W3000577 W3000586 Idle Diagnostic Cummins only W3000579 W3000577 W3000584 24 ...

Page 27: ...ngine Brake Off Low Hi VOLVO Cum mins M11 W3000578 W3000577 W3000597 Pneumatic Electrical Switches Terminal Switch Switch Function A B C D Interaxle DLO To Cluster Telltale Lamp 12V Supply Ground 12V Illumination Control Fifth Wheel Slide To Cluster Telltale Lamp Not used Ground 12V Illumination Control Suspension Dump To Cluster Telltale Lamp Not used Ground 12V Illumination Control W3000574 W300...

Page 28: ...re on the stalk on the right hand side of the steering column Intermittent wipers are standard see section on Wiper washer module in this manual Wiper washer Switch Connector Pin Circuit No Description A 383 High Speed Wiper B 387 12V Supply to Washer Motor C 384 12V Supply to Wiper Motor D 382 Low Speed Wiper E 389 12V Supply to Wiper Control Module F 388 12V Supply to Wiper Control Module Interm...

Page 29: ...eam lowbeam switch includes a flash to pass feature It is possible to increase the engine speed with the button at the end of the stalk To reduce the engine speed move the switch on the stalk towards Resume W3000807 W3000811 Cruise Control Switch Note Numbers inside parenthesis are circuit numbers Cruise Control Connector Pin Circuit No Description A 558E 559E Common Engine dependent B 562 Cruise ...

Page 30: ...rn Signal Connector 4 way Pin Circuit No Description A 111 Turn signal switch feed B Not used C 112 Left turn signal lamp indicator feed D 113 Right turn signal lamp indicator feed Headlamp Dimmer Switch Connector Pin Circuit No Description A 44L Output to DRL module low beam left B 31 Dimmer switch power supply C 33L Headlamp high beam ground left D Not used E 33A Flash to pass contact F 33R Head...

Page 31: ...he maxi fuses are designed for larger amounts of current than regular fuses The micro relays are smaller in size than conventional relays and the pin arrangement is different Accessory and ignition power relays and the daytime running light module are mounted under the relay panel They are accessed by removing the top TEC tray Several multifunction modules are also mounted under the relay panel Th...

Page 32: ...Group 30 Electrical System VNL VNM Design and Function Relays in Top TEC Panel R1 R13 W3000774 Maxi Fuses W3000828 A Battery Maxi fuses B Ignition Maxi fuses 30 ...

Page 33: ...ctrical System VNL VNM Design and Function Fuses in Front TEC Panel 1 40 W3000773 Fuses in Top Panel 41 48 W3000775 Note Refer to the decal inside the TEC cover for vehicle s exact fuse descriptions and ratings 31 ...

Page 34: ...d Ignition Power Relays The Accessory and Ignition Power relays are used to transfer the heavy current load coming from the battery to the Ignition Accessory circuits They are located under the relay panel and may be accessed for troubleshooting by removing the top TEC tray For replacement procedure see Service Procedures For more information refer to the vehicle electrical schematics and the sect...

Page 35: ...weep is desired The interval can be set to between 1 and 10 seconds The wipers will also make a single sweep if the wiper stalk is slightly depressed and held The wipers return to the park position when the lever is released W3000554 Wiper Washer Module Connector Pin Circuit Number Description Input Output Characteristics 1 0G Battery ground I Battery 2 3 4 5 Not used 6 388 Switch intermittent wip...

Page 36: ...relay panels W3000553 Central Door Lock Module Connector Pin Circuit Number Description Input Output Characteristics 1 710 Battery supply voltage I Unswitched battery supply 2 713R To passenger side motor unlock O Internally switched to GND or Unswitched Batt 3 713L To driver side motor unlock O Internally switched to GND or Unswitched Batt 4 714R To passenger side motor lock O Internally switched...

Page 37: ...rical Center and to a switch Headlights The VN Series headlights are of a new design The right and left headlights are on separate circuits Each is supplied power from the battery through a fuse and controlled by the headlight switch and dimmer switch The low beam circuit is tied into the Daytime Running Lights circuit Wiring for the headlights passes from the cab interior to the chassis through t...

