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Cab Upholstery - VN - Heavy Haulers RV Resource Guide

1. W8001380 Using a small flat bladed screwdriver carefully remove the six plugs in the door panel oe oe W8001381 Remove the three bolts and three 14 mm socket screws holding the panel to the door Torx 25 Group 85 Upholstery The door panel is now held in place by the Christmas tree fasteners Care fully pry the door panel away from the door 6 Disconnect the electrical connectors for the electrical equipment in the door panel Remove the door panel Installation 1 Lift the panel into place on the door Connect the electrical connectors 2 Line up the panel so the holes in the door match the fasteners in the panel Press the fasteners into the holes 3 Install the three bolts and the three screws Install the cover plugs into the panel 10 W8001382 Torx 25 14 mm socket Torx 25 Service Procedures 4 If equipped install the window regula tor crank on the shaft Tighten the screw Install the crank cover by twist ing it into place and pressing over the end of the crank Install the door lock handle Install the screw and tighten it Install the rubber plug in the hole in the handle 6 Lift the panel into place on the door Connect the electrical connectors 7 Line up the panel so the holes in the door match the fasteners in the panel Press the fasteners into the holes 8 Install the three bolts and the three screws Insta
2. Position the right bunk fascia panel into its mounting location Secure the panel to the tower cabinets with the plastic stud nuts Secure the panel to the wall with screws Torque to 3 0 5 Nm 27 4 in lb 2 Secure the lower right trim with Christ mas tree and or interlock fasteners W8002182 Torx 25 Socket 11 mm Torque wrench 3 0 5 Nm 27 4 in lb Service Procedures W8002180 Secure the duct hose in the upper Torx 25 right tower cabinet to the right bunk fascia panel W8002183 Install the duct from the bunk HVAC Torx 25 unit to the right bunk fascia panel Torque wrench Torque the screws to 3 0 5 Nm 3 0 5 Nm 27 4 in lb 27 4 in lb 15 Group 85 Upholstery Service Procedures ws8002177 Install the cabinet below the lower right Torx 25 bunk window Torque the 3 bottom Torque wrench screws to 3 0 5 Nm 27 4 in lb 3 0 5 Nm 27 4 in lb a 6 ws8002181 Install the seat belt shoulder harness 50 10 Nm bracket and recoiler Start the bolts in 37 7 ft lb both then torque bolts to 68 7 Nm 50 10 Nm 37 7 ft lb Volvo seat 50 5 ft lb 68 7 Nm 50 5 ft lb National seat Install the recoiler cover and the bolt cover on the shoulder harness bracket 4 Install the support beam trim cover be hind the right seat Install the four retaining clips holding the trim cover W8002458 Install the 4 bunk window
3. 18 3 ft lb 6 Install the A pillar trim secure with the molding clip Repeat on opposite side 31 Group 85 Upholstery 7 Install the grab handles Tighten the bolts to a torque of 24 4 Nm 18 3 ft lb Install the cover plugs 8 Install the door seals 9 Install the bezel for the front overhead roof storage pockets with the star fasteners W8001428 Install the front curtain rail assembly Use caution not to deform the rail as sembly Position rail and snap into retaining clips 11 Install the sleeper curtain rail assem bly Torque to 5 1 Nm 45 7 in lb 32 Socket 12 mm 24 4Nm 18 3 ft lb Torx 25 5 1Nm 45 7 in lb Service Procedures W8002513 Install the long overbunk cabinet as Torx 40 follows Torx 25 Insert the interior light wiring through Torque wrench the cabinet access hole 24 4Nm Position the cabinet and install the 18 3 ft lb mounting bolts 2 Torque to 24 4Nm 24 4 Nm 18 3 ft lb 18 3 ft lb Install the left lower bunk restraint 3 0 5 Nm tether bracket with spacer 3 Torque 27 4 in lb to 24 4 Nm 18 3 ft lb Install the lower bolt trim covers Connect the light connector and install the light connector cover 1 Torque to 3 0 5 Nm 27 4 in lb Note In vehicles with an upper bunk the long overbunk cabinet is replaced by a short cabinet Group 85 Upholstery 13 ws002514 Install the upper ri
4. 6 Remove the 2 speakers 4 Torx 25 Group 85 Upholstery ws8002517 The headliner is now held in place by screws and the bunk trim Remove all screws that holds the headliner Note In older vehicles built 1998 and before the headliner may also be fas tened with interlocking fasteners Carefully work the back of the head liner out from behind the bunk wall trim then allow the rear of the head liner to drop enough to slide the front out from under the front headliner Disconnect the lamp connectors and remove the headliner from the vehicle Note Use caution not to bend the headliner to the point at which a permanent crease will show in the ma terial 8 Remove the lamp assemblies for in Torx 20 stallation in the replacement headliner Service Procedures Installation 1 Install the lamp assemblies in the re Torx 20 placement headliner 2 Position the headliner in the cab below its mounting location Connect the lamp assembly connectors Note Use caution not to bend the headliner to the point at which a permanent crease will show in the ma terial 2 people are required for this step ws8002517 Lift the headliner assembly into posi tion by sliding the front of the bunk headliner under the rear of the front headliner Work the rear of the bunk headliner behind the bunk wall trim panels Install all screws Note 2 people required for this step Note In older trucks built
5. Remove the fascia panel from its mounting location and remove it from the vehicle Service Procedures 11 W8002492 Remove the upper right tower cabinet Torx 40 as follows Torx 30 Remove any objects stored in the cab Torx 20 inet Socket 11 mm Unplug the power supply connectors Socket 12 mm Remove the 5 bolts from the rear bot tom wall 2 Remove the 6 bolts between the upper and lower cabinet 1 Pull the upper front trim panel back to expose the upper front wall mounting bolt Remove the bracket from the cab inet that holds the interlock fastener Pull back the B pillar trim to expose the lower front wall mounting bolt Remove the 5 wall mounting bolts 3 12 Remove the upper right tower cabinet from its mounting location and out of the vehicle Note This step requires 2 people 45 Service Procedures Group 85 Upholstery ne MI PAY Remove the refrigerator if equipped Open the refrigerator door Remove the 2 locks from the floor mounting rail 1 14 Slide the refrigerator out from the cabinet and disconnect the 12 V con nector Remove it from the vehicle 15 Remove the left tower cabinet drawer stop Remove the sink plumbing and electrical connectors if equipped Re move the drawer 46 Ww3002102 Torx 30 Torx 20 Socket 7 mm Slotted screw driver Remove the bunk master control panel from the left bunk fascia panel as fol lows Remo
6. Torx 20 Socket 12 mm Socket 13 mm Phillips screw driver Torque wrench 24 4 Nm 18 3 ft lb 24 4 Nm 18 3 ft lb 10 1 5Nm 89 13 in Ib Group 85 Upholstery W8002494 Torx 25 Socket 11 mm Torque wrench 3 0 5 Nm 27 4 in lb Fit the bunk master control panel through the cut out in the left bunk fas cia panel Position the left bunk fascia panel into its mounting location Secure the panel to the tower cabinets with the plastic stud nuts Secure the panel to the wall with screws Torque to 3 0 5 Nm 27 4 in lb 8 Secure the lower left trim with Christ mas tree and or interlock fasteners W8002493 Connect the bunk master control panel Phillips screw connectors 2 and install the control driver panel into the left bunk fascia panel with its 6 screws 1 10 Install the left lower cabinet drawer Torx 20 Connect the sink plumbing and electri Socket 7 mm cal connectors if equipped Slotted screw Install the drawer stops driver Service Procedures 11 W3002102 Install refrigerator if equipped as fol Torx 30 lows Torque wrench Position the refrigerator in the floor 13 2 Nm mounting rails and connect the 12 volt 10 1 5 ft lb connector Slide the refrigerator as far back on the tracks as possible Open the refrig erator door and install the mounting strips 1 Torque to 13 2 Nm 10 1 5 ft lb 12 Install the upper right tower cabinet as f
7. move the control unit by lifting it up If necessary remove air cushions 27 Install components in the reverse or der of removal Group 85 Upholstery 8526 03 02 13 Service Procedures Seat Height Control Cylinder Replacement T8006510 Fig 6 Seat height control X Spacer 9 Cylinder Pin 11 Control Cylinder 13 Guide Disc Unit 14 Level Control Valve 18C Lock Ring 19 Bolt N DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death See Fig 6 Seat height control page 89 11 1 Remove the seat cushion and seat cushion base Release the bellows from the front of the upper and lower frames Block the seat in its upper po sition using a 150 mm 6 in long spacer X placed between the frames 22 Pin 25 Lock Cylinder 27 Screw 28 Screw 96 Hose 97 Hose 2 Loosen the clamping sleeves and pull hoses 96 and 97 off from the con trol cylinder 11 Remove the cylinder pin 9 Loose screw 27 a little and lightly press the guide disc unit 13 lever plates apart where they are con nected to the control cylinder and remove the cylinder 3 Install the components in reverse or der of removal Tighten screw 27 a little Pull the control for height adjust ment upward and check that the lock cylinder 25 can move f
8. 1 3 4 W3003110 1 Roof plate 2 Roof panel 3 Headlining 4 Fully engage fasteners pressing firmly Install the 2 Christmas tree fasteners in the center of the headliner Install the 2 remaining clips in the center of the headliner Press in the center but ton to secure Engage the securing interlocking fasteners Note Two people are required for this step 19 Group 85 Upholstery 4 Install the screws securing the front and sides of the headliner Torque to 3 0 5 Nm 27 4 in lb 5 Install the B pillar trim 6 Install the A pillar trim Install the molding press in the center bottom to secure If equipped install the plastic rivet fasteners 7 Install the door seals Install the grab handles Torque to 24 4 Nm 18 3 ft lb Replace the bolt cover trim 9 If equipped install the rear speakers in the headliner 10 Install the coat hooks to the rear of the headliner Torque to 3 0 5 Nm 25 5 in lb 11 Install the front overhead storage cabi net carrier rail Torque to 24 4 Nm 18 3 ft lb 12 Install the right sun visor Torque to 5 0 8 Nm 45 7 in Ib 13 Install the front overhead storage cabi net together with the sun visor Torque to 5 0 8 Nm 45 7 in lb Note Install only the sun visor if the vehicle is not equipped with a front overhead storage cabinet 20 Torx 15 3 0 5 Nm 27 4 in lb Socket 12 mm 24 4Nm 18 3 ft lb Torx 25 Torx
9. 2 Install the cushions in the reverse or der of removal Test seat for function Group 85 Upholstery 8526 03 02 03 Service Procedures Seat Control Harness Replacement T8006505 Fig 2 Seat Exploded View H Left Hand Cover 2 Solenoid Valve Connectors 3 Electric Motors Connectors N DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death See Fig 2 Seat Exploded View page 81 A 16 45 Left Hand Coever Screws 50 Seat Heating Connector 1 Note Disconnect the batteries before doing any work on the seat If a defect is found in the wire harness the complete harness must be re placed Block the seat in its upper position us ing a 150 mm 6 in extension between the frames Disconnect con nector 1 81 Group 85 Upholstery 2 Remove the seat cushion seat cush ion base and backrest cushion Unscrew the five screws 16 and 45 for the seat frame left hand cover H Pull apart connector 50 at the switch for the seat heating elements 3 Remove the bellows from the front part of the upper frame on the control side and disconnect the solenoid valve connectors 2 and the remaining con nectors 3 at the electric motors Cut off the tie straps and pull out the wire harness 4 Install the new harness in the rever
10. 4 screws to the floor and 2 screws to the cowl It is covered around the edges by the floor mat The engine cover is different for a VNL and a VNM In the VNM cab the engine is located further back into the cab resulting in a larger cut out in the floor To remove the engine cover see Engine Cover Re placement page 99 W8002524 Group 85 Upholstery Design and Function Headliners W8002579 Headliners are made of form pressed urethane The day cab liner is made in one sec tion but the sleeper cab liners are made as multiple sections Headliners are mainly held in place by screws In older vehicles there are also pressfasteners that holds the headliners In the sleeper cabs there are separate sections for the sleeper compartment W8001423 Group 85 Upholstery Service Procedures Service Procedures 8511 03 02 01 Door Panel Replacement N DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death Removal W8001398 Remove the knob on the door by Torx 10 pulling the rubber plug out with a scriber Remove the screw W8001379 If the vehicle is equipped with me Torx 25 chanical window regulators remove the crank Lift the vinyl cover in the wide end twist it to one end Remove the screw
11. Cover Replacement Rear cssccceeeeeeeeeeteeeeeeeeees 78 Seat Frame Cover Replacement Right Side teeeeeseeeeereeees 78 Seat Frame Cover Replacement Left Side seeceeeeeeeeeees 79 Seat Compressed Air Valve Replacement eeesesesseeeseeteeeeeees 79 Seat Heater Switch Replacement eseeseeeceerecseeceeneresneresneeerees 79 Seat Adjustment Switch Panel Replacement eeseeeseeereees 80 Seat Cushion Base Replacement is ciaisssisicisaseriaveidissavinievseriaveisicinn 80 Seat Backrest Air Cushion Replacement sessreseereseeeeeeeeees 80 Seat Control Harness Replacement is cisesciseisnrisiereressveversaveaveisreivee 81 Seat Motor Replacement Cushion Position cceeseeeeeeeees 83 Feedback Operation Numbers General Group 85 Upholstery General ee H ANA V 5 f V w9000178 This manual contains design and function and service procedures for upholstery seats and other trimming It covers all VN cabs Other cab components such as Electrical System and Air Conditioning and Heating System are not covered in this manual See Electrical System group 3 and Air Conditioning and Heating System Group 87 Group 85 Upholstery General General Precautions AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutr
