Service BulletinVolvo Trucks North America, Inc.Greensboro, NC USA

Date Group No. Page

3.2002 397 002 1(22)

Trucks

Volvo Link SystemService Procedures

Satellite Communication System Service Proce-dures

W3004840

Volvo Link ECU

The Volvo Link System provides satellite communications. It includes the Volvo LinkECU, GPS antenna, wiring harnesses and dash switch. This system allows communi-cations between the fleet, via Volvo’s Web based software, and the vehicle.

This information covers repair procedures of the vehicle portion of the Volvo Link sys-tem. For design and troubleshooting information, see service information in group 397.

This information contains:

• “Volvo Action Service Switch, Replacement” page 2• “ECU, Replacement” page 2• “GPS Antenna, Replacement” page 4• “GPS Antenna Cable, Replacement” page 5• “Radio Adapter Cables, Replacement” page 9• “Wiring Harness, Replacement” page 10• “Kit, Installation” page 12

PV776-TSP168911 USA11191

Page 2

Service Procedures

3646-03-02-44Volvo Action Service Switch,ReplacementNOTE: The Volvo Action Service Switch may not be pro-vided with all Volvo Link systems.

1

Before working on a vehicle, set theparking brakes, place the transmis-sion in neutral, and block thewheels. Failure to do so can resultin unexpected vehicle movementand can cause serious personal in-jury or death.

Make certain the vehicle ignition isOFF.

2Insert a small slotted screwdriver intothe bottom of the switch to release thelocking tab.

3

W3004860

Pull the switch out of the dash by“rocking” out at the bottom, then pullingout at the top. Disconnect the electri-cal connector and remove the switch.

4Connect the electrical connector to thenew switch. Install by pushing into thepanel until it locks into position.

3970-03-02-01ECU, ReplacementVolvo Link ECU

NOTE: Replacing a Volvo Link ECU with another ECUfrom a different vehicle will not work. There are systemchecks within the ECU that will not allow it to work if ithas been changed from the VIN that it was originally in-stalled or configured for.

NOTE: When replacing early model Volvo Link ECUs,the ECU should be ordered from Volvo per the vehicle’sengine type. Early model ECUs will be programmed be-fore delivery. Later model ECUs may be programmed inthe field using the VCADS Pro tool.

1

Before working on a vehicle, set theparking brakes, place the transmis-sion in neutral, and block thewheels. Failure to do so can resultin unexpected vehicle movementand can cause serious personal in-jury or death.

Make certain the vehicle ignition isOFF.

2Remove the right upper grab handlemounting bolt.

3

W8001131

Remove the center and right lowerdash panels.

Volvo Trucks North America, Inc. Date Group No. Page

Service Bulletin 3.2002 397 002 3(22)

4

W3004853

1 2–sided tape2 Volvo Link ECU

Note all connections to the ECU to aidin assembly. Remove all cable andwiring connections. Remove the fas-teners and remove the ECU from thevehicle. Note: Early ECUs may be se-cured with 2–sided tape.

5Replace all removed panels.

6Install the upper right grab handlemounting bolt. Torque tighten to 24 ± 4Nm (18 ± 2 ft-lb).

7If necessary, program the Volvo LinkECU with the VCADS Pro tool.

NOTE: This step is not included in theVolvo Standard Time (VST) calcula-tions.

8In-warranty ECUs that are defectivemust be returned to Volvo’s TMAC fol-lowing parts return procedures.

Page 4

3970-03-02-03GPS Antenna, ReplacementVolvo Link System1

Before working on a vehicle, set theparking brakes, place the transmis-sion in neutral, and block thewheels. Failure to do so can resultin unexpected vehicle movementand can cause serious personal in-jury or death.

Make certain the vehicle ignition isOFF.

2

W3004855

Remove the right antenna whip (1)and right mirror backing (2).

3Disconnect the GPS antenna from theGPS antenna cable. Remove tiestraps as needed.

4Remove the GPS antenna and bracketassembly from underneath the multi-plex antenna mounting nut and seal.Note the stack-up of components forinstallation.