Page 38: ...e cab under the relay panel The DRL module reduces the voltage to the headlamps by using pulse width modulation to pulse the low beams on and off at a rate of 70 Hz which is faster than the eye can detect The reduction in voltage is about 24 RMS of the applied voltage If the applied voltage is 13 8 VDC a DC voltmeter such as a Fluke 87 will show the average voltage between 7 5 and 8 5 VDC The left...

Page 39: ...rd Turn Lights The hazard and turn indicators are powered through a Battery Maxi fuse through wire 110 which powers the flasher unit Wire 121 feeds power from the flasher unit to the hazard switch When the hazard switch is OFF wire 111 powers the turn signal switch When the left turn signal is ON power comes through the switch to wires 112 and 115 When the right turn signal is ON power comes throu...

Page 40: ...unded by 0R K which connects to wire 0R J to the bus bar in the TEC Stop Hazard Lights With Right Turn Signal On Wire 113 supplies power to the right front turn light Ground is through wire 0H B to a ground stud on the passenger side cowl in the engine compartment Wire 113 sends a signal to the instrument cluster for the right turn indicator Wire 113 also supplies power to the trailer connector an...

Page 41: ...gh wire 39 to the LED input on the switch for switch illumination wire 0J G provides ground Wire 39 goes from the Auxiliary light switch to the Aux Lamp Change Over Relay R10 which is tied to the low beam headlight circuit The relay sends power over wire 35 to the fog lights Wire 35 splices into wires 35L and 35R for the left and right lights The fog lights are grounded by wire 0M then splice with...

Page 42: ...0 59 Overhead Dome Lamp Front 1156 2 1 Overhead Dome Spot Lamp Front 1156 dome 67 spot 2 1 0 59 Overhead Dome Lamp 41 Sleeper Passenger Side Only 1156 2 1 Overhead Fluorescent Lamp Sleeper PL L 24W 827 4PP Phillips 16944 GE 2 0 Reading Lamp Under Bunk Storage Compartment 561 GE 0 97 Combined Reading Spot Lamp Under Bunk Storage Compartment 561 GE reading 906 GE spot 0 97 0 69 Luggage Compartment L...

Page 43: ...ure gauges and the remainder of the warning lamps Axle temp and air pressure gauges may be installed For more information on the instrumentation see the Instrumentation VNL VNM manual Graphic Display The graphic display is in the lower left hand side of the instrument cluster It is operated by the up down mode and set buttons in the center section With the mode set buttons the driver can select th...

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Page 45: ...a water tight seal Important To splice a wire or repair one that is frayed or broken always use rosin flux solder to bond the splice and sealant shrink tubing to cover all splices joints or bare wires Never use acid core solder The use of dielectric grease is recommended for all terminals exposed to the weather salt dirt or water Dielectric grease is needed to provide protection against moisture a...

Page 46: ...ts mounted on the engine can cause serious damage to the engine ECU Preventing Electrostatic Discharge ESD Anti static wrist strap and mat CAUTION A wrist grounding strap must be worn when working on electronic equipment such as the instrument cluster This is to prevent electrostatic discharge ESD which can damage electronic components To use the wrist strap in a vehicle attach the alligator clip ...

Page 47: ...ght because oxidation or terminal misalignment are hidden by the connectors Merely wig gling a connector or a sensor in the wiring harness may correct the open circuit condition This should always be considered when an open circuit is indicated while trou bleshooting Intermittent problems may also be caused by oxidized or loose connections Steam Cleaning and Pressure Washing Do not steam clean or ...

Page 48: ... terminal Do not cut or nick the wire when stripping 4 Slide a piece of sealant shrink tubing onto the wire 5 Insert the wire in the terminal and with a pair of crimpers as recommended by the connector manu facturer squeeze the small tabs onto the wire insulation Not all types of ter minals have these tabs Be certain to use the crimpers recommended by the connector manufacturer With a blunt instru...

