Service Manual Trucks Group 85 Cab, Upholstery VN

Service Manual
Trucks
Group 85
Cab, Upholstery
VN
PV776-TSP133527
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 number: 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
General .................................................................................................... 3
General Precautions .............................................................................. 4
Design and Function ............................................................................. 5
Interior Door Panels .............................................................................. 5
Wall Panels ............................................................................................ 5
Seats ...................................................................................................... 5
Floor Covering ....................................................................................... 7
Engine Cover ......................................................................................... 7
Headliners .............................................................................................. 8
Service Procedures ............................................................................... 9
Door Panel, Replacement ..................................................................... 9
Bunk, Replacement (Upper) ................................................................ 11
Removal ............................................................................................. 11
Headliner, Replacement ...................................................................... 17
Day Cab ............................................................................................. 17
Headliner, Replacement (Front) .......................................................... 21
VN420 ................................................................................................ 21
Headliner, Replacement (Bunk) .......................................................... 26
VN420 ................................................................................................ 26
Headliner, Replacement (Front) .......................................................... 29
VN610 ................................................................................................ 29
Headliner, Replacement (Bunk) ......................................................... 34
VN610 ................................................................................................ 34
Headliner, Replacement (Bunk) ......................................................... 38
VN660 ................................................................................................ 38
Headliner, Replacement (Bunk) .......................................................... 43
VN770 ................................................................................................ 43
Headliner, Replacement (Front Lower) ............................................... 55
VN660/770 ......................................................................................... 55
Headliner, Replacement (Front Upper) ............................................... 59
VN660 ................................................................................................ 59
Headliner, Replacement (Front Upper) ............................................... 62
VN770 ................................................................................................ 62
Seat, Replacement .............................................................................. 73
Standard Seat ................................................................................... 73
Volvo Seat ......................................................................................... 74
Seat, Overhaul ....................................................................................... 75
Seat Cushion, Replacement ................................................................ 77
Seat Backrest Cushion, Replacement ................................................ 77
Seat Headrest, Replacement .............................................................. 77
Seat Backrest Cover, Replacement (Upper) ....................................... 77
Seat Backrest Cover, Replacement (Lower) ....................................... 78
Seat Frame Cover, Replacement (Rear) ............................................. 78
Seat Frame Cover, Replacement (Right Side) .................................... 78
Seat Frame Cover, Replacement (Left Side) ...................................... 79
Seat Compressed Air Valve, Replacement ......................................... 79
Seat Heater Switch, Replacement ...................................................... 79
Seat Adjustment Switch Panel, Replacement ..................................... 80
Seat Cushion Base, Replacement ...................................................... 80
Seat Backrest Air Cushion, Replacement ........................................... 80
Seat Control Harness, Replacement ................................................... 81
Seat Motor, Replacement (Cushion Position) ..................................... 83
1
Seat Motor, Replacement (Seat Positioning) ...................................... 84
Seat Motor, Replacement (Cushion Tilt) ............................................. 85
Seat Electro-Pneumatic Height Control Valve, Replacement ............. 86
Seat Motor, Replacement (Backrest Tilt) ............................................ 87
Seat Motor, Replacement (Upper Backrest Tilt) ................................. 88
Seat Control Unit, Replacement .......................................................... 88
Seat Height Control Cylinder, Replacement ....................................... 89
Seat Height Setting Guide Plate, Replacement .................................. 90
Seat Height Guide Disc Unit, Replacement ........................................ 91
Seat Height Level Control Valve, Replacement .................................. 93
Seat Height Two-Way Valve, Replacement ......................................... 94
Seat Cam Disc, Replacement ............................................................. 95
Seat Cam Disc Cable, Replacement ................................................... 96
Seat Air Spring, Replacement ............................................................. 97
Seat Vertical Shock Absorber, Replacement ...................................... 98
Engine Cover, Replacement ................................................................ 99
Feedback
Operation Numbers
2
Group 85 Upholstery General
General
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.
3
Group 85 Upholstery General
General Precautions
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.
WARNING
Always wear appropriate eye protection to prevent the
risk of eye injury due to contact with debris or fluids.
CAUTION
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.
4
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.
W8001378
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
A luxury Volvo seat offers many adjustments and 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.
T8006503
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.
W8001386
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.
W8001387
6
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 W8002591
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. 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
7
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
8
Group 85 Upholstery Service Procedures
Service Procedures
8511-03-02-01 3
Door Panel, Replacement

jury or death.
Removal
1
W8001380
Using a small, flat bladed screwdriver,

carefully remove the six plugs in the
door panel.
W8001398
Remove the knob on the door by Torx 10

pulling the rubber plug out with a
scriber. Remove the screw.
W8001381
Remove the three bolts and three 14 mm socket;

screws holding the panel to the door. Torx 25
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.
9
5 4
If equipped, install the window regula- Torx 25
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.
5
Install the door lock handle. Install the Torx 10
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 14 mm socket;
screws. Install the cover plugs into the Torx 25
panel.
W8001382 9
If equipped, install the window regula- Torx 25
The door panel is now held in place by
tor crank on the shaft. Tighten the
the Christmas tree fasteners. Care-
screw. Install the crank cover by twist-
fully pry the door panel away from the
ing it into place and pressing over the
door.
end of the crank.
6
10
Disconnect the electrical connectors Torx 25
Install the door lock handle. Install the Torx 10
for the electrical equipment in the door
screw and tighten it. Install the rubber
panel. Remove the door panel.
plug in the hole in the handle.
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 14 mm socket;
screws. Install the cover plugs into the Torx 25
panel.
10
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.
W8002176
Remove the 4 bunk window trim Phillips screw-

bezels. There are 10 screws to be re- driver
moved for each windows trim bezel.
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 W8002177
away to release the trim edge.
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 three clips fastening the
trim panel to the tower cabinet, re-
move the trim panel.
11
3 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.
W8002178
Remove the 6 torx screws holding the Torx 25

ducting from the bunk HVAC unit to
the right bunk fascia panel.
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.
W8002180
Remove the duct hose in the upper Torx 25

right tower cabinet from the right bunk
fascia panel.
12
Tower Cabinets, Removal 4

Remove the 4 nuts and washers (5)
1 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.
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 W8002159
bolt. Remove the bracket from the cab-

inet that holds the interlock fastener.
Pull back the B pillar trim to expose CAUTION
the lower front wall mounting bolt.
Remove the 5 wall mounting bolts (3). Use caution when removing the bunk assembly from
the truck, to prevent the mounting hinge from being
impacted and possibly coming unlatched from the
2 flat position.
Remove the power socket connectors
and remove the mounting screw in the
center of the 120 V outlet cover (if With the bunk in the lower position lift

equipped). Remove the cover. it to about 45 angle and pull it out.
3
Remove the four torx bolts (4) holding
the lower tower cabinet to the wall.
13
Upper Bunk, Installation Tower Cabinets, Installation

1 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.
W8002158
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)
and hinge into the mounting holes on
the rear wall. Torque to 68 Nm (50 ft-
lb).
4
Lift up the bunk from the lower posi- 28 Nm
W8002492
tion to the upper position. Install the (21 ft-lb)
Install the upper right tower cabinet as Torx 40
two screws through holes in the hinge
follows: Torx 30
valance storage area and into the
Start all cabinet mounting bolts before Torx 20
bunk assembly. Torque the screws to
beginning tightening. Socket 12 mm
28 Nm (21 ft-lb).
Install the 5 wall mounting bolts (3). Socket 13 mm
Torque to 24 4 Nm (18 3 ft-lb). Phillips screw-
5 Install the 6 bolts between the upper driver
Continue with Tower Cabinets, Instal- and lower cabinet (1). Torque to Torque wrench
lation page 14. 24 4 Nm (18 3 ft-lb). 24 4 Nm
Install the 5 bolts to the rear bottom (18 3 ft-lb)
wall (2). Torque to 10 1.5 Nm 24 4 Nm
(7 1 ft-lb). (18 3 ft-lb)
Torque all cabinet mounting bolts. 10 1.5 Nm
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.
14
Fascia Panel and Trim, Installation 3
W8002180
Secure the duct hose in the upper Torx 25

right tower cabinet to the right bunk
fascia panel.
W8002182
4
Position the right bunk fascia panel Torx 25
into its mounting location. Secure the Socket 11 mm
panel to the tower cabinets with the Torque wrench
plastic stud nuts. Secure the panel to 3 0.5 Nm
the wall with screws. Torque to (27 4 in-lb)
3 0.5 Nm (27 4 in-lb).
2
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)
15
5 3
W8002177
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)
W8002181
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 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 4 Nm
3 0.5 Nm stall the two mounting bolts and trim (18 5 ft-lb)
(27 4 in-lb) caps. Torque bolts to 24 4 Nm (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
8554-03-02-01 5
If equipped, remove the rear speakers Torx 25
Headliner, Replacement from the headliner.

jury or death.
Day Cab
Removal
1
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
Remove the front left overhead storage Torx 25 opposite side.
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.
17
7 10
The headliner is now held in place by
a few interlocking fasteners and the
rear wall B-pillar 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-
W3003095
sembles and remove the headliner
1 Curtain rail or trim washer
from the vehicle.
2 Plastic spacer Note: This step requires 2 people.
3 Cab metal Use caution not to bend the headliner
4 Headliner to the point at which a permanent
5 Screw crease will show in the material.
Remove the screws securing the front Torx 15
and sides of the headliner.
Installation
Note: The screws are equipped with
plastic spacers between the headliner 1
and the cab sheet metal. Use caution Install the headliner in the vehicle.
not to lose them during headliner re- Connect the lamp assembles. Note the
moval. position of the interlocking fasteners.
Start with the front of the headliner
down and lift up on the rear to engage
8 the rear headliner lip behind the rear
Release the 2 retaining clips in the wall trim. At the same time work the
center of the headliner by pressing in side edges behind the B-pillar trim.
the center button. Remove the retain-
ing clips. Note: Two people are required for this
step.
Note: May not apply, depending on in-
terior trim level.
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
2 3
W3003095

