Front Bumper
Contents
1. Service Procedures 6 a EGS Ve W 8000973 Torque the cab bumper nuts and bolts 85 15 Nm to 85 15 Nm 63 11 ftlb 63 11 ft lb 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 Dept 516 Service Publications iii 7825 National Service Road P O Box 26115 Greensboro NC 27402 6115 USA Fax 336 393 3170 Comments proposals 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 www volvotrucks volvo com PV776 TSP103726 1 1000 12 1997 Volvo Trucks North America Inc 19972. bumper There are two front bumpers available for the VN series vehicles The standard is the SMC sheet molded com pound bumper This bumper is molded from a fiberglass type material It is exceptionally strong and lightweight The SMC bumper design is aerodynamic and includes the front air dam and the fog lamp and driving light recesses Mounting studs have been molded into the ma terial for mounting the bumper to the mounting brackets The optional bumper is the steel five piece bumper This bumper is bolted on with two bolts and nuts on each Side Its five piece design consists of replaceable plastic ends and a two piece removable plastic air dam The fog lamps and driving lights are mounted to a bracket that mounts under the steel bumper Group 86 Front Bumper General Group 86 Front Bumper Specifications Specifications Front Bumper SMC front bumper 2274 mm 2574 mm ALL AROUND X W8001080 ren 1 SMC front bumper 2 Hood Specification Chart SMC Front Bumper Torque Chart SMC Front Bumper Bumper to mounting bracket nuts 65 15 Nm 63 11 ft lb Mounting bracket to chassis bolts 200 30 Nm 148 22 ft lb Tow eye storage bolts 48 8 Nm 35 6 ftlb Group 86 Front Bumper Specifications Steel front bumper 7to 13 mm VNL and VNM a 30 to 36 mm ALL AROUND S W8002127 1 Steel bumper 2 Hood Specification Chart Steel Front Bumper Bumper to hood gap 30 36 mm Mounting brack
3. bumper mounting brackets to the chassis N W 8000992 Center the side to side bumper align ment by measuring the distance from the side of the hood to the side of the bumper Slide the bumper right or left as necessary until the measurement is equal on both sides Service Procedures u av i W8002129 Using the Kent Moore J 42764 1 gauge block on a VNM steel bumper Note Before checking the bumper to hood gap the vehicle air system must be at full capacity and the hood must be closed and latched Using the Kent Moore J 42764 1 Gauge Block between the cab bumper and the hood move the bumper as sembly as necessary to attain the proper gap between the bumper and the hood and to attain the proper fore and aft adjustment Note On all VNL models Because of a slightly different hood curvature on the VNL the gauge block should be placed in the center of the bumper while checking the gap and fore and aft spacing Note On all VNM models To use the gauge block correctly it should be placed at the inside edge of the headlamp on each side while checking the gap and the fore and aft spacing 19 Group 86 Front Bumper Tighten the four nuts and bolts that at tach the bumper and the bumper mounting brackets Nen W8000991 W 8000978 200 30 Nm 148 22 ft lb Torque the nuts and bolts that attach the bumper mounting brackets to the chassis to 200 30 Nm 148 22 ft ID 20
4. number PV776 TSP103726 1 1997 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 213 2 y RR v bk iii k arr tent tar kek a 3 e cane a EOC INN ea b ks kondi pike rato pk os aie kiye ni ia kb ii 5 e iva 5 i KM PP e oo E O asec sede AR TW W PA aes 7 Front Bumper SPECS TOOS sueros 7 Design ana FUNGUON sra 9 ETONE INN AN A 9 componen Sg Ne dara a 9 SEIVICE PIOOCOUPOS ae een 13 Front Bumper Replacement aaa 13 Front Bumper Replacement acari 13 Front Bumper AUSTEN aaa 17 Front Bumper Adjustment session 19 Feedback Group 86 Front Bumper General General Front Bumper Introduction This service information covering front bumpers on all VN series VOLVO vehicles fer is a revision of Service Manual Front Bumper VNL VNM PV 776 TSP 28192 IMPACT previously released informa tion This information includes an update of the special tools required for bumper adjustment Also included are the service procedures for efficient front bumper removal adjustment and installation AO OA An 1 MIND IIA MN III ANNI e A _ il 111 III 1 IN IN ZII BEI W 8000925 Front
5. of a slightly different hood curvature on the VNL the gauge block should be placed in the center of the bumper while checking the gap and fore and aft spacing Note On all VNM models To use the gauge block correctly it should be placed at the inside edge of the headlamp on each side while checking the gap and the fore and aft spacing Group 86 Front Bumper Gs Ve EP 7 i if iu W8000973 85 15 Nm 63 11 ft Ib After the side to side adjustment has been completed and the bumper gap has been set tighten the nuts and then torque them to 85 15 Nm 63 11 ft lb 5 Ser ha W8000950 If the vehicle is equipped with driving 10 1Nm lights and or fog lamps reconnect the 89 9 in lb connectors and secure them with tie Straps as needed Replace the bolt to the fog lamp support bracket Torque the bracket nut to 10 1 Nm 89 9 in lb Service Procedures 8611 05 02 01 Front Bumper Adjustment SMC Bumper Gap and fore and aft adjustments eo Me o LON z gt Mr man SN o E W8000953 Loosen the three mounting bolts on each side that bolt the front bumper mounting brackets to the chassis 17 Group 86 Front Bumper W8002128 Using the Kent Moore J 42207 A gauge block on an SMC bumper VNL VNM Place the Kent Moore J 42207 A Gauge Block between the cab bumper and the hood Move the bumper as sembly as necessary to attain the proper gap b