Page 49: ...rcuit before beginning this procedure to prevent another fusible link from melting Failure to repair the short circuit which caused the fusible link to melt will result in the new fusible link melting 4 Loosen the bolt that goes through the battery cable clamping bracket Re move the cable from the clamp This will allow the cable to be removed from the solenoid 5 1 Ground Side Fusible Link 2 Starte...

Page 50: ... tubing 5 Install the wires back onto the sole noid see illustration in Removal procedure Torque the nut to 27 34 Nm 238 300 in lb 27 34 Nm 238 300 in lb 6 Connect the battery cables into the clamp bracket Torque the bolt to 23 Nm 200 in lb Install the and ter minals onto the battery installing the positive terminal first Torque nuts to 20 3 24 4 Nm 15 18 ft lb 23 Nm 200 in lb 20 3 24 4 Nm 15 18 f...

Page 51: ...minal from the starter 6 Remove the nut on the side of the en gine block where the fusible link is connected and remove the fusible link from the vehicle Installation 1 1 Ground Side Fusible Link 2 Starter Ground Stud 3 Starter Solenoid Post 4 Battery Side Fusible Links 2 5 Engine Ground Stud Note location varies by engine Install the fusible link terminal and negative battery cable at the starter...

Page 52: ...terminal first 2 W3000655 Remove the 2 clips at the bottom of the steering column cover 3 Adjust the steering column up and to ward you where possible Remove the front steering column cover by re moving the 3 torx bolts from the cover and sliding the rubber grommets off of the cover at the stalk switches 4 W3000648 Adjust the steering column forward and up where possible Remove the 3 torx bolts fr...

Page 53: ...n place start both screws before tightening see il lustration in Removal procedure Torque to 1 7 0 5 Nm 15 4 in lb 1 7 0 5 Nm 15 4 in lb 3 Connect the ignition switch electrical connector 4 Pull steering column back and up where possible Install front cover by installing torx bolts Torque to 5 0 8 Nm 44 7 in lb 5 0 8 Nm 44 7 in lb 5 Adjust the steering column forward and up where possible Install ...

Page 54: ...uld cause serious com ponent damage Disconnect the ground terminal first 2 W3000655 Remove the 2 clips at the bottom of the steering column cover 3 Adjust the steering column up and to ward you where possible Remove the front steering column cover by re moving the 3 torx bolts from the cover and sliding the rubber grommets off of the cover at the stalk switches 4 W3000648 Adjust the steering colum...

Page 55: ...he steering column with the 2 bolts see illustration in Removal procedure Torque to 24 4 Nm 18 3 ft lb 24 4 Nm 18 3 ft lb 3 Connect the ignition switch electrical connector 4 Adjust the steering column up and to ward you where possible Install front cover by installing torx bolts and at taching rubber grommets at stalk switches Torque bolts to 5 0 8 Nm 44 7 in lb 5 0 8 Nm 44 7 in lb 5 Adjust the s...

Page 56: ...re connectors from the underneath side of the button 3 W3000791 1 Horn Contacts 2 Contact Assembly Remove the bolt from the steering wheel Pull the steering wheel from the steering shaft 4 Remove the 2 clips at the bottom of the steering column cover Slide the rubber grommets off of the cover at the stalk switches 5 Adjust the steering column up and to ward you where possible Remove the 3 torx bol...

Page 57: ...g wheel where the old contact was Align with the tab on the contact housing 2 W3000792 Install the horn contact ring onto the steering shaft The ring should slide down over the shaft Route the wires as they originally were and connect the electrical connector 3 Adjust the steering shaft forward and up where possible Install the rear cover of the steering column Torque the 3 bolts to 5 0 8 Nm 44 7 ...

Page 58: ...ng certain the dowel is aligned with the hole in the steering wheel Push the button into place 3643 03 02 01 Turn Signal CC Switch Re placement Includes checking switch function Removal 1 Make certain the vehicle ignition is OFF before beginning this procedure 2 W3000655 Remove the 2 clips at the bottom of the steering column cover 3 W3000653 Adjust the steering column up and to ward you where pos...