2 Plastic spacer
3 Cab metal
4 Headliner
5 Screw
W3003110
With one person holding the headliner, Torx 15
1 Roof plate
allow the front of the headliner down
2 Roof panel
enough to install the mounting screws.
3 Headlining
The mounting screws and the trim
4 Fully engage fasteners pressing firmly
should be installed up through the
headliner and a spacer installed be- Install the 2 Christmas tree fasteners
tween each screw and the cab in the center of the headliner. Install
mounting holes. A thin plastic lip on the 2 remaining clips in the center of
the spacer will hold it in mounting po- the headliner. Press in the center but-
sition. After all screws and spacers are ton to secure. Engage the securing
in place, carefully lift the headliner up interlocking fasteners.
to the roof.
Note: Two people are required for this
Note: Two people are required for this step.
step.
19
4
Install the screws securing the front Torx 15
and sides of the headliner. Torque to 3 0.5 Nm
3 0.5 Nm (27 4 in-lb). (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.
8
Install the grab handles. Torque to Socket 12 mm
24 4 Nm (18 3 ft-lb). Replace the 24 4 Nm
bolt cover trim. (18 3 ft-lb)
9
If equipped, install the rear speakers Torx 25
in the headliner.
10
Install the coat hooks to the rear of the Torx 25
headliner. Torque to 3 0.5 Nm 3 0.5 Nm
(25 5 in-lb). (25 5 in-lb)
11
Install the front overhead storage cabi- 24 4 Nm
net carrier rail. Torque to 24 4 Nm (18 3 ft-lb)
(18 3 ft-lb).
12
Install the right sun visor. Torque to Socket 8 mm
5 0.8 Nm (45 7 in-lb). 5 0.8 Nm
(45 7 in-lb)
13
Install the front overhead storage cabi- Torx 25
net together with the sun visor. Torque Socket 8 mm
to 5 0.8 Nm (45 7 in-lb). 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
8554-03-02-02 5
Remove the driver side window visor Socket 8 mm
Headliner, Replacement (Front) assembly. Pry off end screw covers.
Remove mounting screws.
6
Remove the sleeper curtain rail as- Torx 25
sembly.
wheels. Failure to do so can result in unexpected Note: The curtains do not need to be
vehicle movement and can cause serious personal in- removed from the rail.
jury or death.
7
VN420
Removal
1
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 vehicle.
Remove the front left overhead storage Torx 25 Note: Use caution not to deform the
cabinet together with the sun visor. Socket 8 mm rail assembly.
2
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.
21
8 9
W3003095

2 Plastic spacer
3 Cab metal
4 Headliner
5 Screw
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. W3003260
1 Plastic rivets (day cab vehicles only)

2 Molding clip
Remove the upper grab handle bolt

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.
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.
22
11 Installation
1
W3003261
1 Headliner
2 Christmas tree fastener
3 Removal tool J38778 W3003110
Remove the 2 Christmas tree fasten- J-38778 1 Roof plate

ers in the center of the headliner with 2 Roof panel
the removal tool. Use caution not to 3 Headlining
damage the headliner material. 4 Fully engage fasteners pressing firmly
Note: May not apply, depending on Note the location of all interlocking
the interior trim level. fasteners on the headliner to aid in in-
stallation. Position the headliner in the
cab below its mounting location. Con-
12 nect the lamp assembly connectors.
Remove all the screws that holds the
headliner. After all screws have been Note: Use caution not to bend the
removed and the headliner drops, dis- headliner to the point at which a
connect the lamp assembles and permanent crease will show in the ma-
remove the headliner from the vehicle. terial.
Use caution not to bend the headliner
to the point at which a permanent 2
crease will show in the material. Lift the headliner assembly into posi-
Note: In older vehicles (built 1998 and tion. Temporarily secure with a few
before) the headliner may also be fas- interlocking fasteners.
tened with 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
5 8
W3003095

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 0.5 Nm
lon spacers between headliner and (27 4 in-lb)
cab screw holes. Install all screws 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.
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
net carrier rail. Torque to 24 4 Nm 24 4 Nm Replace the bolt cover trim. (18 3 ft-lb)
(18 3 ft-lb). (18 3 ft-lb)
10
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 0.5 Nm
(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
14
Install the front right overhead storage Torx 25

cabinet (if equipped) as follows: Socket 8 mm
Install the 4 mounting screws, with 2 0.3 Nm
their rubber washer, to the carrier rail. (17 3 in-lb)
Torque to 2 0.3 Nm (17 3 in-lb). 3 0.5 Nm
Install the 2 screws over the wind- (25 5 in-lb)
shield. Torque to 3 0.5 Nm
(25 5 in-lb). Install the mounting
screw covers.
15
5 0.8 Nm (45 7 in-lb). 5 0.8 Nm
(45 7 in-lb)
16
Install the front left overhead storage Torx 25
cabinet together with the sun visor. In- Socket 8 mm
stall the 4 mounting screws, with their 2 0.3 Nm
rubber washer, to the carrier rail. (17 3 in-lb)
Torque to 2 0.3 Nm (17 3 in-lb). 3 0.5 Nm
Install the 6 screws, with their rubber (25 5 in-lb)
washer, over the windshield. Torque to
3 0.5 Nm (25 5 in-lb).
25
8554-03-02-03 3
Headliner, Replacement (Bunk)

jury or death.
VN420
Removal
1
Remove the mattress from the vehicle.
W8002519
Remove the front curtain rail assembly Slotted screw-

(1). Use a wide blade screwdriver to driver
clip.
Remove the rail assembly from the ve-
hicle.

rail assembly.
W8002490
Remove the bunk curtain rail assem- Torx 25 4

bly. Remove the 2 bunk restraint tether Torx 40
brackets and spacer (2).
Note: The curtains dont need to be
removed from the rail.
5
Remove the 2 coat hooks from the Torx 25
rear wall (3).
6
Remove the 2 speakers (4). Torx 25
26
7 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.
W8002517
2 people are required for this step.
The headliner is now held in place by
screws and the bunk trim. 3
Remove all screws that holds the
headliner.
Note: In older vehicles (built 1998 and
before) the headliner may also be fas-
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.

headliner to the point at which a W8002517
permanent crease will show in the ma- Lift the headliner assembly into posi-
terial. tion by sliding the front of the bunk
headliner under the rear of the front
headliner.
8
Work the rear of the bunk headliner
Remove the lamp assemblies for in- Torx 20
behind the bunk wall trim panels.
stallation in the replacement headliner.
Install all screws.
Note: 2 people required for this step.
Note: In older trucks (built 1998 and

before) the headliner may also be fas-
27
4 8
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
W8002519
Install the rear speakers in the head- Torx 25

liner as follows (4): Torque wrench
Connect the connector. 3 0.5 Nm
Install and torque the 4 screws to (27 4.5 in-lb)
3 0.5 Nm (27 4.5 in-lb).
Install the cover.
5
Install the 2 coat hooks (3). Torque to Torx 25
3 0.5 Nm (27 4.5 in-lb). Torque wrench
3 0.5 Nm
(27 4.5 in-lb)
6
Install the 2 bunk restraint tether Torx 40
brackets and spacer (2). Torque to Torque wrench
18 3 Nm (13 2 in-lb). 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
8554-03-02-02 5
Remove driver side window visor as- Socket 8 mm
Headliner, Replacement (Front) sembly:
Pry off the end screw covers. Remove
the mounting screws.
Before working on a vehicle, set the parking brakes, 6

jury or death.
VN610
Removal
1
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.
Front overhead storage cabinets
Remove the front left overhead storage Torx 25

cabinet together with the sun visor. Socket 8 mm
2
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 rail assem- Torx 40
bling screws.
29
7 10
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. W8001428
Remove the mounting screw covers Remove the front curtain rail assem- Slotted screw-
and remove the 8 wall mounting bolts
bly. Use a wide blade screw driver to driver
(2), including the one to the lower
bunk tether (3). then the other side on each retaining
clip. After all retaining clips are re-
Note: In vehicles with an upper bunk leased, remove the front curtain rail
the long overbunk cabinet is replaced assembly from the vehicle.
by a short cabinet.
8 rail assembly.
11
W3003095

W8002490
2 Plastic spacer
3 Cab metal
Remove the sleeper curtain rail as- Torx 25 4 Headliner
sembly. 5 Screw
Note: The curtains do not need to be Remove the screws securing the front Torx 15
removed from the rail. and sides of the headliner.
9 Note: The screws are equipped with

Remove the bezels for the front over- plastic spacers between the headliner
head roof storage pockets. and the cab sheet metal. Use caution
not to lose them during headliner re-
moval.
Note: Use caution not to break the
bezel mounting post.
30
12 Installation
1
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.
terial.
2
Lift the headliner assembly into posi-
tion. Use the front overhead roof
storage pockets as a guide to assist in
proper positioning.
W3003260
1 Plastic rivets (day cab vehicle only)

2 Molding clip
Remove the upper grab handle bolt Socket 12 mm

the bolt and pull the upper grab handle
out of the cover. Repeat on the other W3003095
side. 1 Curtain rail or trim washer

Pull the door seal away from the A- 2 Plastic spacer
pillar trim and the top of the door. 3 Cab metal
Remove the molding clip by pressing 4 Headliner
in the center button. Remove the A- 5 Screw
pillar trim. Repeat on opposite side. Install the mounting screws for the Torx 15
front curtain rail assembly. 3 0.5 Nm
13 Add the nylon spacers between head- (25 5 in-lb)
Remove all the screws that holds the liner and cab screw holes. Install all
headliner. After all screws have been screws and retaining clips. Torque to
removed and the headliner drops, dis- 3 0.5 Nm (25 5 in-lb).
connect the lamp assembles and
remove the headliner from the vehicle. 4
Use caution not to bend the headliner Install all remaining screw to the head-
to the point at which a permanent liner.
crease will show in the material.
Note: In older vehicles (built 1998 and
Note: In older vehicles (built 1998 and before) the headliner may also be fas-
before) the headliner may also be fastened with interlocking fasteners.
5
net assembly carrier rails. Torque to 24 4 Nm
24 4 Nm (18 3 ft-lb). (18 3 ft-lb)
6
Install the A-pillar trim, secure with the
molding clip. Repeat on opposite side.
31
7 12
Install the grab handles. Tighten the Socket 12 mm
bolts to a torque of 24 4 Nm 24 4 Nm
(18 3 ft-lb). Install the cover plugs. (18 3 ft-lb)
8
9
Install the bezel for the front overhead
roof storage pockets with the star
fasteners.
10
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 4 Nm
Position the cabinet and install the (18 3 ft-lb)
mounting bolts (2). Torque to 24 4 Nm
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.
W8001428