12. and install the lamp Torque the screws to 3 0 5 Nm 27 4 in lb 7 Install the bunk headliner speakers as follows Connect the connector on the back and install using the 4 screws Torque to 3 0 5 Nm 27 4 in lb Install the cover W8002459 Torx 25 Torque wrench 3 0 5 Nm 27 4 in lb Torx 25 Torque wrench 3 0 5 Nm 27 4 in lb W8002490 Install the bunk curtain rail assembly Torque the screws to 5 1 Nm 44 9 in Ib Torx 25 Torque wrench 5 1Nm 44 9 in lb Group 85 Upholstery Ww8002513 Install the left overbunk cabinet as fol lows Torx 25 Torx 40 Insert the interior light wiring through Torque wrench the cabinet access hole 24 4Nm Position the cabinet and install the 18 3 ft lb mounting bolts 2 Torque to 24 4Nm 24 4 Nm 18 3 ft lb 18 3 ft lb Install the left lower bunk restraint 3 0 5 Nm tether bracket with spacer 3 Torque 27 4 in lb to 24 4 Nm 18 3 ft lb Install the lower bolt trim covers Connect the light connector and install the light connector cover 1 Torque to 3 0 5 Nm 27 4 in lb Note In vehicles with an upper bunk the long overbunk cabinet is replaced by a short cabinet Service Procedures 10 W8002514 Install the upper right cabinet as fol lows Torx 30 Torx 40 Insert the power supply and coaxial Torque wrench cable through the upper cabinet ac 24 4 Nm cess hole Insert th
13. below the lower Torx 25 right bunk window Torque the 3 Torque wrench screws in the bottom of the cabinet to 3 0 5 Nm 3 0 5 Nm 27 4 in lb 27 4 in lb W8002180 Secure the duct hose in the upper Torx 25 right tower cabinet from the right bunk fascia panel 17 W8002176 Install the 4 bunk window trim bezels Phillips screw Torque to 3 0 5 Nm 27 4 in lb driver Torque wrench 3 0 5 Nm 27 4 in lb W8002183 Install the duct from the bunk HVAC Torx 25 20 unit to the right bunk fascia panel Torque wrench Install bunk ladder assembly if Torx 30 Install the 6 torx screws holding the 3 0 5 Nm equipped Torque to 10 1 5 Nm Torque wrench ducting to the fascia panel Torque to 27 4 in lb 7 1 ft lb 10 1 5Nm 3 0 5 Nm 27 4 in lb 7 1 ft lb 71 Group 85 Upholstery 21 ws8002501 Install both right and left B pillar trims Torx 50 Secure the B pillar trim to the upper Torque wrench tower cabinets with the Christmas tree 68 7 Nm fasteners Properly position the B pillar 50 5 ft lb trim and reinstall the door seal to se cure Install the seat belt shoulder harness mounting bolt Torque to 68 7 Nm 50 5 ft lb Note Use caution not to crease the trim panel 22 W8002490 Install the sleeper curtain rail assem Torx 25 bly Torque to 5 1 Nm 44 9 in lb Torque wrench 5 1Nm 44 9 in lb 23 Complete this procedure by installing the front
14. bunk from the vehicle Socket 12 mm Socket 16 mm Note Two people are required for this step W8002457 Socket 16 mm Remove the upper bunk restraint by removing the 2 bolts 6 Remove the rear wall interior trim J 38778 panel Its held in place with Christmas tree and interlocking fasteners Disengage fasteners and remove the panel from the vehicle 7 p eee ha sa a lt a ee eo l 7 me Ss es A W8002459 Remove the overhead lamp assembly Torx 25 from the center rear headliner Discon nect the electrical connector Group 85 Upholstery CN Remove the 2 trim strips on each side of the center bunk headliner Note no tools required they pop out 9 Remove the center bunk headliner It s held in place by Christmas tree and interlocking fasteners Disengage fas teners and remove the panel from the vehicle J 38778 10 W8002456 Torx 25 Remove the right side upper bunk support by removing the 2 screws to the cover and the 2 screws to the striker plate 11 Remove the right side lower bunk re straint tether bracket Torx 40 W8002461 Service Procedures W8002463 Torx 20 Torx 15 Remove the right side center trim panel as follows Remove the front curtain rail from the first 2 right side clips to allow removal of one panel bottom mounting screw nylon spacer and curtain rail mounting clip 1 Remove one forward mounting screw wit
15. fasteners as necessary Carefully work the bunk headliner out from under the front headliner and away from the rear wall trim Remove it from the vehicle Use cau tion not to crease the headliner material 35 Group 85 Upholstery Installation 1 Carefully work the bunk headliner un der the front headliner and behind the rear wall trim Secure with interlock and Christmas tree fasteners Use caution not to crease the headliner material Note Two people are required for this step 2 Install the bezels around the left and right overhead storage bins over the seats 3 Install the top rear wall trim panel as follows Work the panel into position behind the top of the center wall trim panel Install the snap screws and covers Engage the Velcro fasteners Work the rear window seal around the panel 4 Engage the interlock fasteners on the center rear wall trim panel Install the 2 coat hooks and torque the screws to 3 0 5 Nm 27 4 in lb Install the right upper trim panel as fol lows Work the interior light wiring through the panel Position the panel and engage the in terlock fasteners Install the right lower bunk restraint tether bracket Torque the bolt to 24 4 Nm 18 3 ft lb 36 Torx 25 Torque wrench 3 0 5 Nm 27 4 in lb Torx 40 Torque wrench 24 4Nm 18 3 ft lb Service Procedures YG NX Py Connect the bunk headliner overhead lamp assembly connector
16. one to the lower bunk tether 3 Note In vehicles with an upper bunk the long overbunk cabinet is replaced by a short cabinet W8002490 Remove the bunk curtain rail assem Torx 25 bly 5 Remove the bunk headliner speakers Torx 25 as follows Remove the speaker cover the 4 screws and finally disconnect the con nector on the back Group 85 Upholstery W8002459 Remove the bunk headliner overhead Torx 25 lamp assembly Disconnect the con nector 7 Remove the right upper trim panel as Torx 40 follows Remove the right lower bunk restraint tether bracket Separate the interlock fasteners at the top to allow the trim panel fold down Note The panel doesn t have to be completely removed It s enough if it just falls down a bit 8 Remove the 2 coat hooks from the Torx 25 center rear wall trim panel Separate the interlock fasteners at the top to allow the trim panel to be pulled back for removal of the top rear wall trim panel 9 Remove the top rear wall trim panel as follows Remove the 2 snap covers and screws Separate the Velcro fasteners and re move the panel from the vehicle Use caution not to tear the panel around the rear window seal 10 Remove the bezels around the left and right overhead storage bins over the seats Service Procedures W8002515 Remove the bunk headliner as follows J 38778 Remove the 2 Christmas tree fasten ers and separate the interlocking
17. screws to 3 0 5 Nm 27 4 5 in lb Install the lamp cover Ws8002459 Torx 25 Torque wrench 3 0 5 Nm 27 4 5 in lb Secure the rear wall trim panel with the 4 Christmas tree fasteners 50 W8002498 Service Procedures Install the upper bunk roof restraint re ceivers 1 Torque to 24 4 Nm 18 3 ft lb Install the upper bunk rear wall re straint tongues 2 Torque to 68 7 Nm 26 5 ft lb W8002497 Torx 40 Socket 18 mm Torque wrench 24 4Nm 18 3 ft lb 68 7 Nm 26 5 ft lb Position the bunk upper rear wall stor age cabinet to its mounting location Connect the speaker connectors and secure the cabinet with the 8 screws 1 Torque to 24 4 Nm 18 3 ft lb W8002496 Torx 40 Torque Wrench 24 4 Nm 18 3 ft lb Group 85 Upholstery 10 Position the upper left tower cabinet into its mounting location Work the cabinet around trim panels and pull the wiring through the cabinet as nec essary Note This step requires 2 people 11 Service Procedures 12 FO TS AN ay Ks ZS aS W8002494 Fit the bunk master control panel Torx 25 through the cut out in the left bunk fas Socket 11 mm cia panel 3 0 5 Nm Position the left bunk fascia panel into 27 4 in lb Install the upper left tower cabinet as follows Start all cabinet mounting bolts before beginning tightening Install th
18. seat cushion and seat cush ion base Block the seat in its upper position using a 150 mm 6 in exten sion between the frames Release bellows at the front of the seat frame remove nut 37 Disconnect wire con nections at motor 2 Remove the screws 45 pull out the drive cable and lift out the motor 3 Remove worm gear unit locking plate 64 Remove lock washer 9 and shaft 8 Remove the screw 13 then twist the worm gear unit and spindle nut 27 out of the attachment 65 84 Group 85 Upholstery Service Procedures 8526 03 02 06 Seat Motor Replacement Cushion Tilt W8001432 Fig 4 Seat base exploded view 8 Shaft 59 Valve Screws Lock Washer 61 Hose 13 Worm Gear Unit Screw 62 Distribution Pipe 27 Spindle Nut 64 Locking Plate 45 Seat Motor Screws 65 Seat Motor Attachment 1 AX DANGER Remove the seat cushion and seat cushion base Set the seat at its great Before working on a vehicle set the parking brakes est tilt angle Disconnect the wire place the transmission in neutral and chock the connectors at the motor wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death 2 Remove the screws 45 pull out the drive cable and lift out the motor See Fig 4 Seat base exploded view page 85 C 85 Group 85 Upholstery 3 Remove worm gear unit locking plate 64 Remove lock washer 9 and shaft 8 Remove the screw 13 then tw
19. the cable pulley 140 Install the components in reverse from re moval 96 Service Procedures Group 85 Upholstery 8526 03 02 16 Seat Air Spring Replacement Service Procedures T8006500 Fig 10 Seat base exploded view X Spacer 4 Screw 6 Seat Air Spring J N DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death See Fig 10 Seat base exploded view page 97 6 30 Seat Vertical Shock Absorber 37 Screw 95 Hose 1 Release the bellows from the front and side of the upper frame Block the seat in its upper position using a 150 mm 6 in long spacer X placed between the frames Pull back the clamping ring on the air spring connection and pull off the hose 95 Remove the screws 4 and 37 97 Group 85 Upholstery Service Procedures 2 Install the components in reverse from removal The air spring can not be twisted when installed If necessary slightly loosen screw 4 and allow the spring to move up and down under pressure Tighten down the screw while the air spring is under pressure 8529 03 02 03 Seat Vertical Shock Absorber Replacement AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicl
20. the front left overhead storage cabinet together with the sun visor In stall the 4 mounting screws with their rubber washer to the carrier rail Torque to 2 0 3 Nm 17 3 in lb Install the 6 screws with their rubber washer over the windshield Torque to 3 0 5 Nm 25 5 in lb Torx 25 Socket 8 mm 2 0 3 Nm 17 3 in lb 3 0 5 Nm 25 5 in lb Socket 8 mm 5 0 8 Nm 45 7 in lb Torx 25 Socket 8 mm 2 0 3 Nm 17 3 in lb 3 0 5 Nm 25 5 in lb Service Procedures 25 Group 85 Upholstery 8554 03 02 03 Headliner Replacement Bunk AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death VN420 Removal 1 Remove the mattress from the vehicle W8002490 Remove the bunk curtain rail assem Torx 25 bly Note The curtains don t need to be removed from the rail 26 Service Procedures W8002519 Remove the front curtain rail assembly Slotted screw 1 Use a wide blade screwdriver to driver carefully pry the rail out of one side then the other side on each retaining clip Remove the rail assembly from the ve hicle Note Use caution not to deform the rail assembly 4 Remove the 2 bunk restraint tether Torx 40 brackets and spacer 2 5 Remove the 2 coat hooks from the Torx 25 rear wall 3
21. to expose the lower front wall mounting bolt Re move the 5 wall mounting bolts 3 Remove the cabinet out of the vehicle Note This step requires 2 people 66 W8002495 Torx 40 Torx 30 Torx 20 Socket 12 mm Socket 13 m Phillips screw driver Service Procedures Remove the right front overhead stor age compartment as follows Remove the bezel net screws to the center overhead storage compartment Disconnect any electrical components if equipped Remove the rear support rod 1 Re move the bottom mounting screws 2 Carefully work the compartment out of its mounting location back and around the bunk headliner trim Remove it from the vehicle 20 Remove the left front overhead stor age compartment as follows Remove the bezel net screws to the center overhead storage compartment Remove the rear support rod Remove the bottom mounting screws Carefully work the compartment out of its mounting location back and around the bunk headliner trim Remove it from the vehicle 21 Remove the 2 shark fin dividers from the center compartment shelf as fol lows Remove the 2 support rods tube and bracket assemblies Pull back the car pet at each divider enough to access the mounting screws Remove the screws and remove the dividers W8002512 Socket 13 mm Torx 20 mm Socket 13 mm Torx 20 mm Socket 13 mm Torx 20 mm Torx 15 Group 85 Upholstery 22 Remove the 1 front and 2 rear Chr
22. to expose the lower front wall mounting bolt Remove the 5 wall mounting bolts 3 20 Remove the upper left tower cabinet from its mounting location and out of the vehicle Note This requires 2 people 47 Group 85 Upholstery W8002496 Remove any objects stored in the Torx 40 bunk upper rear wall storage cabinet Remove the 8 bolts and disconnect the speaker connectors Remove the cabinet from the vehicle W8002497 Socket 18 mm Torx 40 Remove the upper bunk rear wall re straint tongues 2 Remove the upper bunk roof restraint receivers 1 48 Service Procedures 23 W8002498 Disengage the Christmas tree fasten J 38778 ers on the top of the rear wall trim panel to allow access to the rear part of the center headliner Note The 2 lower Christmas tree fas teners are not visible 24 lt a x A W8002459 Remove the center bunk headliner Torx 25 overhead lamp assemblys Disconnect the connector 25 Remove the 2 trim strips on each side of the center bunk headliner 26 Disengage the Christmas tree fasten J 38778 ers that secure the plastic support strips between the bunk center and side headliners Use caution when bending back the side headliner pan els not to crease the material Group 85 Upholstery 27 W8002499 Disengage the 2 Christmas tree fas J 38778 teners at the front and the 3 at the rear of the center bun