5

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1 Antenna mounting nut2 Spacer3 GPS antenna and bracket4 Cell phone antenna

Install the replacement GPS antennaand bracket assembly under the multi-plex antenna mounting nut and seal.See the figure for proper installation.

6Connect the GPS antenna to the GPScable. Secure as needed.

7Install the mirror backing and multiplexantenna whip.

Volvo Trucks North America, Inc. Date Group No. Page

Service Bulletin 3.2002 397 002 5(22)

3970-03-02-04GPS Antenna Cable, Replace-mentVolvo Link System1

Before working on a vehicle, set theparking brakes, place the transmis-sion in neutral, and block thewheels. Failure to do so can resultin unexpected vehicle movementand can cause serious personal in-jury or death.

Make certain the vehicle ignition isOFF.

2Remove the right upper grab handlemounting bolt.

3

W8001131

Remove the center and right lowerdash panels.

4

W8001178

Remove the right dash speaker grille,and the speaker.

5

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Remove the right upper dash panel (1)and lower right plenum (2).

Page 6

6

W3000667

Remove the right side cab step.

7

W3000662

Remove the upper tank fairing.

8

W3004854

Remove the bolts securing the lowerright mirror mounting arm.

9

W3000661

Remove the right quarter fender.

Volvo Trucks North America, Inc. Date Group No. Page

Service Bulletin 3.2002 397 002 7(22)

10

W3000663

Remove the right drip molding.

11Remove the right side cowl panelmounting bolts. Then carefully workthe cowl around the lower mirror armmount and remove from the vehicle.Note the position of the lower fresh airseal to aid in installation.

12

W3004855

Remove the right antenna whip (1),right mirror backing (2), and lower armcover (3).

13Note the routing of the existing GPSantenna cable from the Volvo LinkECU to the antenna whip in the mirrorhead. Cut the tie straps securing theantenna cable. Disconnect the GPScable from the GPS antenna and theVolvo Link ECU. Remove the GPS ca-ble.

14Disconnect all mirror connectors toallow installation of a new cowl pass-through seal.

15

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CAUTION

Do not cut or nick wiring. Doing socould cause an electricalshort-circuit.

Carefully cut away the old pass-through seal.

Page 8

16

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CAUTION

It is important to route the cable ex-actly as instructed. Failure to do socan damage to the cable, resultingin poor communication.

Route the new GPS antenna cablethrough the cowl pass-through open-ing. Install the new cowl pass-throughseal over all the wiring and into itsmounting position. Do not heat shrinkto the cowl at the same time. Note: Besure that the threaded cable end goesto the mirror assembly.

17Connect the replacement cable to theGPS antenna. Connect all mirrorwiring connectors.

18Pull the excess cable into the cab.Route the Volvo Link antenna cableand mirror wiring along the same routewhere the mirror wiring was previously.Secure with tie straps as needed.

19

W3004844

Secure the cowl seal to the cowl. Usea heat gun to shrink the seal.

20Install the right mirror backing, lowerarm cover and antenna whip.

21Position the lower fresh air seal andinstall the right cowl panel.

22Install the bolts securing the lowerright mirror mounting arm. Torquetighten to 24 ± 4 Nm (18 ± 2.9 ft-lb).

24 ± 4 Nm (18± 2.9 ft-lb)

23Install the right drip molding. Torquetighten the top 2 screws to 1.2 ± 0.2Nm (10.6 ± 2 in-lb), and the lowerscrew to 3 Nm ± 0.5 (26 ± 5 in-lb).

1.2 ± 0.2 Nm(10.6 ± 2 in-lb)3 Nm ± 0.5(26 ± 5 in-lb)

Volvo Trucks North America, Inc. Date Group No. Page

Service Bulletin 3.2002 397 002 9(22)

24Install the right quarter fender. Torquetighten to 24 ± 4 Nm (18 ± 2.9 ft-lb).

24 ± 4 Nm (18± 2.9 ft-lb)

25Install the upper tank fairing. Start allbolts, then tighten after aligning fairing.Torque tighten to 24 ± 4 Nm (18 ± 2.9ft-lb).

24 ± 4 Nm (18± 2.9 ft-lb)

26Install the right cab step. Start all 4bolts, then tighten after aligning thestep. Torque tighten to 12 ± 1 Nm (106± 8 in-lb).