Use caution not to deform the rail as-
sembly. Position rail and snap into
retaining clips.
11
bly. Torque to 5 1 Nm (45 7 in-lb). 5 1 Nm
(45 7 in-lb)
32
13 15
W8002514 W8002510
Install the upper right cabinet as fol- Torx 40 If removed, install the front right over- Torx 25
lows: Torx 30 head storage cabinet. Install the 4 Socket 8 mm
Insert the power supply and coaxial Torque wrench mounting screws, with their rubber Torque wrench
cable through the upper cabinet ac- 24 4 Nm washer, to the carrier rail. Torque to 2 0.3 Nm
cess hole. Insert the light wire through (18 3 ft-lb) 2 0.3 Nm (18 3 in-lb). (18 3 in-lb)
the lower access hole. 5 1 Nm Install the 6 screws over the wind- 3 0.5 Nm
Install the 4 wall mounting bolts (3). (44 9 inlb) shield. Torque to 3 0.5 Nm (27 4 in-lb)
Torque to 24 4 Nm (18 3 ft-lb). (27 4 in-lb).
Connect the interior light (2) and Install the mounting screw covers.
power supply connector.
Install the TV support plate with its 6
screws (1). Torque the screws to 16
5 1 Nm (44 9 inlb). Install the right sun visor. Torque to Socket 8 mm
5 0.8 Nm (44 7 in-lb). Torque wrench
Note: Position of long and short over- 5 0.8 Nm
bunk cabinets may vary between RH (44 7 in-lb)
and LH side locations.
Note: TV support plate may be omit- 17

14
sembly. Torque the screws to 5 0.8 Nm
5 0.8 Nm (45 7 in-lb). (45 7 in-lb)
Install the screw covers.
W8002511

bin/sun visor assembly. Install the 4 Socket 8 mm
mounting screws, with their rubber Torque wrench
washer, to the carrier rail. Torque to 2 0.3 Nm
2 0.3 Nm (18 3 in-lb). (18 3 in-lb)
Install the 6 screws, with their rubber 3 0.5 Nm
washer, over the windshield. Torque to (27 4 in-lb)
3 0.5 Nm (27 4 in-lb).
33
8554-03-02-03 3

jury or death.
VN610
W8002513
Removal Remove the left overbunk cabinet as Torx 40
follows: Torx 25
1
Remove the interior light connector
cover plate (1) with its 3 screws and
unplug the light connector.
2 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.
W8002514
Remove the upper right cabinet as fol- Torx 40

lows: Torx 30
Remove the TV support plate by re-
Unplug the interior light (2) and power
supply connector.
Remove the 4 wall mounting bolts (3).
Note: Position of long and short over-

bunk cabinets may vary between RH W8002490
and LH side locations. Remove the bunk curtain rail assem- Torx 25
bly.
Note: TV support plate may be omit-
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.
34
6 11
W8002459
Remove the bunk headliner overhead Torx 25 W8002515

lamp assembly. Disconnect the con- Remove the bunk headliner as follows: J-38778
nector. Remove the 2 Christmas tree fasten-
ers and separate the interlocking
fasteners as necessary.
7
Carefully work the bunk headliner out
Remove the right upper trim panel as Torx 40
follows: from under the front headliner and
away from the rear wall trim.
Remove the right lower bunk restraint
Remove it from the vehicle. Use cau-
tether bracket. Separate the interlock
fasteners at the top to allow the trim tion not to crease the headliner
material.
panel fold down.
Note: The panel doesnt have to be

completely removed. Its 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.
35
Installation 6
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.

step.
2
Install the bezels around the left and
right overhead storage bins over the W8002459
seats. Connect the bunk headliner overhead Torx 25

lamp assembly connector and install Torque wrench
the lamp. Torque the screws to 3 0.5 Nm
3 3 0.5 Nm (27 4 in-lb). (27 4 in-lb)
Install the top rear wall trim panel as
follows:
Work the panel into position behind 7
the top of the center wall trim panel. Install the bunk headliner speakers as Torx 25
Install the snap screws and covers. follows: Torque wrench
Engage the Velcro fasteners. Connect the connector on the back 3 0.5 Nm
Work the rear window seal around the and install using the 4 screws. Torque (27 4 in-lb)
panel. to 3 0.5 Nm (27 4 in-lb).
Install the cover.
4
Engage the interlock fasteners on the Torx 25 8
center rear wall trim panel. Install the Torque wrench
2 coat hooks and torque the screws to 3 0.5 Nm
3 0.5 Nm (27 4 in-lb). (27 4 in-lb).
5
Install the right upper trim panel as fol- Torx 40
lows: Torque wrench
Work the interior light wiring through 24 4 Nm
the panel. (18 3 ft-lb)
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).
W8002490

Torque the screws to 5 1 Nm Torque wrench
(44 9 inlb). 5 1 Nm
(44 9 inlb)
36
9 10
W8002514
Install the upper right cabinet as fol- Torx 40

lows: Torx 30
W8002513
Insert the power supply and coaxial Torque wrench
Install the left overbunk cabinet as fol- Torx 40 cable through the upper cabinet ac- 24 4 Nm
lows: Torx 25 cess hole. Insert the light wire through (18 3 ft-lb)
Insert the interior light wiring through Torque wrench the lower access hole. 5 1 Nm
the cabinet access hole. 24 4 Nm Install the 4 wall mounting bolts (3). (44 9 inlb)
Position the cabinet and install the (18 3 ft-lb) Torque to 24 4 Nm (18 3 ft-lb).
mounting bolts (2). Torque to 24 4 Nm Connect the interior light (2) and
24 4 Nm (18 3 ft-lb). (18 3 ft-lb) power supply connector.
Install the left lower bunk restraint 3 0.5 Nm Install the TV support plate with its 6
tether bracket with spacer (3). Torque (27 4 in-lb) screws (1). Torque to 5 1 Nm
to 24 4 Nm (18 3 ft-lb). (44 9 inlb).
Install the lower bolt trim covers.
Connect the light connector and install Note: Position of long and short over-
the light connector cover (1). Torque to bunk cabinets may vary between RH
3 0.5 Nm (27 4 in-lb). and LH side locations.
Note: In vehicles with an upper bunk Note: TV support plate may be omit-
the long overbunk cabinet is replaced ted in some short overbunk cabinets.
by a short cabinet.
11
Install the mattress in the vehicle.
37
8554-03-02-03 4
Remove the upper bunk mounting Socket 12 mm
Headliner, Replacement (Bunk) bolts (two 12 mm and two 16 mm Socket 16 mm
bolts) and remove the bunk from the
vehicle.

step.
wheels. Failure to do so can result in unexpected 5
jury or death.
VN660
Removal
1
2
Remove the upper right cabinet as fol- W8002457
lows: Remove the upper bunk restraint by Socket 16 mm
Disconnect the HVAC duct in the removing the 2 bolts.
wardrobe from the duct in the upper
cabinet.
Remove the bolt and spacer between 6
the upper and lower cabinet. Remove the rear wall interior trim J-38778
Disconnect the power supply connec- panel. Its held in place with Christmas
tor. tree and interlocking fasteners.
Finally remove the 4 wall mounting Disengage fasteners and remove the
bolts and remove the cabinet from the panel from the vehicle.
vehicle.
7
3
W8002459
Remove the overhead lamp assembly Torx 25

W8002490
from the center rear headliner. Discon-
Remove the bunk curtain rail assem- Torx 25 nect the electrical connector.
bly.
Note: The curtains do not need to be

removed from the rail.
38
8 12
W8002461
W8002463
Remove the 2 trim strips on each side Remove the right side center trim Torx 20
of the center bunk headliner. Note: no panel as follows: Torx 15
tools required they pop out. Remove the front curtain rail from the
first 2 right side clips to allow removal
9 of one panel bottom mounting screw,
Remove the center bunk headliner. Its J-38778 nylon spacer and curtain rail mounting
held in place by Christmas tree and clip (1).
interlocking fasteners. Disengage fas- Remove one forward mounting screw
teners and remove the panel from the with curtain hold-back snap fitting to
vehicle. allow removal of the plastic trim cover.
10 13
W8002462
The panel is now held in place with J-38778

Christmas tree and interlocking fasten-
W8002456 ers.
Remove the right side upper bunk Torx 25 Disengage fasteners and remove the
support by removing the 2 screws to panel from the vehicle.
the cover and the 2 screws to the
striker plate.
11
Remove the right side lower bunk re- Torx 40
straint tether bracket.
39
14 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.
step.
2
Install the speaker in the right side Torx 25
W8002458
bunk headliner panel as follows: Torque wrench
Remove the right side bunk window Phillips screw- Connect the connector on the back, 3 0.5 Nm
trim bezel. driver install the speaker and torque the 4 (27 4 in-lb)
screws to 3 0.5 Nm (27 4 in-lb).
Install the speaker cover.
15
Remove the speaker assembly from Torx 25
the right side bunk headliner panel as 3
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.
W8002458
Install the right side sleeper window Phillips screw-

trim bezel. Torque the screws to driver
3 0.5 Nm
(27 4 in-lb)
40
4 6
W8002456
W8002463
Install the right side center trim panel Torx 20 Install the right side upper bunk sup- Torx 25
as follows: Torx 15 port cover and striker plate. Torque the 10 1.5 Nm
Note the position of the Christmas tree Torque wrench screws to 10 1.5 Nm (7 1 ft-lb). (7 1 ft-lb)
and interlocking fasteners. 5 1 Nm
At the bottom of the panel, install the (44 9 in-lb)
mounting screw, nylon spacer and cur- 3 0.5 Nm 7
tain rail mounting clip (1). Torque to (27 4 in-lb) Install the center bunk headliner and
5 1 Nm (44 9 in-lb). secure with Christmas tree and inter-
Put the trim cover piece in place and locking fasteners.
install the forward mounting screw with
curtain hold-back snap fitting. Torque
to 3 0.5 Nm (27 4 in-lb). 8
Snap the front curtain rail into the
mounting clips.
Note: Older vehicles (from 10/99 and
before) dont 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- Torx 40
straint tether bracket. Torque the bolt Torque wrench W8002461
to 24 4 Nm (18 3 ft-lb). 24 4 Nm Install the 2 trim strips on each side of

(18 3 ft-lb) the center bunk headliner.
41
9 11
W8002457
Install the upper bunk safety restraint. Socket 16 mm