6. Service Manual Trucks Group 66 Front Bumper VNL VNM PV776 TSP103726 1 VOLVO Foreword The descriptions and service procedures contained in this manual are based on de signs and methods studies carried out up to December 97 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
7. et to chassis bolts Group 86 Front Bumper Tools Tools Front Bumper Special Tools The following tools are required to adjust the VN Series front bumper To order contact Kent Moore at 1 800 328 6657 Note The Stainless Steel bumper referenced on J42207 A is not currently available from Volvo Trucks North America J42207 A J 42764 1 J 42764 W0001507 Kent Moore Front bumper hood alignment kit J 42764 Other special equipment 2 W 8000993 1 Torque wrench 0 to 68 Nm 0 to 600 in Ib 2 Torque wrench 41 to 340 Nm 30 to 250 ft lb Group 86 Front Bumper Front Bumper Design and Function Front Bumper Component descriptions SMC front bumper The standard VNL series front bumper is the SMC bumper This bumper is a one piece molded design that is lightweight flexible and aerodynamic It has built in recesses for driving lights and fog lamps The SMC material allows for easy repair and painting if the bumper is damaged The wrap around bumper adds to the aerodynamic design and splash and spray protec tion The SMC front bumper attaches to the front bumper mounting brackets with four studs that are molded into the SMC bumper Steel front bumper The steel front bumper is a five piece design with a steel center and a bolt on plastic cap on each end The de Sign of the steel bumper allows exceptional strength and durability The wrap around end caps and lower spoiler also add to the splash a
8. etween the bumper and the hood and to attain the proper fore and aft adjustment Note Before checking the bumper to hood gap and the fore and aft spacing the vehicle air system must be at full Capacity and the hood must be closed and latched Note To use the Kent Moore Gauge Block correctly it should be placed at the inside edge of the headlamp on each side while checking the gap and the fore and aft Spacing 3 L x 2 ON Sa N S NY ANS 7 Lo N A N NE ae Ya ZAN i A TNS aS de ee A 4 a y A O yi Ni NN N W8000979 Tighten the mounting bolts and then 200 30 Nm torque them to 200 30 Nm 148 22 ft lb 148 22 ft lb 18 Service Procedures Side to side adjustment 1 W 8000954 Loosen the four nuts that attach the front bumper to the bumper mounting bracket TI UIA li I W 8000967 Center the side to side alignment of the bumper to the hood by measuring the distance from the side of the hood to the side of the bumper Slide the bumper right or left as necessary until the measurement Is equal on both Sides 3 After the side to side adjustment has 85 15 Nm been completed tighten the nuts and 63 11 ftlb then torque them to 85 15 Nm 63 11 ftlb Group 86 Front Bumper 8611 05 02 01 Front Bumper Adjustment Steel Bumper W8000991 Loosen the four nuts and bolts on each side that attach the bumper to the bumper mounting brackets and the
9. in the luggage compart ment on sleeper model vehicles They are held in place with storage bolts which are torqued to 48 8 Nm 35 6 ft lb rr l i o ao Sree j wu Ph AA AR Lea W8000942 Recovery eye storage location in the luggage com partment The recovery eyes are stored behind the seats on non sleeper model vehicles They are held in place with Storage bolts which are torqued to 48 8 Nm 35 6 ft Ib It is important that the recovery eyes always be prop erly stored using the provided fasteners In the event the vehicle is involved in an accident loose recovery eyes could strike occupants and injure them or cause other damage W8000943 Recovery eye storage location behind the drivers seat 12 Group 86 Front Bumper Service Procedures Service Procedures 8611 03 02 01 Front Bumper Replacement SMC Bumper Removal 1 W8000970 If the vehicle is equipped with driving lights and or fog lamps disconnect the wiring at the connectors before begin ning the steps to remove the bumper W 8000954 Remove the four nuts from the studs on each side and remove the bumper from the bumper mounting brackets Installation 1 W 8001087 Install the bumper onto the bumper mounting brackets and install the nuts onto the bumper studs Do not tighten the nuts at this time SE My S lll ZI Center the side to side alignment of the bumper to the hood by mea