Page 59: ...mbly to steering column with the 2 bolts and connect all electrical connectors Torque bolts to 5 0 8 Nm 44 7 in lb 5 0 8 Nm 44 7 in lb 2 Pull steering column back and up where possible Install front cover by installing torx bolts Torque bolts to 5 0 8 Nm 44 7 in lb 5 0 8 Nm 44 7 in lb 3 Push the steering column forward and up where possible Install the rear cover of the steering column by in stall...

Page 60: ...the steering column cover 3 W3000654 Adjust the steering column up and to ward you where possible Remove the front steering column cover by re moving the 3 torx bolts from the cover and sliding the rubber grommets off of the cover 4 W3000648 Adjust steering column forward and up where possible Remove bolts from rear column cover and remove cover 5 W3000652 Disconnect electrical connector Re move t...

Page 61: ... steering column back and up where possible Install front cover by installing torx bolts Torque to 5 0 8 Nm 44 7 in lb 5 0 8 Nm 44 7 in lb 3 Push steering column forward and up where possible Install rear cover of steering column by installing torx bolts and attaching rubber grommets at stalk switches Torque to 5 0 8 Nm 44 7 in lb 5 0 8 Nm 44 7 in lb 4 W3000655 Install the 2 clips on the bottom of...

Page 62: ... Remove the two screws at the top of the instrument cluster and lay the clus ter face down on the steering column if steering column is adjustable ad just as far back as possible before leaning cluster out 3 W3000650 To release the switch panel reach be hind the panel and depress the top and bottom clips on the left side 4 W3000996 Pull the panel through the front of the dash pulling toward the dr...

Page 63: ...river 7 W3000682 Note The light switch is removed through the front of the panel Installation 1 W3000680 Install new headlight parking lamp switch into panel Push the switch into the panel until it locks Push back on the switch to make certain it is locked in the panel Connect electrical con nector 2 W3000647 Install the panel by inserting tips on right side and pushing the panel into position The...

Page 64: ...emove the two screws at the top of the instrument cluster and lay the clus ter face down on the steering column if steering column is adjustable ad just as far back as possible before leaning cluster out 3 W3000650 To release the switch panel reach be hind the panel and depress the top and bottom clips on the left side 4 W3000996 Pull the panel through the front of the dash pulling toward the driv...

Page 65: ...m to release the locking tabs 7 W3000682 Note The light switch is removed through the front of the panel Installation 1 W3000680 Install new fog driving lamp switch into panel Push the switch into the panel until it locks Push back on the switch to make certain it is locked in the panel Connect electrical connector 2 W3000647 Install the panel by inserting tips on right side and pushing the panel ...

Page 66: ...ate Remove the two screws at the top of the instrument cluster and lay the clus ter face down on the steering column if steering column is adjustable ad just as far back as possible before leaning cluster out 3 W3000650 To release the dimmer switch panel reach behind the panel and depress the top and bottom clips on the left side 4 W3000996 Pull the panel through the front of the dash pulling towa...

Page 67: ...00798 Use the rheostat removal tool Kent Moore P N J 42395 to remove the shaft nut from the rheostat Installation 1 Install the new rheostat into panel In stall the nut on the rheostat shaft Connect the terminal connectors and install the knob 2 W3000647 Install panel by inserting tips on right side and pushing the panel into posi tion The clips will snap in place on the left side 65 ...

Page 68: ...fferential Lockout Valve Re placement In dash includes transfer fittings For service procedure see Dash Air Switch Replace ment page 66 5633 03 02 19 Axle Lock Control Valve Re placement In dash includes transfer fittings For service procedure see Dash Air Switch Replace ment page 66 Dash Air Switch Replacement Includes checking switch function Removal 1 Make certain the vehicle ignition is OFF be...

Page 69: ... in on the ring and air line then pulling the air line out 6 W3000658 To remove switch insert No 1 flat tip screwdriver into back of switch at top and bottom to release locking tabs Push switch out of the panel Installation 1 Install new air switch into the panel pushing the switch into the panel until it locks Push back on the switch to make certain it is locked in the panel 2 Connect air lines t...