Make sure the latch is on the right Torque wrench
W8002459
hand side. Torque the bolts to 68 7 Nm
Connect the electrical connector for Torx 25 68 7 Nm (50 5 ft-lb). (50 5 ft-lb)
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) 12
Install the upper bunk by first securing Socket 12 mm
the hinge bracket upper bolts. Torque Socket 16 mm
10 to 24 4 Nm (18 3 ft-lb). Torque wrench
Then secure the hinge bracket with 24 4 Nm
the upper bunk restraint using the (18 3 ft-lb)
lower bolt. Torque to 68 7 Nm 68 7 Nm
(50 5 in-lb). (50 5 in-lb)

step.
13
bly. Torque the screws to 5 1 Nm Torque wrench
(44 9 in-lb). 5 1 Nm
(44 9 in-lb)
14
Install the upper right cabinet as fol- Torx 40
W8002455 lows: Socket 10 mm
Install the rear wall interior trim panel Loosen the lower duct (inside the Torque wrench
as follows: wardrobe). 68 7 Nm
First pull back the rear section of the Lift the cabinet into position and insert (50 5 ft-lb)
left and right center trim panels (this the power supply wiring and coaxial 12 2 Nm
will aid in installation). cable. Fit the cabinet over the HVAC (78 1.5 ft-lb)
Noting the position of the Christmas duct at the rear of the cabinet.
tree and interlocking fasteners, posi- Install the 4 wall mounting bolts and
tion the rear wall trim panel high on torque to 68 7 Nm (50 5 ft-lb).
the rear wall. Slide the panel down the Install the duct inside the wardrobe by
wall and behind the lower trim panel sliding it up into the duct behind the
AND behind the left and right center upper cabinet.
trim panels. Install the through bolt and spacer be-
After the panel is properly positioned tween the upper and lower cabinet.
secure with the Christmas tree and in- Torque to 12 2 Nm (106 18 in-lb).
terlocking fasteners.
Note: Two people are required for this 15
step. Install the mattress in the vehicle.
42
8554-03-02-03 3

jury or death.
VN770
Removal W8002491
1 Remove the following in both the right J-38778

Remove the lower mattress/work sta- and left sides: Torx 50
tion cushions from the vehicle. Remove the shoulder harness mount-
ing bolts (1).
Pull back the upper rear of the door
2 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).
W8002490
Remove the bunk curtain rail assem- Torx 25

bly.
43
5 7
W8002178
Remove the 6 torx screws holding the Torx 25

W8002176 ducting from the bunk HVAC unit to
the right bunk fascia panel.
bezels. There are 10 screws to be re- driver
moved for each windows trim bezel.
8
W8002177
Remove the torx screws holding the Torx 25

cabinet below the lower right bunk
windows.
W8002180

fascia panel.
44
9 11
Pull back the lower right trim panel to J-38778
expose the lower right bunk fascia
panel mounting screws. This panel is
terlock fasteners.
10
W8002492

as follows: Torx 30
inet. Socket 11 mm
Unplug the power supply connectors. Socket 12 mm
tom wall (2).
Remove the 6 bolts between the upper
and lower cabinet (1).
W8002179
Remove 5 torx screws, 3 along the top Torx 25 expose the upper front wall mounting
and 2 behind the trim panel, mounting Socket 11 mm bolt. Remove the bracket from the cab-
the vent fascia to the wall. inet that holds the interlock fastener.
Remove the eight nuts from the plastic Pull back the B pillar trim to expose
studs. the lower front wall mounting bolt.
Remove the fascia panel from its Remove the 5 wall mounting bolts (3).
mounting location and remove it from
the vehicle.
12
Remove the upper right tower cabinet
from its mounting location and out of
the vehicle.
45
13 16
W3002102
Remove the refrigerator (if equipped). Torx 30 W8002493
Open the refrigerator door. Remove Remove the bunk master control panel Phillips screw-
the 2 locks from the floor mounting rail from the left bunk fascia panel as fol- driver
(1). lows:
Remove the 6 screws (1), disconnect
14 the two connectors at the top (2) and
Slide the refrigerator out from the let the bunk master control panel hang
cabinet and disconnect the 12 V con- from the wiring harness.
nector. Remove it from the vehicle.
17
15 Pull back the lower left trim panel to J-38778
Remove the left tower cabinet drawer Torx 20 expose the lower left bunk fascia panel
stop. Remove the sink plumbing and Socket 7 mm mounting screws. The panel is
electrical connectors (if equipped). Re- Slotted screw- secured with Christmas tree and/or in-
move the drawer. driver terlock fasteners.
46
18 19
W8002494
Remove the screws securing the left Torx 25

bunk fascia panel to the wall and the Socket 11 mm
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.
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.

expose the upper front wall mounting
bolt.
Remove the bracket from the cabinet
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).
20
Remove the upper left tower cabinet
the vehicle.
Note: This requires 2 people.

47
21 23
W8002496 W8002498
Remove any objects stored in the Torx 40 Disengage the Christmas tree fasten- J-38778
bunk upper rear wall storage cabinet. ers on the top of the rear wall trim
Remove the 8 bolts and disconnect panel to allow access to the rear part
the speaker connectors. Remove the of the center headliner.
cabinet from the vehicle.
Note: The 2 lower Christmas tree fas-
teners are not visible.
22
24
W8002459
Remove the center bunk headliner Torx 25

overhead lamp assemblys. Disconnect
W8002497
the connector.
Remove the upper bunk/rear wall re- Socket 18 mm
straint tongues (2). Torx 40
Remove the upper bunk/roof restraint 25
receivers (1). 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.
48
27 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.
W8002499
Disengage the 2 Christmas tree fas- J-38778

teners at the front and the 3 at the
rear of the center bunk 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.
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
6 8
W8002459
Install both overhead lamp assemblies Torx 25

as follows: Torque wrench
Connect the connector. Install the as- 3 0.5 Nm
sembly and torque the 4 screws to (27 4.5 in-lb)
W8002497
3 0.5 Nm (27 4.5 in-lb).
Install the lamp cover. Install the upper bunk/roof restraint re- Torx 40
ceivers (1). Torque to 24 4 Nm Socket 18 mm
(18 3 ft-lb). Torque wrench
7 Install the upper bunk/rear wall re- 24 4 Nm
straint tongues (2). Torque to (18 3 ft-lb)
68 7 Nm (26 5 ft-lb). 68 7 Nm
(26 5 ft-lb)
W8002498
Secure the rear wall trim panel with

the 4 Christmas tree fasteners.
W8002496
Position the bunk upper rear wall stor- Torx 40

age cabinet to its mounting location. Torque
Connect the speaker connectors and Wrench
secure the cabinet with the 8 screws 24 4 Nm
(1). Torque to 24 4 Nm (18 3 ft-lb). (18 3 ft-lb)
50
10 12
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.
11
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)
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-
W8002495 mas tree and/or interlock fasteners.
Install the upper left tower cabinet as Torx 40
follows: Torx 30
Start all cabinet mounting bolts before Torx 20 14
beginning tightening. Install the 5 wall Socket 12 mm
mounting bolts (3). Torque to Socket 13 mm
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 4 Nm
(18 3 ft -lb)
Note: The lower cabinet door hinges 24 4 Nm
may need to be temporarily removed (18 3 ft -lb)
to install the 2 front bolts. Re-install 10 1.5 Nm
hinges after the bolts between the up- (7 1 ft-lb)
per and lower cabinet have been
tightened.
Install the 5 bolts to the rear bottom

W8002493
wall (2). Torque to 10 1.5 Nm
(7 1 ft-lb). Connect the bunk master control panel Phillips screw-
Torque all cabinet mounting bolts. connectors (2). Using the 6 screws (1), driver
Install the bracket that holds the inter- install the bunk master control panel
lock fastener to the cabinet. Secure into the left bunk fascia panel.
terlock fasteners. Connect the power
supply connectors.
51
15 18
Install the left tower cabinet drawer. Torx 20
Connect the sink plumbing and electri- Socket 7 mm
cal connectors (if equipped). Install the Slotted screw-
drawer stop. driver
16
W3002102
Install the refrigerator (if equipped) as Torx 30

follows: Torque wrench
Place the refrigerator on the floor just 13 2 Nm
in front of the cabinet. (10 1.5 ft-lb) W8002492
Connect the 12 V power supply, using Install the upper right tower cabinet as Torx 40
the locking connector. follows: Torx 30
Align the refrigerator mounting brack- Start all cabinet mounting bolts before Torx 20
ets with the floor tracks and slide it as beginning tightening. Socket 12 mm
far back on the tracks as possible. Install the 5 wall mounting bolts (3). Socket 13 mm
Open the refrigerator door and install Torque to 24 4 Nm (18 3 ft-lb). Phillips screw-
the locks in the floor mounting rail (1). Install the 6 bolts between the upper driver
Torque to 13 2 Nm (10 1.5 ft-lb). and lower cabinet (1). Torque to Torque wrench
24 4 Nm (18 3 ft-lb). 24 4 Nm
Install the 5 bolts to the rear bottom (18 3 ft-lb)
17 wall (2). Torque to 10 1.5 Nm 24 4 Nm
Position the upper right tower cabinet (7 1 ft-lb). (18 3 ft-lb)
into its mounting location. Work the Torque all cabinet mounting bolts. 10 1.5 Nm
cabinet around trim panels and pull Install the bracket that holds the inter- (7 1 ft-lb)
wiring through the cabinet as neces- lock fasteners to the cabinet. Secure
sary. the upper front trim panel with the in-
terlock fasteners.
52
19 21
W8002180

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
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
23 26
W8002177
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 W8002501
(27 4 in-lb) Install both right and left B pillar trims Torx 50
as follows: Torque wrench
Secure the B pillar trim to the upper 68 7 Nm
24 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).

trim panel.
27
W8002458

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 Torque wrench
10 1.5 Nm (7 1 ft-lb). W8002490

bly. Torque the screws to 5 1 Nm Torque wrench
(44 9 in-lb). 5 1 Nm
(44 9 in-lb)
28
Install the lower mattress/work station
cushions to the vehicle.
54
8554-03-02-04 3
Headliner, Replacement (Front

Lower)

jury or death.
VN660/770 W8002510
Remove the front right overhead stor- Torx 25

Removal age cabinet. There are 2 bolts in the Socket 8 mm
upper front and 6 bolts in the back.
1
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 storage Torx 40
cabinet assembly carrier rails. 3 bolts
holds each carrier rail.
5
Remove the window visor on the Socket 8 mm
drivers side. Remove the 2 covers to
gain access to the 2 screws.
W8002511
Remove the front left overhead stor- Torx 25 6

age cabinet/sun visor assembly. There Socket 8 mm
are 4 bolts in the upper front and 6
bolts in the back.
2
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
clip. Remove the rail assembly from
the vehicle.