23. trim bezels Phillips screw Torque the screws to 3 0 5 Nm driver 5 27 4 in lb Torque wrench Install the right rear grab handle In 24 4Nm 3 0 5Nm stall the two mounting bolts and trim 18 5 ft lb 27 4 in Ib caps Torque bolts to 24 4Nm 18 5 ft lb B Pillar Trim Panel and Seat Belt Assembly Installation 1 Install the B pillar trim panel Install the three retaining clips that hold the panel to the tower cabinet Install the trim panel around the support beam and fit at the top behind the curtain rail and behind the mat trim at the floor 2 Install the plastic trim retainer edge with the door sealant 16 Group 85 Upholstery 8554 03 02 01 Headliner Replacement Z N DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death Day Cab Removal 1 Remove the front left overhead storage Torx 25 cabinet together with the sun visor Socket 8 mm Note On vehicles that are not equipped with an overhead storage cabinet remove only the sun visor 2 Remove the right sun visor Socket 8 mm 3 If equipped remove the front left stor Torx 40 age cabinet carrier rail 4 Remove the coat hooks from the rear Torx 25 of the headliner Service Procedures 5 If equipped remove the rear speakers Torx 25 from the headline
24. work the com 24 4Nm partment into its mounting location 18 3 ft lb Secure the bottom mounting screws Install the rear support rod Torque to 24 4 Nm 18 3 ft lb Secure the bezel net screws to the center overhead storage compartment Connect any electrical components if equipped Group 85 Upholstery ws002490 Install the bunk curtain rail assembly Torque to 5 1 Nm 44 9 in lb 7 Install the upper right bunk storage cabinet as follows Lift the cabinet into position and insert the power supply wiring and coaxial cable Fit the cabinet over the HVAC duct at the rear of the cabinet Install the 4 wall mounting bolts and torque to 68 7 Nm 50 5 ft lb Install the through bolt and spacer be tween the upper and lower cabinet Torque to 12 2 Nm 9 1 5 ft lb 8 Install the upper left bunk storage cab inet as follows Lift the cabinet in place and install the 4 mounting bolts Torque to 68 7 Nm 50 5 ft lb 9 Complete this procedure by installing the front lower headliner see Headliner Replacement Front Lower page 55 Torx 25 5 1Nm 44 9 in lb Torx 40 Socket 10 mm Torque wrench 68 7 Nm 50 5 ft lb 12 2 Nm 9 1 5 ft lb Torx 40 Torque wrench 68 7 Nm 50 5 ft lb Service Procedures 61 Group 85 Upholstery 8554 03 02 05 Headliner Replacement Front Upper AN DANGER Before working on a vehicle set the parking brakes place the tra
25. 03 02 01 8522 03 02 02 8522 03 02 03 8523 03 02 01 8523 03 02 02 8524 03 02 01 8524 03 02 02 8524 03 02 03 8524 03 02 04 8526 03 02 01 8526 03 02 02 8526 03 02 03 8526 03 02 04 8526 03 02 05 8526 03 02 06 8526 03 02 07 8526 03 02 08 8526 03 02 09 8526 03 02 10 8526 03 02 11 8526 03 02 12 8526 03 02 13 8526 03 02 14 8526 03 02 15 8526 03 02 16 8526 03 02 17 8526 03 02 18 8529 03 02 01 8529 03 02 02 8529 03 02 03 8554 03 02 01 8554 03 02 02 8554 03 02 03 8554 03 02 04 8554 03 02 05 8561 03 02 01 Operation Numbers Engine Cover Replacement 2 0005022 eee 99 Door Panel Replacement 00002 eee eee eee 9 Seat Replacement 22 42 eee Bie ee Eee Re aE RAE SEY OEE SSH 73 Seat Frame Cover Replacement Rear oaoa oaa a a 78 Seat Frame Cover Replacement Right Side 78 Seat Frame Cover Replacement Left Side 79 Seat Cushion Replacement onoo a a a a ae Seat Cushion Base Replacement lt s s s sa os anos amoa oao a a a 80 Seat Backrest Cushion Replacement o aooaa a 77 Seat Backrest Cover Replacement Lower a a a a a a a a a a 78 Seat Backrest Cover Replacement Upper a a a a a a a 77 Seat Backrest Air Cushion Replacement aoa a a a a a 80 Seat Heater Switch Replacement oaoa oaa a a 79 Seat Adjustment Switch Panel Replacement 80 Seat Control Harness Replacement 2 248 81 Seat M
26. 13 mm Phillips screw driver Torque wrench 24 4 Nm 18 3 ft lb 24 4 Nm 18 3 ft lb 10 1 5Nm 7 1 ft lb Group 85 Upholstery Service Procedures 19 21 W8002180 Secure the duct hose in the upper Torx 25 right tower cabinet to the right bunk fascia panel W8002182 Position the right bunk fascia panel Torx 25 into its mounting location Secure the Socket 11 mm 22 panel to the tower cabinets with the Torque wrench plastic stud nuts Secure the panel to 3 0 5 Nm A the wall with screws Torque to 27 4 in lb 3 0 5 Nm 27 4 in lb 20 Secure the lower right trim with Christ mas tree and or interlock fasteners W8002183 Install the duct from the bunk HVAC Torx 25 unit to the right bunk fascia panel Torque wrench Torque the screws to 3 0 5 Nm 3 0 5 Nm 27 4 in lb 27 4 in lb 53 Group 85 Upholstery 23 Wws8002177 Install the cabinet below the lower right Torx 25 bunk window Torque the 3 bottom Torque wrench screws to 3 0 5 Nm 27 4 in lb 3 0 5 Nm 27 4 in lb W8002458 Phillips screw Install the 4 bunk window trim bezels Torque the screws to 3 0 5 Nm driver 27 4 in lb Torque wrench 3 0 5 Nm 27 4 in lb 25 Install bunk ladder assembly if Torx 30 equipped Torque the bolts to 10 1 5 Nm 7 1 ft lb Torque wrench 54 Service Procedures ws8002501 Install both right and left B pillar trims Torx
27. 1998 and before the headliner may also be fas tened with interlocking fasteners 27 Service Procedures Group 85 Upholstery Install the rear speakers in the head liner as follows 4 Connect the connector Install and torque the 4 screws to 3 0 5 Nm 27 4 5 in lb Install the cover 5 Install the 2 coat hooks 3 Torque to 3 0 5 Nm 27 4 5 in lb Install the 2 bunk restraint tether brackets and spacer 2 Torque to 18 3 Nm 13 2 in lb 7 Install the front curtain rail assembly 1 Use caution not to deform the rail assembly Position the rail and snap it into the re taining clips 28 W8002519 Torx 25 Torque wrench 3 0 5 Nm 27 4 5 in lb Torx 25 Torque wrench 3 0 5 Nm 27 4 5 in lb Torx 40 Torque wrench 18 3 Nm 13 2 in lb W8002490 Install the bunk curtain rail assembly Torx 25 Torque to 3 0 5 Nm 27 4 5 in lb Torque wrench 3 0 5 Nm 27 4 5 in lb 9 Install the mattress into the vehicle Group 85 Upholstery 8554 03 02 02 Headliner Replacement Front Z N DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death VN610 Removal 1 Front overhead storage cabinets Remove the front left overhead storage Torx 25 cabinet together with the sun visor S
28. 25 3 0 5 Nm 25 5 in lb 24 4Nm 18 3 ft lb Socket 8 mm 5 0 8Nm 45 7 in lb Torx 25 Socket 8 mm 5 0 8 Nm 45 7 in lb Service Procedures Group 85 Upholstery 8554 03 02 02 Headliner Replacement Front Z N DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death VN420 Removal 1 Remove the front left overhead storage Torx 25 cabinet together with the sun visor Socket 8 mm 2 Remove the right sun visor Socket 8 mm 3 If equipped remove the front right Torx 25 overhead storage cabinet Socket 8 mm Note Two screw covers on the far right facing panel must be removed to gain access to the mounting screws 4 Remove the front overhead storage Torx 40 cabinet carrier rail Service Procedures 5 Remove the driver side window visor assembly Pry off end screw covers Remove mounting screws Socket 8 mm 6 Remove the sleeper curtain rail as Torx 25 sembly Note The curtains do not need to be removed from the rail W8001428 Remove the front curtain rail assem Slotted screw bly Use a wide blade screwdriver to driver carefully pry the rail out of one side then the other side on each retaining clip After all retaining clips are re leased remove the front curtain rail assembly from the vehic
29. 5 wall mounting bolts 3 2 Remove the power socket connectors and remove the mounting screw in the center of the 120 V outlet cover if equipped Remove the cover 3 Remove the four torx bolts 4 holding the lower tower cabinet to the wall Service Procedures 4 Remove the 4 nuts and washers 5 holding the lower tower cabinet to the floor Remove the lower cabinet from the cab Upper Bunk Removal 1 Remove the left side switch panel and housing 2 With the bunk in the up position remove the two screws mounting re straint bracket and rear wall bracket into bunk assembly 3 Remove the two bunk mounting bolts from the mounting hinge brackets on rear wall W8002159 Use caution when removing the bunk assembly from the truck to prevent the mounting hinge from being impacted and possibly coming unlatched from the flat position With the bunk in the lower position lift it to about 45 angle and pull it out Group 85 Upholstery Upper Bunk Installation Wws8002158 Make sure that the bunk is flat and the mounting hinge is latched If not put the bunk in a vise Pull the bunk down and latch it Note Install rags on the vise to avoid damage to the paint 2 Install the bunk assembly into the truck Position the hinge to align with the mounting holes on the rear wall 3 Install the two mounting bolts through 68 Nm the bunk restraint seat belt brackets 50 ft lb a
30. 50 as follows Torque wrench Secure the B pillar trim to the upper 68 7 Nm tower cabinets with the Christmas tree 50 5 ft lb fasteners Properly position the B pillar trim and reinstall the door seal to se cure Install the seat belt shoulder harness mounting bolts Torque to 68 7 Nm 50 5 ft lb Note Use caution not to crease the trim panel 27 W8002490 Install the sleeper curtain rail assem Torx 25 bly Torque the screws to 5 1 Nm Torque wrench 44 9 in lb 5 1Nm 44 9 in lb 28 Install the lower mattress work station cushions to the vehicle Group 85 Upholstery 8554 03 02 04 Headliner Replacement Front Lower N DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death VN660 770 Removal ws002511 Remove the front left overhead stor Torx 25 age cabinet sun visor assembly There Socket 8 mm are 4 bolts in the upper front and 6 bolts in the back 2 Remove the right sun visor Socket 8 mm Service Procedures W8002510 Remove the front right overhead stor Torx 25 age cabinet There are 2 bolts in the Socket 8 mm upper front and 6 bolts in the back Note 2 screw covers on the far right facing panel must be removed to gain access to the mounting screws 4 Remove the front overhead stora
31. 7 4 in lb screws to 3 0 5 Nm 27 4 in lb Install the speaker cover W8002458 Phillips screw trim bezel Torque the screws to driver Install the right side sleeper window 3 0 5 Nm 27 4 in lb Torque wrench 3 0 5 Nm 27 4 in lb Group 85 Upholstery Install the right side center trim panel as follows Note the position of the Christmas tree and interlocking fasteners At the bottom of the panel install the mounting screw nylon spacer and cur tain rail mounting clip 1 Torque to 5 1 Nm 44 9 in lb Put the trim cover piece in place and install the forward mounting screw with curtain hold back snap fitting Torque to 3 0 5 Nm 27 4 in lIb Snap the front curtain rail into the mounting clips Note Older vehicles from 10 99 and before don t have the trim cover piece If so the rail mounting clip with screw needs to go through the hole in the panel trim material and the exces sive trim material needs to be tucked under the bottom edge of the panel 5 Install the right side lower bunk re straint tether bracket Torque the bolt to 24 4 Nm 18 3 ft lb W8002463 Torx 20 Torx 15 Torque wrench 5 1Nm 44 9 in lb 3 0 5 Nm 27 4 in lb Torx 40 Torque wrench 24 4Nm 18 3 ft lb Service Procedures W8002456 Install the right side upper bunk sup Torx 25 port cover and striker plate Torque the 10 1 5Nm screws to 10 1 5 Nm 7 1 ft lb 7 1 ft
32. 7 Hose 161 Hose See Fig 8 Seat height control page 93 14 1 Remove the seat cushion and seat cushion base Release the bellows from the front and side of the upper frame Block the seat in its upper posi tion using a 150 mm 6 in spacer X placed between the frames 93 Group 85 Upholstery 2 Remove both screws 15 from the level control valve 14 Loosen the hose clamps and pull off hoses 94 95 and 161 Install components in reverse from removal 94 Service Procedures 8526 03 02 09 Seat Height Two Way Valve Replacement AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death See Fig 8 Seat height control page 93 16 1 Remove the seat cushion and seat cushion base Release the bellows from the front of the upper frame Loosen the hose clamps and pull hoses 23 24 96 97 and 107 off from the two way valve Remove screw 17 Install components in re verse from removal Group 85 Upholstery 8526 03 02 14 Seat Cam Disc Replacement Service Procedures T8006499 Fig 9 Seat cam disc X Spacer 11 Control Cylinder 13 Guide Disc Unit 14 Level Control Valve 18A Lock Washer 18B Lock Washer Z N DANGER Before working on a vehicle set the parking brakes place the transm
33. Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death See illustration Fig 1 Seat Exploded View page 75 E 1 Pull off backrest cushion see B and upper cover see D Remove inside screws 16A or remove outside screws 29 for cover See illustration 2 Install the cover in the reverse order of removal Test seat for function 78 Service Procedures 8522 03 02 01 Seat Frame Cover Replace ment Rear Z N DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death See illustration Fig 1 Seat Exploded View page 75 F 1 Move the seat to its rearmost position Remove the seat frame left hand cover F and the right hand cover G and pull it out See illustration 2 Install the cover in the reverse order of removal Test seat for function 8522 03 02 02 Seat Frame Cover Replace ment Right Side N DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death See illustration Fig 1 Seat