Page 70: ...e cigar lighter 4 W3000696 Push the lighter housing out of the panel enough to get a small flat tip screwdriver under the lip of the cigar lighter Remove the lighter from the LED housing and slide the housing out of the dash Installation 1 Install the LED housing back into the panel Make certain it is properly aligned with the moldings on the hous ing Push the cigar lighter housing into the LED ho...

Page 71: ...luster face down for more than 15 minutes or damage to the gauges may occur Gauge oil can run out the front of the gauge faces and make the gauges inaccurate Remove the two screws at the top of the instrument cluster and lay the clus ter face down on the steering column adjust steering column back before leaning cluster out where possible 3 W3000689 To release the switch panel reach be hind the pa...

Page 72: ...l Connect electrical connector and install panel back in dash 3646 03 02 24 Marker Interrupt Switch Re placement Includes checking switch function For service procedure see Dash Right Side Switch Replacement page 71 3646 03 02 25 Idle Control Switch Replace ment Includes checking switch function For service procedure see Dash Right Side Switch Replacement page 71 3646 03 02 26 Heated Mirror Switch...

Page 73: ...nto the bottom of the switch to release the locking tab 3 W3000645 The switch will rock out at the bottom Pull the switch down from the top and out 4 Disconnect the electrical connector of the switch being removed Installation 1 Connect electrical connection on switch 2 W3000692 Install the new switch pushing the switch into the panel until it locks Push back on the switch to make cer tain it is l...

Page 74: ...8 torx bolts from the panel 3 W3000675 1 Lower Edge of Dash 2 Nut at Radio Mounting Bracket CAUTION To avoid damage to the radio or mounting bracket re move the nut from the rear of the bracket Failure to remove the nut may result in bending the bracket and damaging the radio Remove the nut from the rear of the radio mounting bracket This nut is ac cessible through the opening left when the trim p...

Page 75: ...nnector and antenna 3 W3000675 1 Lower edge of dash 2 Nut at radio mounting bracket Slide the radio into the housing mak ing sure the stud on the rear of the radio is aligned with the mounting bracket Install the nut into the bracket to hold the radio in position Torque to 1 2 1 6 Nm 10 14 in lb Note When sliding the radio into posi tion make certain the antenna cable and electrical connection do ...

Page 76: ... the TEC cen ter by removing the 2 screws 4 Remove the front fuse panel cover by removing the screws from the cover 5 Remove the ashtray from the ashtray housing Remove the 2 screws from the ashtray housing and remove the housing 6 W3001007 1 Spacers Remove the 3 torx bolts from the fuse panel and fold the fuse panel outward from the dash to gain access to the mounting bolts for the top TEC tray R...

Page 77: ...l the OR M and OR N wires to the relay s small top post Install the 196 wire to the relay s small top post Torque both of these to 2 0 5 Nm 18 5 in lb 2 0 5 Nm 18 5 in lb 5 Install the top TEC tray by sliding the tray s rear slots back onto the nuts Start the bolts in the tray at the front before tightening Torque rear nuts to 6 1 Nm 53 in lb Torque front bolts to 10 1 5 Nm 89 in lb 6 1 Nm 53 in l...

Page 78: ...r 5 Remove the ashtray from the ashtray housing Remove the 2 screws from the ashtray housing and remove the housing 6 W3001007 1 Spacers Remove 3 bolts from the fuse panel and fold the fuse panel outward from the dash to gain access to the mount ing bolts for the top TEC tray Removing the lower bolts is made easier by inserting your hand through the ashtray opening to guide the torx driver Note Do...

Page 79: ...e dure Torque to 4 5 0 5 Nm 40 5 in lb 2 Connect the 195 A wire to the relay s large lower post Install nut on the post Torque to 6 25 Nm 55 in lb In stall the rubber stud cover 3 Install the I E wire on the large top post Install the nut on the post Torque to 6 25 Nm 55 in lb Install the rubber stud cover 4 Install the OR N wire to the relay s small top post Torque to 2 0 5 Nm 18 5 in lb Install ...