rail assembly.
55
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.
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/bunk 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
W8002508
Pull down the front of the headliner
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.
terial.
56
Installation 6
Install the A pillar trim. Secure with the
1 molding clip.
Install the lamp assemblies in the re- Repeat on opposite side.
placement headliner.
7
2 Install the grab handle. Torque the bolt Socket 12 mm
Note the location of all the interlocking to 24 4 Nm (18 3 ft-lb). Torque wrench
fasteners on the headliner to aid in in- Replace the bolt cover trim. 24 4 Nm
stallation. Repeat on opposite side. (18 3 ft-lb)
its mounting location and connect the
lamp assembly connectors. 8
9
terial.
Use caution not to deform the rail as-
sembly.
3 Position the rail and snap it into the re-
taining clips.
10
sembly. Torque to 5 0.8 Nm Torque wrench
(44 7 in-lb). 5 0.8 Nm
Install the screw covers. (44 7 in-lb)
11
net assembly carrier rails. Torque to Torque wrench
24 4 Nm (18 3 ft-lb). 24 4 Nm
(18 3 ft-lb)
W8002508
Lift the headliner assembly into posi- 12

tion. Work the rear of the headliner
under the lip of the overhead storage
compartments. Temporarily secure the
interlocking fasteners.
4
Add the nylon spacers between head- Torx 15
liner and cab screw holes. Torque wrench
Install all screws and retaining clips. 3 0.5 Nm
Torque to 3 0.5 Nm (27 4 in-lb). (27 4 in-lb)
W8002510
5 Install the front right overhead storage Torx 25

Install the front curtain snap/bunk cen- Torx 15 cabinet. Install the 4 mounting screws, Socket 8 mm
ter trim panel screw. Torque to Torque wrench with their rubber washer, to the carrier Torque wrench
3 0.5 Nm (27 4 in-lb). 3 0.5 Nm rail. Torque to 2 0.3 Nm 2 0.3 Nm
(27 4 in-lb) (18 3 in-lb). (18 3 in-lb)
Note: VN660 built 11/99 and after: Install the 6 screws over the wind- 3 0.5 Nm
Install the plastic trim covers before in- shield. Torque to 3 0.5 Nm (27 4 in-lb)
stalling the snap/bunk trim panel (27 4 in-lb).
screw. Install the mounting screw covers.
57
13
5 0.8 Nm
(44 7 in-lb)
14
W8002511

bin/sun visor assembly. Install the 4 Socket 8 mm
mounting screws, with their rubber Torque wrench
washer, to the carrier rail. Torque to 2 0.3 Nm
2 0.3 Nm (18 3 in-lb). (18 3 in-lb)
Install the 6 screws, with their rubber 3 0.5 Nm
washer, over the windshield. Torque to (27 4 in-lb)
3 0.5 Nm (27 4 in-lb).
15
Install the lower mattress/work station
cushions to the vehicle.
58
8554-03-02-05 4

Upper)

jury or death.
VN660
Removal
1
Begin by removing the front lower W8002490
headliner, see Headliner, Replace- Remove the bunk curtain rail assem- Torx 25
ment (Front Lower) page 55. bly.
2 5
Remove the upper right bunk storage Torx 40
cabinet as follows: Socket 10 mm
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.
3
Remove the upper left bunk storage Torx 40
cabinet by removing the 4 wall mount-
ing bolts.
W8002512
Remove the right front overhead stor- Socket 13 mm

age compartment as follows: Torx 20
Remove 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
6 Installation
Remove the left front overhead stor- Socket 13 mm
age compartment as follows: Torx 20 1
Remove the bezel net screws to the Install the replacement headliner into
center overhead storage compartment. its mounting location. Secure with the
Remove the rear support rod. Remove 3 Christmas tree fasteners.
the bottom mounting screws.
Carefully work the compartment out of
its mounting location, back and around
the bunk headliner/trim. Remove it
terial.
from the vehicle.
2
7
Slide the front overhead storage com- Socket 13 mm
Disengage the 2 Christmas tree fas-
partment mounting shelf forward into Torx 20
teners on both the right and left center
its mounting position. Torx 40
bunk trim panels directly behind the
Secure the bottom front, top front and Torque wrench
front overhead storage compartment
side mounting bolts. 24 4 Nm
mounting shelf. This will allow the
Install and secure the 2 support rods. (18 3 ft-lb)
shelf to be moved rearward and permit
Torque both bolts and rods to
removal of the skylight headliner.
24 4 Nm (18 3 ft-lb).
8
3
Remove the center front overhead Socket 13 mm
Engage the 2 Christmas tree fasteners
storage compartment mounts as fol- Torx 20
on both the right and left center bunk
lows: Torx 40
trim panels.
Remove the 2 support rods. Remove
the bottom mounting bolts.
Remove the top front and side mount- 4
ing bolts. Install the left front overhead storage Socket 13 mm
Slide the mounting shelf rearward compartment as follows: Torx 20
enough to allow removal of the sky- Install the compartment into the Torque wrench
light headliner. vehicle and carefully work the com- 24 4 Nm
partment into its mounting location. (18 3 ft-lb)
Secure the bottom mounting screws.
9
Install the rear support rod. Torque to
Remove the 1 front and the 2 rear J-38778
24 4 Nm (18 3 ft-lb).
Christmas tree fasteners in the sky-
Secure the bezel net screws to the
light headliner.
10
5
Carefully work the skylight headliner
Install the right front overhead com- Socket 13 mm
out from under the bunk headliner and
partment as follows: Torx 20
out of its mounting location. Remove it
Install the compartment into the Torque wrench
from the vehicle.
vehicle and carefully work the com- 24 4 Nm
Note: Use caution not to bend the partment into its mounting location. (18 3 ft-lb)
headliner to the point at which a Secure the bottom mounting screws.
permanent crease will show in the ma- Install the rear support rod. Torque to
terial. 24 4 Nm (18 3 ft-lb).
Connect any electrical components if
equipped.
60
W8002490

Torque to 5 1 Nm (44 9 in-lb). 5 1 Nm
(44 9 in-lb)
7
Install the upper right bunk storage Torx 40
cabinet as follows: Socket 10 mm
Lift the cabinet into position and insert Torque wrench
the power supply wiring and coaxial 68 7 Nm
cable. Fit the cabinet over the HVAC (50 5 ft-lb)
duct at the rear of the cabinet. 12 2 Nm
Install the 4 wall mounting bolts and (9 1.5 ft-lb)
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- Torx 40
inet as follows: Torque wrench
Lift the cabinet in place and install the 68 7 Nm
4 mounting bolts. Torque to 68 7 Nm (50 5 ft-lb)
(50 5 ft-lb).
9
Complete this procedure by installing
the front lower headliner, see
Lower) page 55.
61
8554-03-02-05 4

Upper)

jury or death.
W8002491
VN770 Remove both (right and left) seat belt J-38778

shoulder harnesses mounting bolts. Torx 50
Removal Pull back the upper rear of the door
seal to loose the B pillar trim.
Gently pull back the B pillar trim and
1
remove the Christmas tree fastener to
Begin by removing the lower front
the upper tower cabinets.
headliner, see Headliner, Replace-
ment (Front Lower) page 55.
trim panel.
2
Remove the lower mattress/work sta- 5
tion cushions from the vehicle. Remove the ladder assembly (if Torx 30
equipped).
3
6
W8002490
Remove the bunk curtain rail assem- Torx 25

bly.
W8002176

bezels. driver
62
7 9
W8002177
Remove the cabinet below the lower Torx 25

right bunk by removing the 3 torx bolts.
W8002180

fascia panel.
W8002178
Remove the duct from the bunk HVAC Torx 25

unit to the right bunk fascia panel.
63
10 11
W8002492

as follows: Torx 30
W8002179
Remove the right bunk fascia panel as J-38778
inet and unplug the power supply Socket 12 mm
follows: Torx 25
connectors. Socket 13 mm
Pull back the lower right trim panel to Socket 11 mm
expose the lower mounting screws.
tom wall (2). Remove the 6 bolts
The panel is secured with Christmas
between the upper and lower cabinet
tree and/or interlock fasteners.
(1).
Remove the 2 lower mounting screws
and the 3 screws along the top.
expose the upper front wall mounting
Remove the 8 nuts securing the panel
bolt. Remove the bracket from the cab-
to the right tower cabinet.
inet that holds the interlock fastener.
Pull the fascia out from the top to clear
Pull back the B pillar trim to expose
the bottom stud.
the lower front wall mounting bolt. Re-
move the 5 wall mounting bolts (3).
12
Remove the upper right tower cabinet
the vehicle.
64
13 16
Pull back the lower left trim panel to J-38778
expose the lower left bunk fascia panel
mounting screws. The panel is
terlocking fasteners.
17
W3002102
Remove the refrigerator (if equipped) Torx 30

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 W8002494
and unplug the 12 volt connector.

Remove the screws securing the left Torx 25
bunk fascia panel to the wall and the Socket 11 mm
nuts securing the panel to the left
14 tower cabinet and remove the fascia
Remove the left tower cabinet drawer Torx 20 panel from its mounting location.
stops. Remove the sink plumbing and Socket 7 mm Turn the bunk master control panel to
electrical connectors (if equipped). Slotted screw- fit through the cut out in the fascia
Remove the drawer. driver panel and remove the panel from the
vehicle.
15
W8002493
Remove the bunk master control panel Phillips screw-

from the left bunk fascia panel by re- driver
Disconnect the 2 top connectors (2)
and allow the control panel to hang
from the wiring.
65
18 19
W8002512
Remove the right front overhead stor- Socket 13 mm

age compartment as follows: Torx 20 mm
Remove the bezel net screws to the
Disconnect any electrical components
(if equipped).
Remove the rear support rod (1). Re-
move the bottom mounting screws (2).
W8002495 Carefully work the compartment out of
Remove the upper left tower cabinet Torx 40 its mounting location, back and around
as follows: Torx 30 the bunk headliner/trim. Remove it
Unplug the power supply connectors. Torx 20 from the vehicle.
Remove the 5 bolts from the rear bot- Socket 12 mm
tom wall (2) and the 6 bolts between Socket 13 m
the upper and lower cabinet (1). Phillips screw- 20
driver Remove the left front overhead stor- Socket 13 mm
Note: The lower cabinet door hinges age compartment as follows: Torx 20 mm
may need to be temporarily removed Remove the bezel net screws to the
to remove the 2 front bolts. Re-install center overhead storage compartment.
hinges before removing the cabinet. Remove the rear support rod. Remove
the bottom mounting screws.
Pull the upper front trim panel back to Carefully work the compartment out of
expose the upper front wall mounting its mounting location, back and around
bolt. Remove the bracket from cabinet the bunk headliner/trim. Remove it
that holds the interlock fastener. from the vehicle.
Pull back the B pillar trim to expose
the lower front wall mounting bolt. Re-
move the 5 wall mounting bolts (3). 21
Remove the cabinet out of the vehicle. Remove the 2 shark fin dividers from Socket 13 mm
the center compartment shelf as fol- Torx 20 mm
Note: This step requires 2 people. lows: Torx 15
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.
66
22 Installation
Remove the 1 front and 2 rear Christ- J-38778
mas tree fasteners in the skylight 1
headliner.
Carefully work the skylight headliner
out from under the bunk headliner and
out of its mounting location. Remove it
from the vehicle.
W8002516
Install the replacement skylight head-

liner into its mounting location. Secure
with the 3 Christmas tree fasteners.