34. Exploded View page 75 G 1 Pull off the seat cushion and backrest cushion see A and B Remove the two screws 45A and the three screws 16B See illustration 2 Install the cover in the reverse order of removal Test seat for function Service Procedures Group 85 Upholstery 8522 03 02 03 Seat Frame Cover Replace ment Left Side Z N DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death See illustration Fig 1 Seat Exploded View page 75 H 1 Pull off seat cushion and backrest cushion see A and B Press out con trol button 3 See illustration 2 Push valve unit clamping hooks 22 to the side and release control unit I push them through hole 21 3 Remove the two screws 45A and the three screws 16B Remove the switch panel K see K 4 Install the cover in the reverse order of removal Test seat for function 8529 03 02 02 Seat Compressed Air Valve Replacement N DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death See illustration Fig 1 Seat Exploded View page 75 I 1 Press out the control button 3 Press t
35. Service Manual Trucks Group 85 Cab Upholstery VN PV776 TSP133527 WOiINO Foreword The descriptions and service procedures contained in this manual are based on de signs and methods studies carried out up to February 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 n
36. Torx 20 Install the compartment into the Torque wrench vehicle and carefully work the com 24 4Nm partment into its mounting location 18 3 ft lb Torque the 5 bottom mounting screws 2 Install the rear support rod 1 and torque to 24 4 Nm 18 3 ft lb Secure the bezel net screws to the center overhead storage compartment Connect any electrical components if equipped 5 Position the upper left tower cabinet into its mounting location Work the cabinet around the trim panels and pull the wiring through the cabinet as necessary Note This step requires 2 people 68 Service Procedures Install the upper left tower cabinet as follows Start all cabinet mounting bolts before beginning tightening them Install the 5 wall mounting bolts 2 and torque to 24 4 Nm 18 3 ft lb Install the 6 bolts between the upper and lower cabinet 1 and torque to 24 4 Nm 18 3 ft lb Note The lower cabinet door hinges may need to be temporarily removed to install the 2 front bolts Re install hinges after the bolts between the up per and lower cabinet have been tightened Install the 5 bolts to the rear bottom wall and torque to 10 1 5 Nm 89 13 in Ib Torque all cabinet mounting bolts Install the bracket that holds the inter lock fastener to the cabinet Secure the upper front trim panel with the in terlock fastener Connect the power supply connectors W8002495 Torx 40 Torx 30
37. al and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death Always wear appropriate eye protection to prevent the risk of eye injury due to contact with debris or fluids Possible damage to electronic components Turn the vehicle ignition switch OFF before disconnecting or connecting any electrical components Failure to de energize circuits may result in electronic equip ment damage Group 85 Upholstery Design and Function Design and Function Interior Door Panels Door panels are made of form pressed plastic and may have different types of fabric depending on the cab trim option The panel is fastened with screws that are cov ered with plugs There is also an inner plate covering the door functional parts Wall Panels Wall panels are made of urethane and fastened to the wall by trim screws and press type fasteners Depend ing on the interior trim option the panels are covered with different types of material W8001383 Seats There are several types of seats available The standard offering is an air suspended mid back seat with head rest As an option this seat comes with air operated support cushions in the back rest seat and lumbar support The front angle of the seat is adjustable and the bottom frame is protected by rubber bellows W8001431 5 Group 85 Upholstery A luxury Volvo seat offers many adjustments a
38. at cushion and seat cushion base Release the bellows from the front of the upper and lower frames Block the seat in its upper po sition using a 150 mm 6 in spacer X placed between the frames 2 Pull the hose 107 off from the lock cylinder 25 Remove the lock ring 18C and remove the bolt 19 Loosen the screw 27 a little and lightly press the guide disc unit 13 lever plates apart where they are con nected to the control cylinder and move them to the side 91 Group 85 Upholstery 3 Make sure that the guide plate 12 does not slide off from the pin 22 Should this happen the ball located in the guide plate cam 26 must be posi tioned on the pin 22 again 4 Install the components in the reverse order of removal Tighten screw 27 a little Pull the control for height adjust ment upward and check that the lock cylinder 25 can move freely If not loosen screw 27 and if necessary also screw 28 a little 92 Service Procedures Group 85 Upholstery 8526 03 02 10 Service Procedures Seat Height Level Control Valve Replacement 14 Level Control Valve 15 Screws 17 Screw 23 Hose 24 Hose 94 Hose N DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death T8006498 95 Hose 96 Hose 97 Hose 10
39. carrier rail Torque to 2 0 3 Nm 18 3 in lb Install the 6 screws with their rubber washer over the windshield Torque to 3 0 5 Nm 27 4 in lb 15 Install the lower mattress work station cushions to the vehicle 58 Socket 8 mm Torque wrench 5 0 8 Nm 44 7 in lb Torx 25 Socket 8 mm Torque wrench 2 0 3 Nm 18 3 in lb 3 0 5 Nm 27 4 in lb Service Procedures Group 85 Upholstery 8554 03 02 05 Headliner Replacement Front Upper N DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death VN660 Removal 1 Begin by removing the front lower headliner see Headliner Replace ment Front Lower page 55 2 Remove the upper right bunk storage cabinet as follows Remove the 4 wall mounting bolts Re move the bolt and spacer between the upper and lower cabinet Unplug the power supply connector and remove the cabinet from the vehi cle Torx 40 Socket 10 mm 3 Remove the upper left bunk storage cabinet by removing the 4 wall mount ing bolts Remove the cabinet from the vehicle Torx 40 Service Procedures 4 ep Remove the bunk curtain rail assem bly W8002490 Torx 25 W8002512 Socket 13 mm Torx 20 Remove the right front overhead stor age compartment as follows Remove
40. ce Procedures 6 Install the A pillar trim Secure with the molding clip Repeat on opposite side 7 Install the grab handle Torque the bolt to 24 4 Nm 18 3 ft lb Replace the bolt cover trim Repeat on opposite side 8 Install the door seals 9 Install the front curtain rail assembly Use caution not to deform the rail as sembly Position the rail and snap it into the re taining clips 10 Install the driver side window visor as sembly Torque to 5 0 8 Nm 44 7 in lb Install the screw covers 11 Install the front overhead storage cabi net assembly carrier rails Torque to 24 4 Nm 18 3 ft lb 12 Socket 12 mm Torque wrench 24 4Nm 18 3 ft lb Socket 8 mm Torque wrench 5 0 8 Nm 44 7 in lb Torx 40 Torque wrench 24 4Nm 18 3 ft lb Install the front right overhead storage cabinet Install the 4 mounting screws with their rubber washer to the carrier rail Torque to 2 0 3 Nm 18 3 in Ib Install the 6 screws over the wind shield Torque to 3 0 5 Nm 27 4 in lb Install the mounting screw covers W8002510 Torx 25 Socket 8 mm Torque wrench 2 0 3 Nm 18 3 in Ib 3 0 5 Nm 27 4 in lb 57 Group 85 Upholstery 13 Install the right sun visor Torque to 5 0 8 Nm 44 7 in Ib 14 ws002511 Install the front left overhead storage bin sun visor assembly Install the 4 mounting screws with their rubber washer to the
41. e 5 wall mounting bolts 3 Torque to 24 4 Nm 18 3 ft Ib Install the 6 bolts between the upper and lower cabinet 1 Torque to 24 4 Nm 18 3 ft lb Note The lower cabinet door hinges may need to be temporarily removed to install the 2 front bolts Re install hinges after the bolts between the up per and lower cabinet have been tightened Install the 5 bolts to the rear bottom wall 2 Torque to 10 1 5 Nm 7 1 ft lb Torque all cabinet mounting bolts Install the bracket that holds the inter lock fastener to the cabinet Secure the upper front trim panel with the in terlock fasteners Connect the power supply connectors W8002495 Torx 40 Torx 30 Torx 20 Socket 12 mm Socket 13 mm Phillips screw driver Torque wrench 24 4 Nm 18 3 ft Ib 24 4 Nm 18 3 ft Ib 10 1 5Nm 7 1 ft lb its mounting location Secure the panel to the tower cabinets with the plastic stud nuts Secure the panel to the wall with screws Torque to 3 0 5 Nm 27 4 in lb 13 Secure the lower left trim with Christ mas tree and or interlock fasteners W8002493 Connect the bunk master control panel connectors 2 Using the 6 screws 1 install the bunk master control panel into the left bunk fascia panel Phillips screw driver 51 Group 85 Upholstery 15 Install the left tower cabinet drawer Connect the sink plumbing and electri cal connectors if equipped Install the draw
42. e light wire through 18 3 ft lb the lower access hole 5 1Nm Install the 4 wall mounting bolts 3 44 9 in b Torque to 24 4 Nm 18 3 ft lb Connect the interior light 2 and power supply connector Install the TV support plate with its 6 screws 1 Torque to 5 1 Nm 44 9 in Ib Note Position of long and short over bunk cabinets may vary between RH and LH side locations Note TV support plate may be omit ted in some short overbunk cabinets 11 Install the mattress in the vehicle 37 Group 85 Upholstery 8554 03 02 03 Headliner Replacement Bunk AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death VN660 Removal 1 Remove the mattress from the vehicle 2 Remove the upper right cabinet as fol lows Disconnect the HVAC duct in the wardrobe from the duct in the upper cabinet Remove the bolt and spacer between the upper and lower cabinet Disconnect the power supply connec tor Finally remove the 4 wall mounting bolts and remove the cabinet from the vehicle W8002490 Remove the bunk curtain rail assem Torx 25 bly Note The curtains do not need to be removed from the rail 38 Service Procedures 4 Remove the upper bunk mounting bolts two 12 mm and two 16 mm bolts and remove the
43. e movement and can cause serious personal in jury or death See Fig 10 Seat base exploded view page 97 30 1 Release the bellows at the front and side of the upper frame Block the seat in its upper position using a 150 mm 6 in long spacer X placed between the frames 2 Remove the lock washer at the upper shock bushing and remove the screw at the lower shock bushing 98 Group 85 Upholstery 8118 03 02 01 Engine Cover Replacement N DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death Removal 1 Remove passenger seat see Seat Replacement page 73 2 Remove the scuff plates in the door opening on both the passenger and driver sides 3 Remove the lower dash panel 4 Pull floor mat back on the right side and lay to the side toward the shift lever to uncover the engine cover Pull back mat on the left side W8002525 Remove the 4 bolts holding the engine 12 mm socket cover to the floor and cowl 6 Pull cover back slightly and swing out from under the dash panel Lift out of the cab Service Procedures Installation 1 Lift engine cover into the cab Place on the floor and slide up under the dash panel Line up the holes for the top bolts and enter the bolts Line up the rear bolt holes Tighten
44. e serious personal in Remove the screws 20 pull the drive jury or death cables out of the worm gear units and lift out the motor unit See Fig 5 Seat backrest exploded view page 87 A 3 Remove four screws 21 and two screws 26 for the worm gear units 87 Group 85 Upholstery 8526 03 02 05 Seat Motor Replacement Up per Backrest Tilt J N DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death See Fig 5 Seat backrest exploded view page 87 B 1 Remove cover for upper backrest Dis connect wire connections at the motor 2 Remove the screws 16 pull out of the drive cable and lift out the motor Remove locking plate 38 and pull the drive cable out of the worm gear unit 3 Remove the lock washer 5 and shaft 4 Remove the screw 7 88 Service Procedures 8526 03 02 18 Seat Control Unit Replacement N DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death See Fig 5 Seat backrest exploded view page 87 C 1 Remove cover for lower backrest Pull all connectors out of the control unit 2 Remove the two screws 19 and re
45. eadliner After all screws have been removed and the headliner drops dis connect the lamp assembles and remove the headliner from the vehicle Use caution not to bend the headliner to the point at which a permanent crease will show in the material Note In older vehicles built 1998 and before the headliner may also be fas tened with interlocking fasteners Service Procedures Installation 1 W3003110 Roof plate Roof panel Headlining Fully engage fasteners pressing firmly AUNI Note the location of all interlocking fasteners on the headliner to aid in in stallation Position the headliner in the cab below its mounting location Con nect the lamp assembly connectors Note Use caution not to bend the headliner to the point at which a permanent crease will show in the ma terial 2 Lift the headliner assembly into posi tion Temporarily secure with a few interlocking fasteners 3 If equipped install the 2 retaining clips in the center of the headliner Secure by pressing in the center button 4 If equipped install the 2 Christmas tree fasteners in the center of the headliner 23 Group 85 Upholstery Service Procedures W3003095 1 Curtain rail or trim washer 2 Plastic spacer 3 Cab metal 4 Headliner 5 Screw Line up the mounting screws for the Torx 15 front curtain rail assembly Add the ny 3 0 5Nm lon spacers between headliner and 27 4 in lb cab screw holes Install all scre