10. nd spray protection as well as its aerodynamic qualities The steel front cab bumper is attached to the front cab mounting brackets with two bolts and nuts on each side W 8000937 W 8000936 Group 86 Front Bumper SMC front bumper mounting brackets The front mounting brackets attach the bumper to the chassis The SMC bumper has four studs that are molded into the bumper The SMC bumper is installed by inserting these four studs into the front mounting brack ets and then installing nuts onto the studs The mounting holes in the front bumper mounting brackets are elon gated to allow for side to side adjustment The SMC front bumper mounting brackets also have three bolt holes that are used for mounting the front mounting brackets to the chassis rails These three holes are elongated to allow for fore and aft adjustment The three holes in the vehicle chassis are also elongated to allow for the up and down adjustment This up and down adjustment is for adjusting the bumper to hood gap Steel front bumper mounting brackets The steel bumper mounting brackets have two bolt holes for mounting the steel bumper and two bolt holes to mount the mounting brackets to the chassis rails The bolt holes in the mounting brackets that mount the brackets to the chassis are elongated to allow for fore and aft adjustment The bolt holes in the mounting brackets provided for the front bumper are also elongated to allow for up and down adjus
11. suring the distance from the side of the hood to the side of the bumper Slide the bumper right or left as necessary until the measurement is equal on both sides W 8000967 13 Group 86 Front Bumper pe lt a Da AD Pa Sr K VA W8000972 After the side to side adjustment has 85 15 Nm been completed tighten the nuts and 63 11 ftlb then torque them to 85 15 Nm 63 11 ft lb W8000971 If the vehicle is equipped with driving lights and or fog lamps reconnect the connectors and secure them with tie straps as needed 14 mi e AK an be W JY Service Procedures W 8002128 Using the Kent Moore J 42207 A gauge block on an SMC bumper VNL VNM Use the Kent Moore J 42207 A Gauge Block to check for the proper gap between the bumper and the hood and the correct fore and aft spacing of the front bumper from the hood If the front bumper needs to be adjusted refer to the Front Bumper Adjustment procedure Note Before checking the bumper to hood gap and the fore and aft spacing the vehicle air system must be at full Capacity and the hood must be closed and latched Note To use the Kent Moore Gauge Block correctly it should be placed at the inside edge of the headlamp on each side while checking the gap and the fore and aft spacing Group 86 Front Bumper 8611 03 02 02 Front Bumper Replacement Steel Bumper Removal W8000951 If the vehicle is equipped with driving ligh
12. tment This up and down adjustment is for setting the bumper to hood gap The mounting holes in the steel bumper are also slightly elongated to allow for side to side adjustment to center the bumper 10 Front Bumper W 8000939 Front bumper mounting bracket for SMC bumper W 8000940 SMC bumper mounted to front bumper mounting bracket W 8000938 Front bumper mounting bracket for steel bumper Group 86 Front Bumper Front recovery eyes The front recovery eyes are intended to be used as a point at the front of the vehicle where the vehicle can be pulled during a recovery type operation The recovery eyes may be used to raise the front of an unloaded vehi cle however the recovery eyes are NOT intended to be used to raise the front of the vehicle for towing purposes A N DANGER Personnel should never work under the truck while it is being suspended from the recovery eyes In the event the recovery eye cable or chain being used to raise the vehicle should break the truck would fall and serious personal injury or death could occur The recovery eyes are inserted into the recovery eye re ceiver and held in place with tractor type pins When not in use the tractor pins remain in the receiver pin holes for storage Front Bumper Front recovery eyes installed Recovery eye being installed to front of vehicle W8000941 W 8000934 11 Group 86 Front Bumper Front Bumper The recovery eyes are stored
13. ts and or fog lamps it will be nec essary to remove the bottom bolt from the support bracket that goes from the bumper mounting bolt to the light bracket on each side W 8000968 If the vehicle is equipped with driving lights and or fog lamps disconnect the wiring at the connectors Service Procedures Remove the two nuts on each side from the bolts that attach the bumper to the bumper mounting brackets 4 Remove the bumper Installation 1 W 8001088 Install the bumper onto the bumper mounting brackets install the bolts through the bumper and install the nuts Do NOT tighten the nuts at this time Note If the vehicle was equipped with driving lights and or fog lamps install the support bracket before installing the nuts 15 Group 86 Front Bumper TI Mijn i Hh i W8000992 Center the side to side bumper align ment by measuring the distance from the side of the hood to the side of the bumper Slide the bumper right or left as necessary until the measurement is equal on both sides 16 Service Procedures je i Z W 8002129 Using the Kent Moore J 42764 1 gauge block on a VNM steel bumper Note Before checking the bumper to hood gap the vehicle air system must be at full capacity and the hood must be closed and latched Use the Kent Moore J 42764 1 Gauge Block to set the proper gap be tween the bumper and the hood Note On all VNL models Because
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