terial.
2
Install the 2 shark fin dividers to the Socket 13 mm
center compartment shelf as follows: Torx 20
Place the dividers in their mounting lo- Torx 15
cation. Secure the mounting screws Torque wrench
and re-position the carpet. 24 4 Nm
Install the 2 support rods, tubes and (18 3 ft-lb)
bracket assemblies. Torque the rods to
24 4 Nm (18 3 ft-lb).
3
Install the left front overhead storage Socket 13 mm
compartment as follows: Torx 20
Torque the 5 bottom mounting screws.
Install the rear support rod and torque
to 24 4 Nm (18 3 ft-lb).
67
4 6
W8002512
Install the right front overhead storage Socket 13 mm

compartment as follows: Torx 20
Torque the 5 bottom mounting screws
(2).
Install the rear support rod (1) and
torque to 24 4 Nm (18 3 ft-lb).
Connect any electrical components (if W8002495
equipped). Install the upper left tower cabinet as Torx 40
follows: Torx 30
Start all cabinet mounting bolts before Torx 20
5 beginning tightening them. Socket 12 mm
Position the upper left tower cabinet Install the 5 wall mounting bolts (2) Socket 13 mm
into its mounting location. Work the and torque to 24 4 Nm (18 3 ft-lb). Phillips screw-
cabinet around the trim panels and Install the 6 bolts between the upper driver
pull the wiring through the cabinet as and lower cabinet (1) and torque to Torque wrench
necessary. 24 4 Nm (18 3 ft-lb). 24 4 Nm
Note: This step requires 2 people. (18 3 ft-lb)
Note: The lower cabinet door hinges 24 4 Nm
may need to be temporarily removed (18 3 ft-lb)
to install the 2 front bolts. Re-install 10 1.5 Nm
hinges after the bolts between the up- (89 13 in-lb)
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-lb).
Torque all cabinet mounting bolts.

Install the bracket that holds the inter-
lock fastener to the cabinet. Secure
terlock fastener.
68
7 11
W8002494 W3002102
Fit the bunk master control panel Torx 25 Install refrigerator (if equipped) as fol- Torx 30
through the cut out in the left bunk fas- Socket 11 mm lows: Torque wrench
cia panel. Torque wrench Position the refrigerator in the floor 13 2 Nm
Position the left bunk fascia panel into 3 0.5 Nm mounting rails and connect the 12 volt (10 1.5 ft-lb)
its mounting location. Secure the (27 4 in-lb) connector.
panel to the tower cabinets with the Slide the refrigerator as far back on
plastic stud nuts. Secure the panel to the tracks as possible. Open the refrig-
the wall with screws. Torque to erator door and install the mounting
3 0.5 Nm (27 4 in-lb). strips (1). Torque to 13 2 Nm
(10 1.5 ft-lb).
8
Secure the lower left trim with Christ- 12
mas tree and/or interlock fasteners. Install the upper right tower cabinet as
follows:
Position the cabinet into its mounting
9 location.
Work the cabinet around trim panels
and pull the wiring through the cabinet
as necessary.
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
69
13 14
W8002492
Install the upper right tower cabinet as Torx 40

follows: Torx 30
Start all mounting bolts in the cabinet Torx20
before beginning tightening. Socket 12 mm
Install the 5 wall mounting bolts (3) Socket 13 mm
and the 6 bolts between the upper and Phillips screw- W8002182
lower cabinet (1). Torque to driver Position the right bunk fascia panel Torx 25
24 4 Nm (18 3 ft-lb). Torque wrench into its mounting location. Secure the Socket 11 mm
Install the 5 bolts to the rear bottom 24 4 Nm panel to the tower cabinets with the Torque wrench
wall (2) and torque to 10 1.5 Nm (18 3 ft-lb) plastic stud nuts. Secure the panel to 3 0.5 Nm
(89 13 in-lb). 24 4 Nm the wall with the 5 torx screws. Torque (27 4 in-lb)
Torque all cabinet mounting bolts. (18 3 ft-lb) to 3 0.5 Nm (27 4 in-lb).
Install the bracket that holds the inter- 10 1.5 Nm
lock fastener to the cabinet. Secure (89 13 in-lb)
the upper front trim panel with the in- 15
terlock fasteners. Secure the lower right trim with Christ-
Connect the power supply connectors. mas thee and/or interlocking fasteners.
70
16 18
W8002177
Install the cabinet 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)
19
W8002180

fascia panel.
17
W8002176

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 1.5 Nm
3 0.5 Nm (27 4 in-lb). (7 1 ft-lb)
71
21
W8002501
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).

trim panel.
22
W8002490

bly. Torque to 5 1 Nm (44 9 in-lb). Torque wrench
5 1 Nm
(44 9 in-lb)
23
Complete this procedure by installing
the front lower headliner, see
Lower) page 55.
72
8521-03-02-01 4
Seat, Replacement
WARNING
The seat is heavy! Do not attempt to lift seat out sin-
gle-handed. Use a second person or other lifting
Before working on a vehicle, set the parking brakes, device. Failure to follow this procedure may result in
place the transmission in neutral and chock the personal injury.
vehicle movement and can cause serious personal in- Lift seat out of the cab.
jury or death.
Standard Seat Installation

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 2
one side and the seat tether on the Install the four bolts holding the seat to 14 mm socket
other side. the floor. Tighten the bolts to a torque Torque wrench
of 48 8 Nm (35 6 ft-lb). 48 8 Nm
(35 6 ft-lb)
3
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
Volvo Seat Installation

1
Removal
1
Empty the air supply line by opening
WARNING
drain cock on the B-system tank.
Empty the supply line by operating the The seat is very heavy! Do not attempt to lift seat up
seat height button. Disconnect air line into the cab single-handed. Use a second person or
from the seat. Disconnect the wire other lifting device. Failure to follow this procedure
connectors. may result in personal injury.
Lift seat into cab and place it over the

2
bolt holes.
Remove the bolts for the safety belt 16 mm socket
D-loop and belt retractor from the B-
pillar. Lay the safety belt on the seat 2
cushion. Install the five bolts holding the seat to 14 mm socket
the floor. Tighten the bolts to a torque Torque wrench
of 48 8 Nm (35 6 ft-lb). 48 8 Nm
3
(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.
W8001397
Remove the five bolts holding the seat 14 mm socket

to the floor.
WARNING
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
Seat, Overhaul
T8006493
Fig. 1: Seat, Exploded View
75
Call-out Description See the following for procedures on the Volvo seat:
A Seat Cushion
B Seat Backrest Cushion Seat Cushion, Replacement page 77
C Seat Headrest Seat Backrest Cushion, Replacement page 77
D Seat Backrest Cover (Upper)
E Seat Backrest Cover (Lower) Seat Headrest, Replacement page 77
F Seat Frame Cover (Rear)
G Seat Frame Cover (Right Side) Seat Backrest Cover, Replacement (Upper) page 77
H Seat Frame Cover (Left Side)
I Seat Compressed Air Valve Seat Backrest Cover, Replacement (Lower) page 78
J Seat Heater Switch Seat Frame Cover, Replacement (Rear) page 78
K Seat Adjustment Switch Panel
L Seat Cushion Base Seat Frame Cover, Replacement (Right Side) page 78
M Seat Backrest Air Cushion
r, o Heating Element Connectors Seat Frame Cover, Replacement (Left Side) page 79
3 Control Button Seat Compressed Air Valve, Replacement page 79
13 Headrest Guides
15 Cover Washer Seat Heater Switch, Replacement page 79
16A Inside Cover Screws
16B Frame Cover Screws Seat Adjustment Switch Panel, Replacement page 80
20 Catches Seat Cushion Base, Replacement page 80
22 Clamping Hooks
24 Relay Box Connector Seat Backrest Air Cushion, Replacement page 80
25 Seat Frame Hole
27 Air Cushion Holder Stay Seat Control Harness, Replacement page 81
28 Lockring Clips
Seat Motor, Replacement (Cushion Position) page 83
29 Outside Cover Screws
32 Rubber Hose Seat Motor, Replacement (Seat Positioning) page 84
45A Frame Cover Screws
45B Switch Panel Screws Seat Motor, Replacement (Cushion Tilt) page 85
43 Seat Cushion Base Screws
50 Heater Switch Connector 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 Vertical Shock Absorber, Replacement page 98
76
8523-03-02-01 8529-03-02-01
Seat Cushion, Replacement Seat Headrest, Replacement
Before working on a vehicle, set the parking brakes, Before working on a vehicle, set the parking brakes,
place the transmission in neutral and chock the place the transmission in neutral and chock the
wheels. Failure to do so can result in unexpected wheels. Failure to do so can result in unexpected
vehicle movement and can cause serious personal in- vehicle movement and can cause serious personal in-
jury or death. jury or death.
See illustration Fig. 1: Seat, Exploded View, page 75, See illustration Fig. 1: Seat, Exploded View, page 75,
(A) (C)
1 1
Pull the seat cushion out of the clamps Pull up the head rest to its stop posi-
(1). Disconnect the connector (r) for tion. Turn the cover washer (15)
the seat cushion heating element. counter-clockwise and remove the
head rest by pulling it up. (See illustra-
tion)
2
Install the cushion in the reverse order
2
of removal. Test seat for function.
Install the headrest in the reverse or-
der of removal. Test seat for function.
8524-03-02-01
Seat Backrest Cushion, Re- 8524-03-02-03
placement Seat Backrest Cover, Replace-
ment (Upper)