46. ed to be removed from the rail 9 Remove the bezels for the front over head roof storage pockets Note Use caution not to break the bezel mounting post 30 Service Procedures 10 W8001428 Remove the front curtain rail assem Slotted screw bly Use a wide blade screw driver to driver carefully pry the rail out of one side then the other side on each retaining clip After all retaining clips are re leased remove the front curtain rail assembly from the vehicle Note Use caution not to deform the rail assembly 11 W3003095 Curtain rail or trim washer Plastic spacer Cab metal Headliner Screw arkwWON Remove the screws securing the front Torx 15 and sides of the headliner Note The screws are equipped with plastic spacers between the headliner and the cab sheet metal Use caution not to lose them during headliner re moval Group 85 Upholstery 12 W3003260 1 Plastic rivets day cab vehicle only 2 Molding clip 3 Grab handle bolt cover Remove the upper grab handle bolt Socket 12 mm cover from the A pillar trim Remove the bolt and pull the upper grab handle out of the cover Repeat on the other side Pull the door seal away from the A pillar trim and the top of the door Remove the molding clip by pressing in the center button Remove the A pillar trim Repeat on opposite side 13 Remove all the screws that holds the headliner After all screws have been removed a
47. eft hand cover Remove the three screws 45B and remove the switch panel K See illustration 2 Pull apart the connector 24 on the relay box Pull apart the wire holders and pull the wire with the connector out of the seat frame and hole 25 3 Install the panel in the reverse order of removal Test seat for function 8523 03 02 02 Seat Cushion Base Replace ment AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death See illustration Fig 1 Seat Exploded View page 75 L 1 Remove the seat cushion see A Re move the screws 43 Pull the seat cushion base L forward See illustra tion 2 Install the seat base in the reverse or der of removal Test seat for function 80 Service Procedures 8524 03 02 04 Seat Backrest Air Cushion Re placement N DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death See illustration Fig 1 Seat Exploded View page 75 M 1 Remove backrest cushion see B Pull off the three rubber hoses from the air cushions connections Unhook the air cushions holder from the stay 27 See illustration
48. embly Install the 4 mounting screws with their rubber washer to the carrier rail Torque to 2 0 3 Nm 18 3 in lb Install the 6 screws with their rubber washer over the windshield Torque to 3 0 5 Nm 27 4 in lb ws002511 Torx 25 Socket 8 mm Torque wrench 2 0 3 Nm 18 3 in lb 3 0 5 Nm 27 4 in lb 33 Group 85 Upholstery 8554 03 02 03 Headliner Replacement Bunk AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death VN610 Removal 1 Remove the mattress from the vehicle W8002514 Remove the upper right cabinet as fol Torx 40 lows Torx 30 Remove the TV support plate by re moving the 6 screws 1 Unplug the interior light 2 and power supply connector Remove the 4 wall mounting bolts 3 Remove the cabinet from the vehicle Note Position of long and short over bunk cabinets may vary between RH and LH side locations Note TV support plate may be omit ted in some short overbunk cabinets 34 Service Procedures W8002513 Remove the left overbunk cabinet as Torx 40 follows Torx 25 Remove the interior light connector cover plate 1 with its 3 screws and unplug the light connector Remove the mounting screw covers and remove the 8 wall mounting bolts 2 including the
49. eople are required for this step 13 Install the sleeper curtain rail assem bly Torque the screws to 5 1 Nm 44 9 in lb 14 Install the upper right cabinet as fol lows Loosen the lower duct inside the wardrobe Lift the cabinet into position and insert the power supply wiring and coaxial cable Fit the cabinet over the HVAC duct at the rear of the cabinet Install the 4 wall mounting bolts and torque to 68 7 Nm 50 5 ft lb Install the duct inside the wardrobe by sliding it up into the duct behind the upper cabinet Install the through bolt and spacer be tween the upper and lower cabinet Torque to 12 2 Nm 106 18 in Ib 15 Install the mattress in the vehicle W8002457 Socket 16 mm Torque wrench 68 7 Nm 50 5 ft lb Socket 12 mm Socket 16 mm Torque wrench 24 4Nm 18 3 ft lb 68 7 Nm 50 5 in lb Torx 25 Torque wrench 5 1Nm 44 9 in lb Torx 40 Socket 10 mm Torque wrench 68 7 Nm 50 5 ft lb 12 2 Nm 78 1 5 ft lb Group 85 Upholstery 8554 03 02 03 Headliner Replacement Bunk Z N DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death VN770 Removal 1 Remove the lower mattress work sta tion cushions from the vehicle W8002490 Remove the bunk curtain rail assem T
50. er stop Torx 20 Socket 7 mm Slotted screw driver TOT MAUI Install the refrigerator if equipped as follows Place the refrigerator on the floor just in front of the cabinet Connect the 12 V power supply using the locking connector Align the refrigerator mounting brack ets with the floor tracks and slide it as far back on the tracks as possible Open the refrigerator door and install the locks in the floor mounting rail 1 Torque to 13 2 Nm 10 1 5 ft lb 17 Position the upper right tower cabinet into its mounting location Work the cabinet around trim panels and pull wiring through the cabinet as neces sary Note This step requires 2 people 52 W3002102 Torx 30 Torque wrench 13 2 Nm 10 1 5 ft lb Service Procedures 18 Install the upper right tower cabinet as follows Start all cabinet mounting bolts before beginning tightening Install the 5 wall mounting bolts 3 Torque to 24 4 Nm 18 3 ft lb Install the 6 bolts between the upper and lower cabinet 1 Torque to 24 4 Nm 18 3 ft lb Install the 5 bolts to the rear bottom wall 2 Torque to 10 1 5 Nm 7 1 ft lb Torque all cabinet mounting bolts Install the bracket that holds the inter lock fasteners to the cabinet Secure the upper front trim panel with the in terlock fasteners Connect the power supply connectors W8002492 Torx 40 Torx 30 Torx 20 Socket 12 mm Socket
51. ge Torx 40 cabinet assembly carrier rails 3 bolts holds each carrier rail 5 Remove the window visor on the drivers side Remove the 2 covers to gain access to the 2 screws Socket 8 mm W8002507 Remove the front curtain rail assem Slotted screw bly Use a wide blade screwdriver to driver carefully pry the rail out of one side Torx 15 then the other side on each retaining clip Remove the rail assembly from the vehicle Note Use caution not to deform the rail assembly 55 Group 85 Upholstery Service Procedures 7 12 Remove the upper grab handle bolt Socket 12 mm Remove the lamp assemblies for in Torx 20 cover from the A pillar trim Remove stallation in the replacement headliner the bolt and pull the handle out of the cover Repeat on opposite side 8 Pull the door seal away from the A pil lar trim at the top of the door Remove the molding clip by pressing in the center button Remove the A pillar trim Repeat on opposite side 9 Check the retaining clips used to at Torx 15 tach the front curtain rail assembly and remove all that are attached with screws Note Nylon spacers are used be tween the headliner and cab mounts Note their position for re assembly 10 Remove the front curtain snap obunk Torx 15 center trim panel screw VN660 built 11 99 and after Remove the plastic trim covers at the rear end of the headliner 11 Ww8002508 Pull down the front of the headli
52. ght cabinet as fol lows Insert the power supply and coaxial cable through the upper cabinet ac cess hole Insert the light wire through the lower access hole Install the 4 wall mounting bolts 3 Torque to 24 4 Nm 18 3 ft lb Connect the interior light 2 and power supply connector Install the TV support plate with its 6 screws 1 Torque the screws to 5 1 Nm 44 9 in Ib Note Position of long and short over bunk cabinets may vary between RH and LH side locations Note TV support plate may be omit ted in some short overbunk cabinets 14 Install the driver side window visor as sembly Torque the screws to 5 0 8 Nm 45 7 in lb Install the screw covers Torx 40 Torx 30 Torque wrench 24 4Nm 18 3 ft lb 5 1Nm 44 9 in lb Socket 8 mm 5 0 8Nm 45 7 in lb Service Procedures 15 If removed install the front right over head storage cabinet Install the 4 mounting screws with their rubber washer to the carrier rail Torque to 2 0 3 Nm 18 3 in lb Install the 6 screws over the wind shield Torque to 3 0 5 Nm 27 4 in lb Install the mounting screw covers 16 Install the right sun visor Torque to 5 0 8 Nm 44 7 in lb 17 w8002510 Torx 25 Socket 8 mm Torque wrench 2 t 0 3 Nm 18 3 in Ib 3 0 5 Nm 27 4 in lb Socket 8 mm Torque wrench 5 0 8 Nm 44 7 in lb Install the front left overhead storage bin sun visor ass
53. h curtain hold back snap fitting to allow removal of the plastic trim cover W8002462 J 38778 The panel is now held in place with Christmas tree and interlocking fasten ers Disengage fasteners and remove the panel from the vehicle 39 Group 85 Upholstery W8002458 Phillips screw Remove the right side bunk window trim bezel driver 15 Remove the speaker assembly from Torx 25 the right side bunk headliner panel as follows Remove the speaker cover remove the 4 screws and finally disconnect the connector on the back 16 The right side bunk headliner panel is J 38778 held in place with an upper trim support piece and Christmas tree fas teners Remove the panel as follows Disengage fasteners pull the wires out through the cut out and remove the panel from the vehicle 40 Service Procedures Installation 1 Install the right side bunk headliner panel as follows Place the panel in position and insert the power supply and coaxial cable through the cut out in the panel Work the panel behind the overhead storage cabinet and under the front headliner After positioning the panel install the upper trim support piece and secure all with Christmas tree fasteners Note Two people are required for this step 2 Install the speaker in the right side Torx 25 bunk headliner panel as follows Torque wrench Connect the connector on the back 3 0 5Nm install the speaker and torque the 4 2
54. he valve unit clamping hooks 22 to the side and release the control unit I See illustration 2 Pull the three air cushion air hoses from the valve unit Pull rubber hose 32 for side support cushions apart at connection 66 Remove rubber hose 63 from distribution pipe 67 3 Press out the switch J and discon nect the connector 50 4 Install the valve in the reverse order of removal Test seat for function 8526 03 02 01 Seat Heater Switch Replace ment N DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death See illustration Fig 1 Seat Exploded View page 75 J 1 Remove control button 3 Push valve unit clamping hooks 22 to the side Remove control unit I Push switch J out and disconnect connector 50 See illustration 2 Install the switch in the reverse order of removal Test seat for function 79 Group 85 Upholstery 8526 03 02 02 Seat Adjustment Switch Panel Replacement AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death See illustration Fig 1 Seat Exploded View page 75 K 1 Remove the seat frame l
55. hree clips fastening the trim panel to the tower cabinet re move the trim panel Service Procedures Group 85 Upholstery ws8002178 Remove the 6 torx screws holding the Torx 25 ducting from the bunk HVAC unit to the right bunk fascia panel W8002180 Remove the duct hose in the upper Torx 25 right tower cabinet from the right bunk fascia panel 12 5 Pull back the lower right trim panel to J 38778 expose the lower right bunk fascia panel mounting screws This panel is secured with Christmas tree and or in terlock fasteners W8002179 Remove 5 torx screws 3 along the top Torx 25 and 2 behind the trim panel mounting Socket 11 mm the vent fascia to the wall Remove the eight nuts from the plastic studs Remove the fascia panel from its mounting location and remove it from the vehicle Group 85 Upholstery Tower Cabinets Removal 1 W8002492 Remove the upper right tower cabinet Torx 40 as follows Torx 30 Remove any objects stored in the cab Torx 20 inet Socket 11 mm Unplug the power supply connectors Socket 12 mm Remove the 5 bolts from the rear bot tom wall 2 Remove the 6 bolts between the upper and lower cabinet 1 Pull the upper front trim panel back to expose the upper front wall mounting bolt Remove the bracket from the cab inet that holds the interlock fastener Pull back the B pillar trim to expose the lower front wall mounting bolt Remove the
56. ission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death 27 Screw 140 Cable Pulley 141 Cam Disc 147 Bolt 148 Spring See Fig 9 Seat cam disc page 95 141 1 Release the bellows from the front and side of the upper frame Block the seat in one of the lower positions Remove the level control valve 14 2 Remove the lock washer 18B and pull out the bolt 147 Pull the 7 step cam disc 141 off from the cable pul ley 140 Install the components in reverse from removal First hook the spring 148 into the cable pulley and then secure it to the plate 95 Group 85 Upholstery 8526 03 02 15 Seat Cam Disc Cable Replace ment AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death See Fig 9 Seat cam disc page 95 142 1 Release the bellows at the front and side of the upper frame Block the seat in its upper position using a 150 mm 6 in long spacer X placed between the frames Loosen screw 27 a little and lightly press the guide disc unit 13 lever plates apart where they are connected to the control cylinder 11 and move them to one side 2 Remove the lock washer 18A and take off the cover washer Unhook the cable at