12 ± 1 Nm(106 ± 8 in-lb)

27Starting inside the right cowl, route thereplacement GPS antenna cable alongthe route the old cable followed to theVolvo Link ECU. Connect the cable tothe ECU and secure as needed.

28Replace all removed panels.

29Install the upper right grab handlemounting bolt. Torque tighten to 24 ± 4Nm (18 ± 2 ft-lb).

3970-03-02-05Radio Adapter Cables, Re-placementVolvo Link System1

Before working on a vehicle, set theparking brakes, place the transmis-sion in neutral, and block thewheels. Failure to do so can resultin unexpected vehicle movementand can cause serious personal in-jury or death.

Make certain the vehicle ignition isOFF.

2Remove the right upper grab handlemounting bolt.

3

W8001131

Remove the center and right lowerdash panels.

4Note the routing of the existing radioantenna adapter cables to aid in in-stallation. Cut the tie straps securingthe adapter cables. Disconnect the ca-bles and remove.

Page 10

5Install the new adapter cables, routingthe same way as the old cables. Con-nect all connectors and secure asneeded.

6Replace all removed panels.

7Install the upper right grab handlemounting bolt. Torque tighten to 24 ± 4Nm (18 ± 2 ft-lb).

3970-03-02-02Wiring Harness, ReplacementVolvo Link System1

Before working on a vehicle, set theparking brakes, place the transmis-sion in neutral, and block thewheels. Failure to do so can resultin unexpected vehicle movementand can cause serious personal in-jury or death.

Make certain the vehicle ignition isOFF.

2Remove the right upper grab handlemounting bolt.

3

W8001131

Remove the center and right lowerdash panels.

Volvo Trucks North America, Inc. Date Group No. Page

Service Bulletin 3.2002 397 002 11(22)

4

W8001178

Remove the right dash speaker grille,and the speaker.

5

W3004847

Remove the right upper dash panel(1).

6Remove top TEC cover.

7Remove the Volvo Action ServiceSwitch (see “Volvo Action ServiceSwitch, Replacement” page 2).

8Observe the routing of the existingVolvo Link wiring harness to aid in in-stallation. Cut tie straps as needed.Disconnect all connectors and removethe harness.

9Install the replacement harness alongthe same route as the old harness.Connect all connectors and secure asneeded.

10Install the Volvo Action Service switch.

11Replace all removed panels.

12Install the upper right grab handlemounting bolt. Torque tighten to 24 ± 4Nm (18 ± 2 ft-lb).

Page 12

3970-18-02-01Kit, InstallationVolvo Link System, CompleteThe following instructions are for installation of kits20469220 and 20469221.

NOTE: Prerequisites for this kit are at least a ’98 instru-ment cluster (from 1999 and forward), RAMI Multiplexerantenna system with dual whips and Lang Mekra mirrors.

NOTE: Volvo Link kits should be ordered from Volvo perthe engine type in the vehicle. Early model ECUs will beprogrammed before delivery. Later model ECUs may beprogrammed in the field using the VCADS Pro tool.

NOTE: The instrument cluster must be programmed tointerface with the Volvo Link ECU. It is assumed that allretrofits will be done at dealer locations with the ability toreprogram the instrument cluster.

1

Before working on a vehicle, set theparking brakes, place the transmis-sion in neutral, and block thewheels. Failure to do so can resultin unexpected vehicle movementand can cause serious personal in-jury or death.

Make certain the vehicle ignition isOFF.

GPS Antenna and Cable Installation

2Remove the right upper grab handlemounting bolt.

3

W8001131

Remove the center and right lowerdash panels.

4

W8001178

Remove the right dash speaker grille,and the speaker.

5

W3004847

Remove the right upper dash panel (1)and lower right plenum (2).

Volvo Trucks North America, Inc. Date Group No. Page

Service Bulletin 3.2002 397 002 13(22)

6

W3000667

Remove the right side cab step.

7

W3000662

Remove the upper tank fairing.

8

W3004854

Remove the bolts securing the lowerright mirror mounting arm.

9

W3000661

Remove the right quarter fender.

Page 14

10

W3000663

Remove the right drip molding.