place the transmission in neutral and chock the Before working on a vehicle, set the parking brakes,
wheels. Failure to do so can result in unexpected place the transmission in neutral and chock the
vehicle movement and can cause serious personal in- wheels. Failure to do so can result in unexpected
jury or death. vehicle movement and can cause serious personal in-
jury or death.
See illustration Fig. 1: Seat, Exploded View, page 75,
(B) See illustration Fig. 1: Seat, Exploded View, page 75,
(D)
1
Pull the backrest cushion off from the 1
backrest frame. Remove the backrest Pull off the backrest cushion (see B).
covers, see D and E. Remove the Remove the head rest (see C). (See il-
lockring clips (28) for the cushion lustration)
clamps. (See illustration)
2
2 Compress the lower part of the guides
Disconnect the connectors (r) and (o) (13) for the head rest, push them up
for the seat cushion and backrest and remove them. If the backrest
cushion heater elements. Separate the cushion is locked behind the backrest
rubber hose (32) at the connection. frame, the guides must be worked
loose and pulled out. Remove screws
(16A) and remove the cover.
3
Install the backrest in the reverse or- Note: Take care not to damage the
der of removal. Test seat for function. catches (20).
77
3 8522-03-02-01
Install the cover in the reverse order of
removal. Test seat for function. Seat Frame Cover, Replace-
ment (Rear)
8524-03-02-02
Seat Backrest Cover, Replace-
ment (Lower) Before working on a vehicle, set the parking brakes,
jury or death.
place the transmission in neutral and chock the See illustration Fig. 1: Seat, Exploded View, page 75, (F)
vehicle movement and can cause serious personal in- 1
jury or death. 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)
(E)
1
2
Pull off backrest cushion (see B) and
upper cover (see D). Remove inside
removal. Test seat for function.
screws (16A) or remove outside
screws (29) for cover. (See illustration)
8522-03-02-02
2
Install the cover in the reverse order of Seat Frame Cover, Replace-
removal. Test seat for function. ment (Right Side)

jury or death.

(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
78
8522-03-02-03 2
Pull the three air cushion air hoses
Seat Frame Cover, Replace- from the valve unit. Pull rubber hose
ment (Left Side) (32) for side support cushions apart at
connection (66). Remove rubber hose
(63) from distribution pipe (67).
3
Before working on a vehicle, set the parking brakes, Press out the switch (J) and discon-
place the transmission in neutral and chock the nect the connector (50).
jury or death. 4
Install the valve in the reverse order of
(H)
1 8526-03-02-01
Pull off seat cushion and backrest
cushion (see A and B). Press out con-
Seat Heater Switch, Replace-
trol button (3). (See illustration) ment
2
Push valve unit clamping hooks (22) to
the side and release control unit (I),
push them through hole (21). Before working on a vehicle, set the parking brakes,
3 vehicle movement and can cause serious personal in-
Remove the two screws (45A) and the jury or death.
three screws (16B). Remove the
switch panel (K), (see K).
See illustration Fig. 1: Seat, Exploded View, page 75, (J)
1
4
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)
8529-03-02-02
Seat Compressed Air Valve, 2
Replacement Install the switch in the reverse order
of removal. Test seat for function.

jury or death.
See illustration Fig. 1: Seat, Exploded View, page 75, (I)
1
Press out the control button (3). Press
the valve unit clamping hooks (22) to
the side and release the control unit
(I). (See illustration)
79
8526-03-02-02 8524-03-02-04
Seat Adjustment Switch Panel, Seat Backrest Air Cushion, Re-
Replacement placement
Before working on a vehicle, set the parking brakes, Before working on a vehicle, set the parking brakes,
place the transmission in neutral and chock the place the transmission in neutral and chock the
wheels. Failure to do so can result in unexpected wheels. Failure to do so can result in unexpected
vehicle movement and can cause serious personal in- vehicle movement and can cause serious personal in-
jury or death. jury or death.
See illustration Fig. 1: Seat, Exploded View, page 75, See illustration Fig. 1: Seat, Exploded View, page 75,
(K) (M)
1 1
Remove the seat frame left-hand Remove backrest cushion (see B). Pull
cover. Remove the three screws (45B) off the three rubber hoses from the air
and remove the switch panel (K). (See cushions connections. Unhook the air
illustration) cushions holder from the stay (27).
(See illustration)
2
Pull apart the connector (24) on the 2
relay box. Pull apart the wire holders Install the cushions in the reverse or-
and pull the wire with the connector der of removal. Test seat for function.
out of the seat frame and hole (25).
3
Install the panel in the reverse order of
8523-03-02-02
Seat Cushion Base, Replace-
ment

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
8526-03-02-03
Seat Control Harness, Replacement
T8006505
Fig. 2: Seat, Exploded View
H Left Hand Cover 16, 45 Left Hand Coever Screws

2 Solenoid Valve Connectors 50 Seat Heating Connector
3 Electric Motors Connectors
1
Note: Disconnect the batteries before
doing any work on the seat.
Before working on a vehicle, set the parking brakes, If a defect is found in the wire harness,
place the transmission in neutral and chock the the complete harness must be re-
wheels. Failure to do so can result in unexpected placed.
vehicle movement and can cause serious personal in- Block the seat in its upper position us-
jury or death. ing a 150 mm (6 in.) extension
between the frames. Disconnect con-
See Fig. 2: Seat, Exploded View, page 81 (A) nector (1).
81
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 reverse
order of removal. Test seat for function.
82
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
Remove the screws (45), pull out the
drive cable and lift out the motor.
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
See Fig. 3: Seat base, exploded view, page 83 (A) nut (11) out of the attachment (10).
1
Remove the seat cushion and seat
cushion base. Disconnect the wire
connectors at the motor.
83
8526-03-02-07
Seat Motor, Replacement (Seat
Positioning)

jury or death.
See Fig. 3: Seat base, exploded view, page 83, (B)
1
Remove 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
3
Remove worm gear unit locking plate
(64). Remove lock washer (9) and
nut (27) out of the attachment (65).
84
8526-03-02-06
Seat Motor, Replacement (Cushion Tilt)
W8001432
8 Shaft 59 Valve Screws

9 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
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.
jury or death. 2
See Fig. 4: Seat base, exploded view, page 85 (C)
85
3 8526-03-02-17
Remove worm gear unit locking plate
(64). Remove lock washer (9) and Seat Electro-Pneumatic Height
Control Valve, Replacement
nut (27) out of the attachment (65).

jury or death.
See Fig. 4: Seat base, exploded view, page 85, (D)
1
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.
86
8526-03-02-04
Seat Motor, Replacement (Backrest Tilt)
T8006495
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.
vehicle movement and can cause 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
8526-03-02-05 8526-03-02-18
Seat Motor, Replacement (Up- Seat Control Unit, Replacement
per Backrest Tilt)

Before working on a vehicle, set the parking brakes, wheels. Failure to do so can result in unexpected
place the transmission in neutral and chock the vehicle movement and can cause serious personal in-
wheels. Failure to do so can result in unexpected jury or death.
jury or death.
See Fig. 5: Seat backrest, exploded view, page 87, (C)
See Fig. 5: Seat backrest, exploded view, page 87, (B) 1
Remove cover for lower backrest. Pull
1 all connectors out of the control unit.
Remove cover for upper backrest. Dis-
connect wire connections at the motor.
2
Remove the two screws (19) and re-
2 move the control unit by lifting it up. If
Remove the screws (16), pull out of necessary, remove air cushions (27).
the drive cable and lift out the motor. Install components in the reverse or-
Remove locking plate (38) and pull the der of removal.
drive cable out of the worm gear unit.
3
Remove the lock washer (5) and shaft
(4). Remove the screw (7).
88
8526-03-02-13
Seat Height Control Cylinder, Replacement
T8006510
Fig. 6: Seat height control
X Spacer 22 Pin
9 Cylinder Pin 25 Lock Cylinder
11 Control Cylinder 27 Screw
13 Guide Disc Unit 28 Screw
14 Level Control Valve 96 Hose
18C Lock Ring 97 Hose
19 Bolt
2
Loosen the clamping sleeves and pull
hoses (96) and (97) off from the con-
Before working on a vehicle, set the parking brakes, trol cylinder (11). Remove the cylinder
place the transmission in neutral and chock the pin (9). Loose screw (27) a little and
wheels. Failure to do so can result in unexpected lightly press the guide disc unit (13)
vehicle movement and can cause serious personal in- lever plates apart where they are con-
jury or death. nected to the control cylinder and
remove the cylinder.
See Fig. 6: Seat height control, page 89 (11)
1 3
Remove the seat cushion and seat Install the components in reverse or-
cushion base. Release the bellows der of removal. Tighten screw (27) a
from the front of the upper and lower little . Pull the control for height adjust-
frames. Block the seat in its upper po- ment upward and check that the lock
sition using a 150 mm (6 in.) long cylinder (25) can move freely. If not,
spacer (X) placed between the frames. loosen screw (27) and, if necessary,
also screw (28) a little.
89
8526-03-02-12
Seat Height Setting Guide
Plate, Replacement

jury or death.
See Fig. 6: Seat height control, page 89, (12)
1
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
8526-03-02-11
Seat Height Guide Disc Unit, Replacement
T8006511
Fig. 7: Seat Height Guide Disc Unit
12 Guide Plate 25 Lock Cylinder

13 Guide Disc Unit 26 Guide Plate Cam
18C Lock Ring 27 Screw
19 Bolt 28 Screw
22 Pin 107 Hose
1
Before working on a vehicle, set the parking brakes, from the front of the upper and lower
place the transmission in neutral and chock the frames. Block the seat in its upper po-
wheels. Failure to do so can result in unexpected sition using a 150 mm (6 in.) spacer
vehicle movement and can cause serious personal in- (X) placed between the frames.
jury or death.
See Fig. 7: Seat Height Guide Disc Unit, page 91, (13) 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
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
8526-03-02-10
Seat Height Level Control Valve, Replacement
T8006498
Fig. 8: Seat height control
14 Level Control Valve 95 Hose

15 Screws 96 Hose
17 Screw 97 Hose
23 Hose 107 Hose
24 Hose 161 Hose
94 Hose
See Fig. 8: Seat height control, page 93 (14)
1
Before working on a vehicle, set the parking brakes, Remove the seat cushion and seat
place the transmission in neutral and chock the cushion base. Release the bellows
wheels. Failure to do so can result in unexpected from the front and side of the upper
vehicle movement and can cause serious personal in- frame. Block the seat in its upper posi-
jury or death. tion using a 150 mm (6 in.) spacer (X)
placed between the frames.
93
2 8526-03-02-09
Remove both screws (15) from the
level control valve (14). Loosen the Seat Height Two-Way Valve,
hose clamps and pull off hoses (94),
(95) and (161). Install components in
Replacement
reverse from removal.