57. ist J 38778 mas tree fasteners in the skylight headliner Carefully work the skylight headliner out from under the bunk headliner and out of its mounting location Remove it from the vehicle Service Procedures Installation 1 Q Tey o S O W8002516 Install the replacement skylight head liner into its mounting location Secure with the 3 Christmas tree fasteners Note Use caution not to bend the headliner to the point at which a permanent crease will show in the ma terial 2 Install the 2 shark fin dividers to the center compartment shelf as follows Place the dividers in their mounting lo cation Secure the mounting screws and re position the carpet Install the 2 support rods tubes and bracket assemblies Torque the rods to 24 4 Nm 18 3 ft lb 3 Install the left front overhead storage compartment as follows Install the compartment into the vehicle and carefully work the com partment into its mounting location Torque the 5 bottom mounting screws Install the rear support rod and torque to 24 4 Nm 18 3 ft lb Secure the bezel net screws to the center overhead storage compartment Socket 13 mm Torx 20 Torx 15 Torque wrench 24 4 Nm 18 3 ft lb Socket 13 mm Torx 20 Torque wrench 24 4 Nm 18 3 ft lb 67 Group 85 Upholstery ws002512 Install the right front overhead storage Socket 13 mm compartment as follows
58. ist the worm gear unit and spindle nut 27 out of the attachment 65 86 Service Procedures 8526 03 02 17 Seat Electro Pneumatic Height Control Valve Replacement N DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death See Fig 4 Seat base exploded view page 85 D 1 Remove the seat cushion and seat cushion base Block the seat in its up per position Release the bellows from the front and left hand side of the seat frame 2 Pull the hose 61 off from the distribu tion pipe 62 Remove the screws 59 for both valves and disconnect the connector and compressed air hose for the valve being changed 3 Install components in the reverse or der of removal Group 85 Upholstery Service Procedures 8526 03 02 04 Seat Motor Replacement Backrest Tilt 78006495 Fig 5 Seat backrest exploded view 4 Shaft 20 Screws 5 Lock Washer 21 Worm Gear Unit Screws 7 Screw 26 Worm Gear Units Screws 16 Screws 27 Air Cushions 19 Control Unit Screws 38 Locking Plate 1 Remove cover for the lower backrest Disconnect motor wire connections J N DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected 2 vehicle movement and can caus
59. k headliner 28 The center bunk headliner is now held in place with interlocking fasteners and the mating headliner components Dis engage fasteners Begin at the front and carefully work the headliner out of the mating headliner components and remove from the vehicle Use caution not to crease the headliner panels or mating components during removal Note This step requires 2 people Service Procedures Installation 1 Note the location of the interlock fasteners before installation of the re placement center bunk headliner 2 Begin at the rear and carefully work the replacement headliner into its mounting location Use caution not to crease the headliner panels or mating components during installation En gage the interlock fasteners when the headliner is properly positioned Note This step requires 2 people ZON W8002499 Engage the 2 Christmas tree fasteners at the front and the 3 at the rear of the center bunk headliner 4 Install the plastic support strips be tween the bunk center and side headliners and secure with Christmas tree fasteners Use caution when bending back the side headliner pan els not to crease the material 5 Install the 2 trim strips on each side of the center bunk headliner 49 Group 85 Upholstery je hs iN gt A NX Py Install both overhead lamp assemblies as follows Connect the connector Install the as sembly and torque the 4
60. lb 7 Install the center bunk headliner and secure with Christmas tree and inter locking fasteners W8002461 Install the 2 trim strips on each side of the center bunk headliner 41 Group 85 Upholstery je W M gt A NX Ss Pp W8002459 Connect the electrical connector for Torx 25 the center bunk overhead lamp as Torque wrench sembly and install Torque the screws 3 0 5 Nm to 3 0 5 Nm 27 4 in lb 27 4 in lb 10 W8002455 Install the rear wall interior trim panel as follows First pull back the rear section of the left and right center trim panels this will aid in installation Noting the position of the Christmas tree and interlocking fasteners posi tion the rear wall trim panel high on the rear wall Slide the panel down the wall and behind the lower trim panel AND behind the left and right center trim panels After the panel is properly positioned secure with the Christmas tree and in terlocking fasteners Note Two people are required for this step 42 Service Procedures Install the upper bunk safety restraint Make sure the latch is on the right hand side Torque the bolts to 68 7 Nm 50 5 ft lb 12 Install the upper bunk by first securing the hinge bracket upper bolts Torque to 24 4 Nm 18 3 ft lb Then secure the hinge bracket with the upper bunk restraint using the lower bolt Torque to 68 7 Nm 50 5 in lb Note Two p
61. lb 48 8Nm 35 6 ft lb 3 Install the safety belt and tethers to 16 mm socket the seat Tighten to a torque of Torque wrench 70 6 Nm 50 5 ft lb 70 6 Nm 50 5 ft lb 4 Connect the air line to the fitting Fill the air tanks and let the seat air spring lift the seat up W8001407 Remove suspension cover bellows if 14 mm socket equipped Remove the four bolts hold ing the seat to the floor 73 Group 85 Upholstery Volvo Seat Removal 1 Empty the air supply line by opening drain cock on the B system tank Empty the supply line by operating the seat height button Disconnect air line from the seat Disconnect the wire connectors 2 Remove the bolts for the safety belt D loop and belt retractor from the B pillar Lay the safety belt on the seat cushion 16 mm socket W8001397 Remove the five bolts holding the seat 14 mm socket to the floor The seat is very heavy Do not attempt to lift seat out single handed Use a second person or other lifting device Failure to follow this procedure may result in personal injury Lift seat out of the cab 74 Service Procedures Installation 1 The seat is very heavy Do not attempt to lift seat up into the cab single handed Use a second person or other lifting device Failure to follow this procedure may result in personal injury Lift seat into cab and place it over the bolt holes 2 Install the five bolts holding the seat t
62. le Note Use caution not to deform the rail assembly 21 Group 85 Upholstery W3003095 Curtain rail or trim washer Plastic spacer Cab metal Headliner Screw akwWND Remove the screws securing the front Torx 15 and sides of the headliner Note The screws are equipped with plastic spacers between the headliner and the cab sheet metal Use caution not to lose them during headliner re moval 22 Service Procedures W3003260 1 Plastic rivets day cab vehicles only 2 Molding clip 3 Grab handle bolt cover Remove the upper grab handle bolt cover from the A pillar trim Remove the bolt and pull the upper grab handle out of the cover Repeat on the other side Pull the door seal away from the A pillar trim and the top of the door Remove the molding clip by pressing in the center button Remove the A pillar trim Repeat on opposite side 10 Release the 2 retaining clips in the center of the headliner by pressing in the center button Remove the retain ing clips Note May not apply depending on the interior trim level Group 85 Upholstery A OR 11 e W3003261 1 Headliner 2 Christmas tree fastener 3 Removal tool J38778 Remove the 2 Christmas tree fasten J 38778 ers in the center of the headliner with the removal tool Use caution not to damage the headliner material Note May not apply depending on the interior trim level 12 Remove all the screws that holds the h
63. ll the cover plugs into the panel 9 If equipped install the window regula tor crank on the shaft Tighten the screw Install the crank cover by twist ing it into place and pressing over the end of the crank 10 Install the door lock handle Install the screw and tighten it Install the rubber plug in the hole in the handle Torx 25 Torx 10 14 mm socket Torx 25 Torx 25 Torx 10 Group 85 Upholstery Service Procedures 8561 03 02 01 Fascia Panel and Trim Removal Bunk Replacement Upper 1 To remove the upper bunk the R H side cabinets and two trim panels must first be removed The following pro cedures are for the right side of the cab the left side is similar Removal B Pillar Trim Panel and Seat Belt Assembly Removal 1 Remove the right rear grab handle by removing the trim caps and bolts in the top and bottom of the grab handle ji W8002176 Remove the 4 bunk window trim Phillips screw bezels There are 10 screws to be re driver moved for each windows trim bezel i W8002181 Remove the seat belt by removing the hex bolt mounting the recoiler and the torx bolt for the shoulder harness bracket Pull the weather stripping away to release the trim edge W8002177 Remove the torx screws holding the Torx 25 cabinet below the lower right bunk 3 windows Remove the four clips for the carpet covering the support beam behind the passengers seat 4 Remove the t
64. lower headliner see Headliner Replacement Front Lower page 55 72 Service Procedures Group 85 Upholstery Service Procedures 8521 03 02 01 4 Seat Replacement N DANGER The seat is heavy Do not attempt to lift seat out sin gle handed Use a second person or other lifting device Failure to follow this procedure may result in personal injury Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in Lift seat out of the cab jury or death Installation Standard Seat Starano 1 Removal 1 WARNING Empty the air supply line by opening drain cock on the B system tank until The seat is heavy Do not attempt to lift seat up into the pressure is low enough that the the cab single handed Use a second person or other pressure protection valve closes lifting device Failure to follow this procedure may re Empty the supply air line to the seat sult in personal injury by raising and lowering the seat Dis connect the air line from the seat Lift seat into cab and place it over the bolt holes 2 Remove the bolts holding the seat 16 mm socket tethers and safety belt to the seat on one side and the seat tether on the Install the four bolts holding the seatto 14 mm socket other side the floor Tighten the bolts to a torque Torque wrench of 48 8 Nm 35 6 ft
65. nd conve niences These functions are electrically operated seat cushion fore aft seat cushion tilt seat fore aft com plete backrest angle upper part of backrest angle These functions are air operated upper middle and lower lumbar support cushions backrest side support cushions and seat height The seat is also equipped with heating elements in the seat cushion and lower backrest For the passenger side there is a stationary seat avail able as an option The base of the seat is a storage box that is accessed by lifting the seat cushion up All seats with exception of the Volvo seat and the sta tionary seat have tethers that extend the safety belt anchoring These tethers are not adjustable Design and Function T8006503 W8001386 W8001387 Group 85 Upholstery Design and Function Floor Covering The floor mat is made of heavy foam rubber covered with synthetic rubber It is held in place by the seats and scuff plates in the door openings The mat bottom is contour molded to fit into the floor shape for good placement W8001384 The shift lever opening for the manual shift lever is insu lated from noise dust and fumes by double boots These are screwed to the floor accessible from above W8001385 ws8002591 Manual shift lever mounting Automatic shift lever mounting Engine Cover The engine cover covers the cutout for the engine com partment It is fastened with a total of 6 screws
66. nd hinge into the mounting holes on the rear wall Torque to 68 Nm 50 ft Ib 4 Lift up the bunk from the lower posi 28 Nm tion to the upper position Install the 21 ft lb two screws through holes in the hinge valance storage area and into the bunk assembly Torque the screws to 28 Nm 21 ft lb 5 Continue with Tower Cabinets Instal lation page 14 14 Service Procedures Tower Cabinets Installation 1 Position the upper right tower cabinet into its mounting location Work the cabinet around trim panels and pull wiring through the cabinet as neces sary Note This step requires 2 people W8002492 Install the upper right tower cabinet as Torx 40 follows Torx 30 Start all cabinet mounting bolts before Torx 20 beginning tightening Socket 12 mm Install the 5 wall mounting bolts 3 Socket 13 mm Torque to 24 4 Nm 18 3 ft lb Phillips screw Install the 6 bolts between the upper driver and lower cabinet 1 Torque to Torque wrench 24 4 Nm 18 3 ft lb 24 4Nm Install the 5 bolts to the rear bottom 18 3 ft lb wall 2 Torque to 10 1 5 Nm 24 4Nm 7 1 ft lb 18 3 ft lb Torque all cabinet mounting bolts 10 1 5Nm Install the bracket that holds the inter 7 1 ft lb lock fasteners to the cabinet Secure the upper front trim panel with the in terlock fasteners Connect the power supply connectors Group 85 Upholstery Fascia Panel and Trim Installation
67. nd the headliner drops dis connect the lamp assembles and remove the headliner from the vehicle Use caution not to bend the headliner to the point at which a permanent crease will show in the material Note In older vehicles built 1998 and before the headliner may also be fas tened with interlocking fasteners Service Procedures Installation 1 Position the headliner in the cab below its mounting location Connect the overhead light connectors In older vehicles only Note the loca tion of all interlocking fasteners on the headliner to aid in installation Note Use caution not to bend the headliner to the point at which a permanent crease will show in the ma terial 2 Lift the headliner assembly into posi tion Use the front overhead roof storage pockets as a guide to assist in proper positioning W3003095 1 Curtain rail or trim washer 2 Plastic spacer 3 Cab metal 4 Headliner 5 Screw Install the mounting screws for the Torx 15 front curtain rail assembly 3 0 5 Nm Add the nylon spacers between head 25 5 in lb liner and cab screw holes Install all screws and retaining clips Torque to 3 0 5 Nm 25 5 in lb 4 Install all remaining screw to the head liner Note In older vehicles built 1998 and before the headliner may also be fas tened with interlocking fasteners Install the front overhead storage cabi Torx 40 net assembly carrier rails Torque to 24 4Nm 24 4 Nm 18 3 ft lb