Page 80: ... or between the spacers and fuse panel Torque to 4 5 0 5 Nm 40 5 in lb 7 W3000794 Reach through the ashtray opening to install the lower fuse panel bolt Torque to 4 5 0 5 Nm 40 5 in lb 8 Install the ashtray housing and ash tray Torque ashtray mounting screws to 0 4 0 1 Nm 3 5 1 in lb 9 Install the fuse panel cover and the top TEC panel cover Torque screws to 2 5 0 5 Nm 22 5 in lb 10 Connect the ba...

Page 81: ...2 screws from the ashtray housing and remove the housing 5 W3001007 1 Spacers Remove 3 bolts from the fuse panel and fold the fuse panel outward from the dash to gain access to the mount ing bolts for the top TEC tray Removing the lower bolts is made easier by inserting the torx driver through the ashtray opening Note Do not lose the 2 plastic spac ers on the back of the fuse panel 6 Remove the to...

Page 82: ... Nm 40 5 in lb Align the 2 plastic spacers with the bolts taking care to route the wires so that none are caught between the spacers and mounting brackets or between the spacers and the fuse panel 5 Install the ashtray housing and ash tray Torque ashtray mounting screws to 0 4 0 1 Nm 3 5 1 in lb 0 4 0 1 Nm 3 5 1 in lb 6 Install the fuse panel cover and the top TEC panel cover Torque screws to 2 5 ...

Page 83: ...4 5 0 5 Nm 40 5 in lb Connect the module electrical connector 4 5 0 5 Nm 40 5 in lb 2 Install the top TEC tray by sliding the tray s rear slots back onto the nuts Start the bolts in the tray at the front before tightening Torque rear nuts to 6 1 Nm 53 1 in lb Torque front bolts to 10 1 5 Nm 89 in lb 6 1 Nm 53 1 in lb 10 1 5 Nm 89 in lb 3 W3001007 1 Spacers Install the fuse panel with 3 torx bolts ...

Page 84: ...rk the wire connectors to keep the arrangement correct 3 W3000802 Insert the mirror window switch re moval tool between the housing clip and the window switch When the tool is inserted push on the switch to clear the switch tabs from the clips Repeat on the opposite end and push the switch out Installation 1 The tabs are different sizes on each end so make certain the switch is aligned the correct...

Page 85: ...ep the arrangement correct 3 W3000803 Insert the mirror window switch re moval tool between the inner housing lip and the mirror switch When the tool is inserted push on the switch to clear the locking tab Then insert the removal tool between the outer lip and the mirror switch Keeping a steady pressure push the switch out of the housing Installation 1 Align the tip of the housing with the in dent...

Page 86: ...ocedure 2 W8000922 Remove the 2 torx bolts from the con trol panel Pull the panel out and to the right to clear the 3 plastic tabs on the rear of the panel s left side 3 W3000698 Disconnect the clock electrical connector Using a small flat tip screw driver release the locking tabs at the top and bottom of the clock to remove the clock from the panel The clock will push out through the front of the...

Page 87: ...nplug the switch connector and release the top and bottom locking tabs using a small flat tip screwdriver The switch will then push out of the front of the panel 3 W3001000 Install the control panel into the bunk by inserting the 3 tabs on the left side back into the air vent trim panel and installing the 2 torx bolts Torque to 1 5 0 5 Nm 13 5 in lb 1 5 0 5 Nm 13 5 in lb 4 Install the bunk light s...

Page 88: ...ocedure see Sleeper Control Panel Switch Replacement page 86 Sleeper Control Panel Switch Replacement Removal 1 Make certain the vehicle ignition is OFF before beginning this procedure 2 W8000922 Remove the 2 torx bolts from the con trol panel Pull the panel out and forward to clear the 3 plastic tabs on the rear of the panel s left side 3 W3000699 Disconnect the switch electrical connector Using ...

Page 89: ... panel by connecting the switch electrical connector and pushing the switch into the panel until it locks in place 3 Gently pull on the switch to make cer tain it is locked in the panel 3631 03 02 04 Windshield Wiper Motor Re placement Includes checking component function Removal 1 WARNING Park the vehicle on a level surface apply the parking brakes and block the wheels to avoid possible injury Fa...