jury or death.
See Fig. 8: Seat height control, page 93, (16)
1
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.
94
8526-03-02-14
Seat Cam Disc, Replacement
T8006499
Fig. 9: Seat cam disc
X Spacer 27 Screw
11 Control Cylinder 140 Cable Pulley
13 Guide Disc Unit 141 Cam Disc
14 Level Control Valve 147 Bolt
18A Lock Washer 148 Spring
18B Lock Washer
See Fig. 9: Seat cam disc, page 95 (141)
1
Before working on a vehicle, set the parking brakes, Release the bellows from the front and
place the transmission in neutral and chock the side of the upper frame. Block the seat
wheels. Failure to do so can result in unexpected in one of the lower positions. Remove
vehicle movement and can cause serious personal in- the level control valve (14).
jury or death.
2
Remove the lock washer (18B) and
pull out the bolt (147). Pull the 7step
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
8526-03-02-15
Seat Cam Disc Cable, Replace-
ment

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 the cable pulley (140). Install
the components in reverse from re-
moval.
96
8526-03-02-16
Seat Air Spring, Replacement
T8006500
X Spacer 30 Seat Vertical Shock Absorber

4 Screw 37 Screw
6 Seat Air Spring 95 Hose
1
Release the bellows from the front and
Before working on a vehicle, set the parking brakes, in its upper position using a 150 mm
place the transmission in neutral and chock the (6 in.) long spacer (X) placed between
wheels. Failure to do so can result in unexpected the frames. Pull back the clamping
vehicle movement and can cause serious personal in- ring on the air spring connection and
jury or death. pull off the hose (95). Remove the
screws (4) and (37).
See Fig. 10: Seat base, exploded view, page 97 (6)
97
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

jury or death.
See Fig. 10: Seat base, exploded view, page 97, (30)
1
Release the bellows at the front and
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
8118-03-02-01 Installation
Engine Cover, Replacement 1
Lift engine cover into the cab. Place 12 mm socket
on the floor and slide up under the
dash panel. Line up the holes for the
top bolts and enter the bolts. Line up
Before working on a vehicle, set the parking brakes, the rear bolt holes. Tighten the bolts.
vehicle movement and can cause serious personal in- 2
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.
W8002525
Place floor mat back into position. In- 12 mm socket

4
stall scuff plates. Tighten screws and 24 4 Nm
Pull floor mat back on the right side
install the plugs. Torque the screws to (18 3 ft-lb)
and lay to the side toward the shift
24 4 Nm (18 3 ft-lb).
lever to uncover the engine cover. Pull
back mat on the left side.
3
5 Install the lower dash panel.
4
Install seat, see Seat, Replacement
page 73.
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.
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
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To From
Volvo Trucks North America, Inc. ..........................................................................

Dept. 516 Service Publications ..........................................................................
7825 National Service Road ..........................................................................
P.O. Box 26115 ..........................................................................
Greensboro, NC 27402-6115 ..........................................................................
USA ..........................................................................
Fax (336) 393-3170 ..........................................................................
Comments/proposals
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Concerns Service Manual: ...............................................................................................................................

Operation Numbers
8118-03-02-01 Engine Cover, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

8511-03-02-01 Door Panel, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8521-03-02-01 Seat, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8522-03-02-01 Seat Frame Cover, Replacement (Rear) . . . . . . . . . . . . . . . . . . . . . 78
8522-03-02-02 Seat Frame Cover, Replacement (Right Side) . . . . . . . . . . . . . . . . . . . 78
8522-03-02-03 Seat Frame Cover, Replacement (Left Side) . . . . . . . . . . . . . . . . . . . 79
8523-03-02-01 Seat Cushion, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
8523-03-02-02 Seat Cushion Base, Replacement . . . . . . . . . . . . . . . . . . . . . . . . 80
8524-03-02-01 Seat Backrest Cushion, Replacement . . . . . . . . . . . . . . . . . . . . . . 77
8524-03-02-02 Seat Backrest Cover, Replacement (Lower) . . . . . . . . . . . . . . . . . . . . 78
8524-03-02-03 Seat Backrest Cover, Replacement (Upper) . . . . . . . . . . . . . . . . . . . . 77
8524-03-02-04 Seat Backrest Air Cushion, Replacement . . . . . . . . . . . . . . . . . . . . . 80
8526-03-02-01 Seat Heater Switch, Replacement . . . . . . . . . . . . . . . . . . . . . . . . 79
8526-03-02-02 Seat Adjustment Switch Panel, Replacement . . . . . . . . . . . . . . . . . . . 80
8526-03-02-03 Seat Control Harness, Replacement . . . . . . . . . . . . . . . . . . . . . . . 81
8526-03-02-04 Seat Motor, Replacement (Backrest Tilt) . . . . . . . . . . . . . . . . . . . . . 87
8526-03-02-05 Seat Motor, Replacement (Upper Backrest Tilt) . . . . . . . . . . . . . . . . . . 88
8526-03-02-06 Seat Motor, Replacement (Cushion Tilt) . . . . . . . . . . . . . . . . . . . . . 85
8526-03-02-07 Seat Motor, Replacement (Seat Positioning) . . . . . . . . . . . . . . . . . . . 84
8526-03-02-08 Seat Motor, Replacement (Cushion Position) . . . . . . . . . . . . . . . . . . . 83
8526-03-02-09 Seat Height Two-Way Valve, Replacement . . . . . . . . . . . . . . . . . . . . 94
8526-03-02-10 Seat Height Level Control Valve, Replacement . . . . . . . . . . . . . . . . . . 93
8526-03-02-11 Seat Height Guide Disc Unit, Replacement . . . . . . . . . . . . . . . . . . . . 91
8526-03-02-12 Seat Height Setting Guide Plate, Replacement . . . . . . . . . . . . . . . . . . 90
8526-03-02-13 Seat Height Control Cylinder, Replacement . . . . . . . . . . . . . . . . . . . . 89
8526-03-02-14 Seat Cam Disc, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 95
8526-03-02-15 Seat Cam Disc Cable, Replacement . . . . . . . . . . . . . . . . . . . . . . . 96
8526-03-02-16 Seat Air Spring, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 97
8526-03-02-17 Seat Electro-Pneumatic Height Control Valve, Replacement . . . . . . . . . . . . 86
8526-03-02-18 Seat Control Unit, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 88
8529-03-02-01 Seat Headrest, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 77
8529-03-02-02 Seat Compressed Air Valve, Replacement . . . . . . . . . . . . . . . . . . . . 79
8529-03-02-03 Seat Vertical Shock Absorber, Replacement . . . . . . . . . . . . . . . . . . . 98
8554-03-02-01 Headliner, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8554-03-02-02 Headliner, Replacement (Front) . . . . . . . . . . . . . . . . . . . . . . . 21, 29
8554-03-02-03 Headliner, Replacement (Bunk) . . . . . . . . . . . . . . . . . . . 26, 34, 38, 43
8554-03-02-04 Headliner, Replacement (Front Lower) . . . . . . . . . . . . . . . . . . . . . . 55
8554-03-02-05 Headliner, Replacement (Front Upper) . . . . . . . . . . . . . . . . . . . . 59, 62
8561-03-02-01 Bunk, Replacement (Upper) . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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-TSP133527 (1 000) 02.2000 Volvo Trucks North America, Inc., 2000

Service Manual Trucks Group 85 Cab, Upholstery VN

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Service Manual Trucks Group 85 Cab, Upholstery VN

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Service Manual

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Note: Indicates a procedure, practice, or condition that must be followed in order to

Volvo Trucks North America, Inc.

Order number: PV776-TSP133527

2000 Volvo Trucks North America, Inc., Greensboro, NC USA

All rights reserved. No part of this publication may be reproduced, stored in

Before working on a vehicle, set the parking brakes,

Design and Function

As an option, this seat comes with air operated support

A luxury Volvo seat offers many adjustments and conve-

The seat is also equipped with heating elements in the

For the passenger side, there is a stationary seat avail-

Manual shift lever mounting Automatic shift lever mounting

The engine cover is different for a VNL and a VNM. In

To remove the engine cover, see Engine Cover, Re-

In the sleeper cabs there are separate sections for the

Before working on a vehicle, set the parking brakes,

Using a small, flat bladed screwdriver,

Remove the knob on the door by Torx 10

Remove the three bolts and three 14 mm socket;

If the vehicle is equipped with me- Torx 25

8561-03-02-01 Fascia Panel and Trim, Removal

To remove the upper bunk the R/H side cabinets and

Remove the 4 bunk window trim Phillips screw-

Remove the seat belt by removing the

Remove the 6 torx screws holding the Torx 25

Remove 5 torx screws, 3 along the top Torx 25

Remove the duct hose in the upper Torx 25

Tower Cabinets, Removal 4

Upper Bunk, Removal

Remove the upper right tower cabinet Torx 40

bolt. Remove the bracket from the cab-

Upper Bunk, Installation Tower Cabinets, Installation

Note: This step requires 2 people.

Make sure that the bunk is flat and the

Note: Install rags on the vise to avoid

Fascia Panel and Trim, Installation 3

Secure the duct hose in the upper Torx 25

Install the duct from the bunk HVAC Torx 25

Install the cabinet below the lower right Torx 25

Install the seat belt shoulder harness 50 10 Nm

Install the 4 bunk window trim bezels. Phillips screw-

B-Pillar Trim Panel and Seat Belt

Before working on a vehicle, set the parking brakes,

1 Plastic rivets (day cab vehicles only)

Remove the upper grab handle bolt Socket 12 mm

Note: On vehicles that are not

Remove the 2 Christmas tree fasten- J-38778

1 Curtain rail or trim washer

Remove the front curtain rail assem- Slotted screw-

Note: Two screw covers, on the far

1 Curtain rail or trim washer

Remove the screws securing the front Torx 15

Note: The screws are equipped with

1 Plastic rivets (day cab vehicles only)

Remove the upper grab handle bolt

Note: May not apply, depending on

Remove the 2 Christmas tree fasten- J-38778 1 Roof plate

1 Curtain rail or trim washer

Line up the mounting screws for the Torx 15

6 1 Plastic rivets (day cab vehicles only)

Note: Use caution not to deform the

Install the front right overhead storage Torx 25