68. ner and work the rear section out from under the overhead storage compart ments Disengage one interlocking fastener Disconnect the lamp connectors Remove the headliner from the vehicle Note Use caution not to bend the headliner to the point at which a permanent crease will show in the ma terial 56 Group 85 Upholstery Installation 1 Install the lamp assemblies in the re placement headliner 2 Note the location of all the interlocking fasteners on the headliner to aid in in stallation Position the headliner in the cab below its mounting location and connect the lamp assembly connectors Note Use caution not to bend the headliner to the point at which a permanent crease will show in the ma terial W8002508 Lift the headliner assembly into posi tion Work the rear of the headliner under the lip of the overhead storage compartments Temporarily secure the interlocking fasteners Note This step requires 2 people 4 Add the nylon spacers between head liner and cab screw holes Install all screws and retaining clips Torque to 3 0 5 Nm 27 4 in lb 5 Install the front curtain snap bunk cen ter trim panel screw Torque to 3 0 5 Nm 27 4 in lb Note VN660 built 11 99 and after Install the plastic trim covers before in stalling the snap bunk trim panel screw Torx 15 Torque wrench 3 0 5 Nm 27 4 in lb Torx 15 Torque wrench 3 0 5 Nm 27 4 in lb Servi
69. net Torx 40 as follows Torx 30 lead Remove any objects stored in the cab Torx 20 es te ngai gunk fagcia panel ag a inet and unplug the power supply Socket 12 mm bare connectors Socket 13 mm Pull back the lower right trim panel to Socket 11 mm expose the lower mounting screws The panel is secured with Christmas tree and or interlock fasteners Remove the 2 lower mounting screws and the 3 screws along the top Remove the 8 nuts securing the panel to the right tower cabinet Pull the fascia out from the top to clear the bottom stud Remove the 5 bolts from the rear bot tom wall 2 Remove the 6 bolts between the upper and lower cabinet 1 Pull the upper front trim panel back to expose the upper front wall mounting bolt Remove the bracket from the cab inet that holds the interlock fastener Pull back the B pillar trim to expose the lower front wall mounting bolt Re move the 5 wall mounting bolts 3 12 Remove the upper right tower cabinet from its mounting location and out of the vehicle Note This step requires 2 people 64 Group 85 Upholstery Remove the refrigerator if equipped as follows Open the door and remove the 2 mounting bolts 1 Remove both mounting strips Slide the refrigerator forward until it comes away from the stationary tracks and unplug the 12 volt connector 14 Remove the left tower cabinet drawer stops Remove the sink plumbing and electrical connectors if equi
70. nsmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death VN770 Removal 1 Begin by removing the lower front headliner see Headliner Replace ment Front Lower page 55 2 Remove the lower mattress work sta tion cushions from the vehicle W8002490 Remove the bunk curtain rail assem Torx 25 bly 62 Service Procedures W8002491 Remove both right and left seat belt J 38778 shoulder harnesses mounting bolts Torx 50 Pull back the upper rear of the door seal to loose the B pillar trim Gently pull back the B pillar trim and remove the Christmas tree fastener to the upper tower cabinets Note Use caution not to crease the trim panel 5 Remove the ladder assembly if Torx 30 equipped W8002176 Remove the 4 bunk window trim Phillips screw bezels driver Group 85 Upholstery W8002177 Remove the cabinet below the lower Torx 25 right bunk by removing the 3 torx bolts 8 A mad ay seen 4 oe eat th w8002178 Remove the duct from the bunk HVAC Torx 25 unit to the right bunk fascia panel Service Procedures W8002180 Remove the duct hose in the upper right tower cabinet from the right bunk fascia panel Torx 25 63 Group 85 Upholstery Service Procedures 11 W8002492 Remove the upper right tower cabi
71. nt page 77 Seat Headrest Replacement page 77 Seat Backrest Cover Replacement Upper page 77 Seat Backrest Cover Replacement Lower page 78 Seat Frame Cover Replacement Rear page 78 Seat Frame Cover Replacement Right Side page 78 Seat Frame Cover Replacement Left Side page 79 Seat Compressed Air Valve Replacement page 79 Seat Heater Switch Replacement page 79 Seat Adjustment Switch Panel Replacement page 80 Seat Cushion Base Replacement page 80 Seat Backrest Air Cushion Replacement page 80 Seat Control Harness Replacement page 81 Seat Motor Replacement Cushion Position page 83 Seat Motor Replacement Seat Positioning page 84 Seat Motor Replacement Cushion Tilt page 85 Seat Electro Pneumatic Height Control Valve Replace ment page 86 Seat Motor Replacement Backrest Tilt page 87 Seat Motor Replacement Upper Backrest Tilt page 88 Seat Control Unit Replacement page 88 Seat Height Control Cylinder Replacement page 89 Seat Height Setting Guide Plate Replacement page 90 Seat Height Guide Disc Unit Replacement page 91 Seat Height Level Control Valve Replacement page 93 Seat Height Two Way Valve Replacement page 94 Seat Cam Disc Replacement page 95 Seat Cam Disc Cable Replacement page 96 Seat Air Spring Replacement page 97 Seat Ver
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73. o the floor Tighten the bolts to a torque 14 mm socket Torque wrench of 48 8 Nm 35 6 ft lb 48 8 Nm 35 6 ft lb 3 Install the safety D loop and belt re Torx 40 tractor to the B pillar Tighten the bolts Torque wrench to a torque of 50 8 Nm 37 3 ft lb 50 8 Nm 37 3 ft lb 4 Push the wire connectors together Connect the air line to the fitting Fill the air tanks and let the seat air spring lift the seat up Service Procedures Group 85 Upholstery Seat Overhaul Fig 1 Seat Exploded View 75 Group 85 Upholstery Call out SrFAGC TOMmMoOWVPY o1 0 o a gt 76 Description Seat Cushion Seat Backrest Cushion Seat Headrest Seat Backrest Cover Upper Seat Backrest Cover Lower Seat Frame Cover Rear Seat Frame Cover Right Side Seat Frame Cover Left Side Seat Compressed Air Valve Seat Heater Switch Seat Adjustment Switch Panel Seat Cushion Base Seat Backrest Air Cushion Heating Element Connectors Control Button Headrest Guides Cover Washer Inside Cover Screws Frame Cover Screws Catches Clamping Hooks Relay Box Connector Seat Frame Hole Air Cushion Holder Stay Lockring Clips Outside Cover Screws Rubber Hose Frame Cover Screws Switch Panel Screws Seat Cushion Base Screws Heater Switch Connector Service Procedures See the following for procedures on the Volvo seat Seat Cushion Replacement page 77 Seat Backrest Cushion Replaceme
74. ocket 8 mm 2 Remove the right sun visor Socket 8 mm 3 If equipped remove the front right Torx 25 overhead storage cabinet Socket 8 mm Note Two screw covers on the far right facing panel must be removed to gain access to the mounting screws 4 Remove the cabinet carrier railassem Torx 40 bling screws Service Procedures 5 Remove driver side window visor as sembly Pry off the end screw covers Remove the mounting screws Socket 8 mm W8002514 Remove the upper right cabinet as fol Torx 40 lows Torx 30 Remove the TV support plate by re moving the 6 screws 1 Unplug the interior light and power supply connector 2 Remove the 4 wall mounting bolts 3 Remove the cabinet from the vehicle Note Position of long and short over bunk cabinets may vary between RH and LH side locations Note TV support plate may be omit ted in some short overbunk cabinets 29 Group 85 Upholstery Ws8002513 Remove the left overbunk cabinet as Torx 40 follows Torx 25 Remove the interior light connector cover plate 1 with its 3 screws and unplug the light connector Remove the mounting screw covers and remove the 8 wall mounting bolts 2 including the one to the lower bunk tether 3 Note In vehicles with an upper bunk the long overbunk cabinet is replaced by a short cabinet W8002490 Remove the sleeper curtain rail as Torx 25 sembly Note The curtains do not ne
75. ollows Position the cabinet into its mounting location Work the cabinet around trim panels and pull the wiring through the cabinet as necessary Note This step requires 2 people 69 Group 85 Upholstery Install the upper right tower cabinet as follows Start all mounting bolts in the cabinet before beginning tightening Install the 5 wall mounting bolts 3 and the 6 bolts between the upper and lower cabinet 1 Torque to 24 4 Nm 18 3 ft lb Install the 5 bolts to the rear bottom wall 2 and torque to 10 1 5 Nm 89 13 in lb Torque all cabinet mounting bolts Install the bracket that holds the inter lock fastener to the cabinet Secure the upper front trim panel with the in terlock fasteners Connect the power supply connectors 70 W8002492 Torx 40 Torx 30 Torx20 Socket 12 mm Socket 13 mm Phillips screw driver Torque wrench 24 4 Nm 18 3 ft lb 24 4 Nm 18 3 ft lb 10 1 5Nm 89 13 in lb Service Procedures Position the right bunk fascia panel into its mounting location Secure the panel to the tower cabinets with the plastic stud nuts Secure the panel to the wall with the 5 torx screws Torque to 3 0 5 Nm 27 4 in lb 15 Secure the lower right trim with Christ mas thee and or interlocking fasteners w8002182 Torx 25 Socket 11 mm Torque wrench 3 0 5 Nm 27 4 in lb Group 85 Upholstery Service Procedures W8002177 Install the cabinet
76. orking on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death See illustration Fig 1 Seat Exploded View page 75 C 1 Pull up the head rest to its stop posi tion Turn the cover washer 15 counter clockwise and remove the head rest by pulling it up See illustra tion 2 Install the headrest in the reverse or der of removal Test seat for function 8524 03 02 03 Seat Backrest Cover Replace ment Upper N DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death See illustration Fig 1 Seat Exploded View page 75 D 1 Pull off the backrest cushion see B Remove the head rest see C See il lustration 2 Compress the lower part of the guides 13 for the head rest push them up and remove them If the backrest cushion is locked behind the backrest frame the guides must be worked loose and pulled out Remove screws 16A and remove the cover Note Take care not to damage the catches 20 77 Group 85 Upholstery 3 Install the cover in the reverse order of removal Test seat for function 8524 03 02 02 Seat Backrest Cover Replace ment Lower J N DANGER
77. orx 25 bly Service Procedures W8002491 Remove the following in both the right J 38778 and left sides Torx 50 Remove the shoulder harness mount ing bolts 1 Pull back the upper rear of the door seal to loosen the B pillar trim Gently pull back the B pillar trim and remove the Christmas tree fastener 2 to the upper tower cabinets Note Use caution not to crease the trim panel 4 Remove the bunk ladder assembly Torx 30 if equipped 43 Group 85 Upholstery Service Procedures W8002178 Remove the 6 torx screws holding the Torx 25 ws002176 ducting from the bunk HVAC unit to na the right bunk fascia panel Remove the 4 bunk window trim Phillips screw bezels There are 10 screws to be re driver moved for each windows trim bezel Li NY Y W8002177 Remove the torx screws holding the Torx 25 cabinet below the lower right bunk windows W8002180 Remove the duct hose in the upper Torx 25 right tower cabinet from the right bunk fascia panel 44 Group 85 Upholstery 9 Pull back the lower right trim panel to expose the lower right bunk fascia panel mounting screws This panel is secured with Christmas tree and or in terlock fasteners J 38778 10 W8002179 Remove 5 torx screws 3 along the top Torx 25 and 2 behind the trim panel mounting Socket 11 mm the vent fascia to the wall Remove the eight nuts from the plastic studs
78. otor Replacement Backrest Tilt 2 0 87 Seat Motor Replacement Upper Backrest Tilt 88 Seat Motor Replacement Cushion Tilt 2 2 85 Seat Motor Replacement Seat Positioning 84 Seat Motor Replacement Cushion Position 83 Seat Height Two Way Valve Replacement 2 94 Seat Height Level Control Valve Replacement 93 Seat Height Guide Disc Unit Replacement 91 Seat Height Setting Guide Plate Replacement 4 90 Seat Height Control Cylinder Replacement 89 Seat Cam Disc Replacement 6 6 6 we ek ee ee ee eR ee Re 95 Seat Cam Disc Cable Replacement 240 96 Seat Air Spring Replacement 2 2 522 022 2 004 97 Seat Electro Pneumatic Height Control Valve Replacement 2 86 Seat Control Unit Replacement s s ss a s sa ke aa wma ek ee we 88 Seat Headrest Replacement onono aa a 77 Seat Compressed Air Valve Replacement oaoa oa a a a 79 Seat Vertical Shock Absorber Replacement oaoa oaoa a a 98 Headliner Replacement oa oa a a a 17 Headliner Replacement Front 2 225220 21 29 Headliner Replacement Bunk 26 34 38 43 Headliner Replacement Front Lower 2 25 55 Headliner Replacement Front Upper 2 08 59 62 B
79. oved rearward and permit removal of the skylight headliner 8 Remove the center front overhead storage compartment mounts as fol lows Remove the 2 support rods Remove the bottom mounting bolts Remove the top front and side mount ing bolts Slide the mounting shelf rearward enough to allow removal of the sky light headliner 9 Remove the 1 front and the 2 rear Christmas tree fasteners in the sky light headliner 10 Carefully work the skylight headliner out from under the bunk headliner and out of its mounting location Remove it from the vehicle Note Use caution not to bend the headliner to the point at which a permanent crease will show in the ma terial 60 Socket 13 mm Torx 20 Torx 40 J 38778 Torque both bolts and rods to 24 4 Nm 18 3 ft lb 3 Engage the 2 Christmas tree fasteners on both the right and left center bunk trim panels 4 Install the left front overhead storage Socket 13 mm compartment as follows Torx 20 Install the compartment into the Torque wrench vehicle and carefully work the com 24 4Nm partment into its mounting location 18 3 ft lb Secure the bottom mounting screws Install the rear support rod Torque to 24 4 Nm 18 3 ft lb Secure the bezel net screws to the center overhead storage compartment Install the right front overhead com Socket 13 mm partment as follows Torx 20 Install the compartment into the Torque wrench vehicle and carefully