Page 90: ...115 in lb 10 13 Nm 88 115 in lb 3 Test the wiper system to ensure proper operation 3639 03 02 01 Windshield Wiper Linkage As sembly Replacement Removal 1 WARNING Park the vehicle on a level surface apply the parking brakes and block the wheels to avoid possible injury Failure to do so can result in personal injury and pos sible damage to the vehicle due to vehicle movement Make certain the vehicle...

Page 91: ...arter fender section in the lower door frame and 2 bolts from the step bracket Remove the quarter fender fairing section 5 W3000663 Remove 3 screws from the right side drip molding and remove the molding 6 Remove 3 torx bolts from the bottom of the right side mirror mounting arm 7 W3000670 Remove the right side cowl panel by removing bolts inside the door jamb and around the cowl panel 89 ...

Page 92: ...the drip molding 9 W3000665 Remove 3 torx bolts from bottom of the left side mirror mounting arm 10 W3000668 Remove the windshield washer bottle by removing the 3 nuts from the washer bottle 11 W3000671 Remove the left side cowl panel by re moving the remaining bolts around the cowl section and inside the door jamb 12 Remove the washer hose 90 ...

Page 93: ...000669 Disconnect the electrical connector from the wiper motor and disconnect the hose to the washer 16 Remove the wiper motor and linkage assembly by removing the 5 torx bolts from assembly Removal of wiper motor from linkage assembly 17 Remove the nut from the motor linkage arm and push the arm from the shaft 18 Push the linkage arm away from the area where the motor is bolted to the housing Re...

Page 94: ...m 29 36 ft lb 3 Install the shaft nut to the linkage arm Make sure the shaft and transmission arm are aligned so that the timing and placement of the wipers will be prop erly aligned when the wipers are in the OFF position Torque to 10 13 Nm 88 115 in lb 10 13 Nm 88 115 in lb 4 W3000669 Align the wiper assembly to the cowl and install it with the 5 torx bolts Torque to 22 5 2 5 Nm 200 22 in lb Con...

Page 95: ...crews to 1 2 0 2 Nm 10 6 2 in lb and the bottom to 3 0 5 Nm 26 5 in lb 1 2 0 2 Nm 10 6 2 in lb 3 Nm 0 5 26 5 in lb 10 Install 3 bolts in the lower right side mirror arm Torque to 24 4 Nm 18 3 ft lb 24 4 Nm 18 3 ft lb 11 W3000671 Install the left side cowl panel using bolts on the outside and inside of the door jamb START all bolts and align the cowl before tightening Torque to 24 4 Nm 18 3 ft lb 2...

Page 96: ...mir ror arm Torque to 24 4 Nm 18 3 ft lb 24 4 Nm 18 3 ft lb 15 W3000661 Install the right side quarter fender section START bolts but do not tighten until after aligning Torque to 24 4 Nm 18 3 ft lb 24 4 Nm 18 3 ft lb 16 W3000662 Install the tank fairing START all bolts then tighten after aligning fairing Torque to 24 4 Nm 18 3 ft lb 24 4 Nm 18 3 ft lb 17 W3000667 Install the step START all 4 bolt...

Page 97: ...sh illumination Rheostat Switch Replacement 64 3646 03 02 22 Auxiliary Light Switch Replacement 69 3646 03 02 24 Marker Interrupt Switch Replacement 70 3646 03 02 25 Idle Control Switch Replacement 70 3646 03 02 26 Heated Mirror Switch Replacement 70 3646 03 02 27 Traction Control TCS Switch Replacement 70 3646 03 02 28 Power Mirror Switch Replacement 83 3646 03 02 30 Sleeper Reading Lamp Switch R...

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Page 100: ... America Inc P O Box 26115 Greensboro NC 27402 6115 Volvo Trucks Canada Ltd 5600A Cancross Court Mississauga Ontario L5R 3E9 http www volvotrucks volvo com PV776 TSP23760 1 6 96 8 1996 Volvo Trucks North America Inc 1996 ...

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Volvo VNL, Service Manual

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