80. pped Remove the drawer Remove the bunk master control panel from the left bunk fascia panel by re moving the 6 screws 1 Disconnect the 2 top connectors 2 and allow the control panel to hang from the wiring W3002102 Torx 30 Torx 20 Socket 7 mm Slotted screw driver W8002493 Phillips screw driver Service Procedures 16 Pull back the lower left trim panel to expose the lower left bunk fascia panel mounting screws The panel is secured with Christmas tree and or in terlocking fasteners 17 Remove the screws securing the left bunk fascia panel to the wall and the nuts securing the panel to the left tower cabinet and remove the fascia panel from its mounting location Turn the bunk master control panel to fit through the cut out in the fascia panel and remove the panel from the vehicle J 38778 W8002494 Torx 25 Socket 11 mm 65 Group 85 Upholstery 18 Remove the upper left tower cabinet as follows Unplug the power supply connectors Remove the 5 bolts from the rear bot tom wall 2 and the 6 bolts between the upper and lower cabinet 1 Note The lower cabinet door hinges may need to be temporarily removed to remove the 2 front bolts Re install hinges before removing the cabinet Pull the upper front trim panel back to expose the upper front wall mounting bolt Remove the bracket from cabinet that holds the interlock fastener Pull back the B pillar trim
81. r W3003260 1 Plastic rivets day cab vehicles only 2 Molding clip 3 Grab handle bolt cover Remove the upper grab handle bolt Socket 12 mm cover from the A pillar trim Remove the bolt and pull the handle out of the cover Pull the door seal away from the A pillar trim and the top of the door Remove the molding clip by pressing in the center button Remove the plas tic rivets at the top of the A pillar trim Remove the A pillar trim Repeat on opposite side Group 85 Upholstery W3003095 Curtain rail or trim washer Plastic spacer Cab metal Headliner Screw oa ARAOUN Remove the screws securing the front Torx 15 and sides of the headliner Note The screws are equipped with plastic spacers between the headliner and the cab sheet metal Use caution not to lose them during headliner re moval 8 Release the 2 retaining clips in the center of the headliner by pressing in the center button Remove the retain ing clips Note May not apply depending on in terior trim level TT Me W3003261 1 Headliner 2 Christmas tree fastener 3 Removal tool J38778 Remove the 2 Christmas tree fasten J 38778 ers in the center of the headliner with the removal tool Use caution not to damage the headliner material Note May not apply depending on the interior trim level 18 Service Procedures 10 The headliner is now held in place by a few interlocking fasteners and the rear wall B pillar
82. reely If not loosen screw 27 and if necessary also screw 28 a little 89 Group 85 Upholstery Service Procedures 8526 03 02 12 Seat Height Setting Guide Plate Replacement AN DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death See Fig 6 Seat height control page 89 12 1 Remove the seat cushion and seat cushion base Release the bellows from the front and side of the upper frame Block the seat in its upper posi tion using a 150 mm 6 in long spacer X placed between the frames 2 Unscrew the level control valve 14 Remove lock ring 18C and remove the bolt 19 3 Pull the guide plate off from the pin 22 Install in the reverse order of re moval 90 Group 85 Upholstery 8526 03 02 11 Service Procedures Seat Height Guide Disc Unit Replacement 12 Guide Plate 13 Guide Disc Unit 18C Lock Ring 19 Bolt 22 Pin N DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death See Fig 7 Seat Height Guide Disc Unit page 91 13 T8006511 25 Lock Cylinder 26 Guide Plate Cam 27 Screw 28 Screw 107 Hose 1 Remove the se
83. se order of removal Test seat for function 82 Service Procedures Group 85 Upholstery Service Procedures 8526 03 02 08 Seat Motor Replacement Cushion Position T8006494 Fig 3 Seat base exploded view 8 Shaft 27 Spindle Nut 9 Lock Washer 37 Nut 10 Worm Gear Unit Attachment 45 Seat Motor Screws 11 Worm Gear Unit 64 Locking Plate 13 Worm Gear Unit Screw 65 Seat Motor Attachment 2 AX DANGER Remove the screws 45 pull out the drive cable and lift out the motor Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected 3 vehicle movement and can cause serious personal in Remove worm gear unit locking plate jury or death 64 Remove lock washer 9 and shaft 8 Remove the screw 13 then twist the worm gear unit and spindle nut 11 out of the attachment 10 See Fig 3 Seat base exploded view page 83 A 1 Remove the seat cushion and seat cushion base Disconnect the wire connectors at the motor 83 Group 85 Upholstery Service Procedures 8526 03 02 07 Seat Motor Replacement Seat Positioning N DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death See Fig 3 Seat base exploded view page 83 B 1 Remove
84. the 3 bezel net screws to the center overhead storage compartment Disconnect any electrical components if equipped Remove the rear support rod 1 Remove the 5 bottom mounting screws 2 Carefully work the compartment out of its mounting location back and around the bunk headliner trim Remove it from the vehicle 59 Group 85 Upholstery 6 Remove the left front overhead stor age compartment as follows Remove the bezel net screws to the center overhead storage compartment Remove the rear support rod Remove the bottom mounting screws Carefully work the compartment out of its mounting location back and around the bunk headliner trim Remove it from the vehicle Socket 13 mm Torx 20 7 Disengage the 2 Christmas tree fas teners on both the right and left center bunk trim panels directly behind the front overhead storage compartment mounting shelf This will allow the Service Procedures Installation 1 Install the replacement headliner into its mounting location Secure with the 3 Christmas tree fasteners Note Use caution not to bend the headliner to the point at which a permanent crease will show in the ma terial 2 Slide the front overhead storage com Socket 13 mm partment mounting shelf forward into Torx 20 its mounting position Torx 40 Secure the bottom front top front and Torque wrench side mounting bolts 24 4Nm Install and secure the 2 support rods 18 3 ft lb shelf to be m
85. the bolts 12 mm socket W8002525 12 mm socket 24 4Nm 18 3 ft lb Place floor mat back into position In stall scuff plates Tighten screws and install the plugs Torque the screws to 24 4 Nm 18 3 ft lb 3 Install the lower dash panel 4 Install seat see Seat Replacement page 73 99 100 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 Volvo Trucks North America Inc 0 han eeeeececeeeeteeeceeeeeeeeeteeeeeeeeeeeeeeeeeeeeeeeestetetsessseseseeees Dept 516 Service Publications a eeeeteetetteteteeteaeeteeeteaeeeeeeeeaeeteaeeseaeeeeeseneeeneeeenes 7825 National Service Road ae eeeteettteeteateteaeeeteetaceeeeueeteaeeteaeeseaeeseeteeneeteneeeaes PO Box 26115 00 eeezade rab bh edeheuete den a debs der vahlich debi ctlicedesseeh Panes Greensboro NC 27402 6115 0 iaeeeettteceeeeececsscneeeececccnaaeeeeeceesceceaeeeeeseesnaaeeeeeeeess USA Fax 336 393 3170 Comments proposals 8118 03 02 01 8511 03 02 01 8521 03 02 01 8522
86. tical Shock Absorber Replacement page 98 Group 85 Upholstery 8523 03 02 01 Seat Cushion Replacement N DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death See illustration Fig 1 Seat Exploded View page 75 A 1 Pull the seat cushion out of the clamps 1 Disconnect the connector r for the seat cushion heating element 2 Install the cushion in the reverse order of removal Test seat for function 8524 03 02 01 Seat Backrest Cushion Re placement N DANGER Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death See illustration Fig 1 Seat Exploded View page 75 B 1 Pull the backrest cushion off from the backrest frame Remove the backrest covers see D and E Remove the lockring clips 28 for the cushion clamps See illustration 2 Disconnect the connectors r and 0 for the seat cushion and backrest cushion heater elements Separate the rubber hose 32 at the connection 3 Install the backrest in the reverse or der of removal Test seat for function Service Procedures 8529 03 02 01 Seat Headrest Replacement N DANGER Before w
87. trim Pull the door seal away from the top of the B pillars Pull the B pillars trim away at the top to allow removal of the headliner Pull the front of the headliner down and lift up on the rear to free the rear headliner lip Disconnect the lamp as sembles and remove the headliner from the vehicle Note This step requires 2 people Use caution not to bend the headliner to the point at which a permanent crease will show in the material Installation 1 Install the headliner in the vehicle Connect the lamp assembles Note the position of the interlocking fasteners Start with the front of the headliner down and lift up on the rear to engage the rear headliner lip behind the rear wall trim At the same time work the side edges behind the B pillar trim Note Two people are required for this step Group 85 Upholstery W3003095 Curtain rail or trim washer Plastic spacer Cab metal Headliner Screw ahwWND With one person holding the headliner Torx 15 allow the front of the headliner down enough to install the mounting screws The mounting screws and the trim should be installed up through the headliner and a spacer installed be tween each screw and the cab mounting holes A thin plastic lip on the spacer will hold it in mounting po sition After all screws and spacers are in place carefully lift the headliner up to the roof Note Two people are required for this step Service Procedures
88. umber PV776 TSP133527 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 MTV atic payee asain IEEE TAIE NE T E E TENE N TN 3 Genen Pecali lons ae eee eg a ore eee E aN 4 Design atd PUMCUGIN isccegsrsia o 5 Miena Doar FANSE sian eee ere eee See e eee see ree eee 5 PU eA PAREI saa patsy png nucdecve teas vanoadeeapadcasaeos mua egor ues aR 5 Re asics stain E A EEA A AEA E A E E R Naas 5 Foo Corong seinen 7 Enone OUVE soretes eaei E SEA T Headings aasre a 8 Service Pro duresS aicseceissedecssssessicassecdsdsenaansnterasssneeraiesiosaecabelanesabeianens 9 Door Panel Replacement scessricicunncasuzesncaanunacsyncasiessniadnengntasucetuianlanteass 9 Bunk Replacement Upper eeessessesesceeeresssneeeeneeeseeeeseeesseneeeners 11 Removal rnibrunpsei an a 11 Headliner Replacement siccsetcsnsscidincaratcsaasaradanincatuaciaeadundiesdaneaudainhsians 17 Dar CaN nunen 17 Headliner Replacement Front cccceceeeeceeeeeeeeeeeeeeeeeeseeeeeeeeees 21 MRA E A E T E E E E 21 Headliner Replacement Bunk ccceeeeeeceeeeeeeeeeeeeeeeeeeeeeeeseees 26 VASO sexe ssguarennees iardetasais teeerantennieis cm AA 26 Headliner Replaceme
89. unk Replacement Upper lt o s s ssor atoa a mo a O a 11 VOLVO 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 Awww volvotrucks volvo com PV776 TSP133527 1 000 02 2000 Volvo Trucks North America Inc 2000
90. ve the 6 screws 1 disconnect the two connectors at the top 2 and let the bunk master control panel hang from the wiring harness 17 Pull back the lower left trim panel to expose the lower left bunk fascia panel mounting screws The panel is secured with Christmas tree and or in terlock fasteners W8002493 Phillips screw driver J 38778 Group 85 Upholstery 18 6 K Ta i gt AX W8002494 Torx 25 Socket 11 mm Remove the screws securing the left bunk fascia panel to the wall and the nuts securing the panel to the left tower cabinet and remove it from its mounting location Turn the bunk master control panel to fit through the cut out in the fascia panel and remove the fascia panel from the vehicle Service Procedures 19 W8002495 Remove the upper left tower cabinet Torx 40 as follows Torx 30 Remove any objects stored in the Torx 20 cabinet Unplug the power supply con Socket 12 mm nectors Socket 13 mm Remove the 5 bolts from the rear bot Phillips screw tom wall 2 Remove the 6 bolts driver between the upper and lower cabinet 1 Note The lower cabinet door hinges may need to be temporarily removed to remove the 2 front bolts Re install hinges before removing the cabinet Pull the upper front trim panel back to expose the upper front wall mounting bolt Remove the bracket from the cabinet that holds the interlock fastener Pull back the B pillar trim
91. ws and retaining clips Torque to 3 0 5 Nm 27 4 in lb W3003260 6 1 Plastic rivets day cab vehicles only Install all remaining screw to the head 2 Molding clip liner 3 Grab handle bolt cover Note In older vehicles built 1998 and Install the A pillar trims Secure with before the headliner may also be fas the molding clips tened with interlocking fasteners 9 7 Install the grab handles Torque to Socket 12 mm Install the front overhead storage cabi Torx 40 24 4 Nm 18 3 ft lb 24 4 Nm 18 3 ft lb 18 3 ft lb 10 Install the door seals 11 Install the front curtain rail assembly Position the rail and snap into the re taining clips Note Use caution not to deform the rail assembly 12 Install the sleeper curtain rail assem Torx 25 bly Torque to 3 0 5 Nm 25 5 in lb 3 0 5Nm 25 5 in lb 13 Install the driver side window visor as Socket 8 mm sembly 5 0 8 Nm Torque the screws to 5 0 8 Nm 45 7 in lb 45 7 in lb and replace the screw covers 24 Group 85 Upholstery 14 Install the front right overhead storage cabinet if equipped as follows Install the 4 mounting screws with their rubber washer to the carrier rail Torque to 2 0 3 Nm 17 3 in lb Install the 2 screws over the wind shield Torque to 3 0 5 Nm 25 5 in lb Install the mounting screw covers 15 Install the right sun visor Torque to 5 0 8 Nm 45 7 in Ib 16 Install

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