11Remove the right side cowl panelmounting bolts. Then carefully workthe cowl around the lower mirror armmount and remove from the vehicle.Note the position of the lower fresh airseal to aid in installation.

12

W3004855

Remove the right antenna whip (1),right mirror backing (2), and lower armcover (3).

13Note the routing of the existing rightantenna cable from the RAMI multi-plexer box to the antenna whip in themirror head. Cut the tie straps secur-ing the cables from the cowl seal tothe mirror assembly.

14Disconnect all mirror connectors toallow installation of a new cowl pass-through seal.

15

W3004845

CAUTION

Do not cut or nick wiring. Doing socould cause an electricalshort-circuit.

Carefully cut away the old pass-through seal.

Volvo Trucks North America, Inc. Date Group No. Page

Service Bulletin 3.2002 397 002 15(22)

16

W3004846

1 Antenna mounting nut2 Spacer3 GPS antenna and bracket4 Cell phone antenna

Install the GPS antenna and bracketassembly under the multiplex antennamounting nut and seal.

17

W3004843

CAUTION

It is important to route the cable ex-actly as instructed. Failure to do socan damage to the cable, resultingin poor communication.

Route the GPS antenna cable throughthe cowl pass-through opening. Installthe new cowl pass-through seal overall the wiring and into its mounting po-sition. Do not heat shrink to the cowlat the same time. Note: Be sure thatthe threaded cable end goes to themirror assembly.

18Connect the Volvo Link cable to theGPS antenna. Connect all mirrorwiring connectors.

19Pull the excess cable into the cab.Route the Volvo Link antenna cableand mirror wiring along the same routewhere the mirror wiring was previously.Secure with tie straps as needed.

Page 16

20

W3004844

Secure the cowl seal to the cowl. Usea heat gun to shrink the seal.

21Install the right mirror backing, lowerarm cover and antenna whip.

22Position the lower fresh air seal andinstall the right cowl panel.

23Install the bolts securing the lowerright mirror mounting arm. Torquetighten to 24 ± 4 Nm (18 ± 2.9 ft-lb).

24 ± 4 Nm (18± 2.9 ft-lb)

24Install the right drip molding. Torquetighten the top 2 screws to 1.2 ± 0.2Nm (10.6 ± 2 in-lb), and the lowerscrew to 3 Nm ± 0.5 (26 ± 5 in-lb).

1.2 ± 0.2 Nm(10.6 ± 2 in-lb)3 Nm ± 0.5(26 ± 5 in-lb)

25Install the right quarter fender. Torquetighten to 24 ± 4 Nm (18 ± 2.9 ft-lb).

24 ± 4 Nm (18± 2.9 ft-lb)

26Install the upper tank fairing. Start allbolts, then tighten after aligning fairing.Torque tighten to 24 ± 4 Nm (18 ± 2.9ft-lb).

24 ± 4 Nm (18± 2.9 ft-lb)

27Install the right cab step. Start all 4bolts, then tighten after aligning thestep. Torque tighten to 12 ± 1 Nm (106± 8 in-lb).

12 ± 1 Nm(106 ± 8 in-lb)

28Starting inside the right cowl, overlaythe GPS antenna cable along theroute of the multiplex antenna cable tothe RAMI box. Secure as needed.

ECU and Wiring Harness Installation

29Remove the top TEC cover.

30Before routing the Volvo Link wiringharness, locate the 2–pin connectorfor the data link (wires 400 and 401)located at the back of the TEC panel.Also locate the 3–pin connector (wires490, 141 and OD-G) for switch illumi-nation under the TEC panel.

Volvo Trucks North America, Inc. Date Group No. Page

Service Bulletin 3.2002 397 002 17(22)

31

W3004852

1 Switch illumination connector2 To Data Link connector

Route the wiring harness per the illus-tration.

32Install the power point connectors toexpansion block positions B1–1 andB2–1 in the TEC panel.

NOTE: If the designated positions arealready in use, connect B1–1 to anavailable ignition connector, and B2–1to an available battery connector.Expansion block and fuse location in-formation is on a decal under the topand front TEC covers.

33Connect the 2–pin data link connectorand 3–pin illumination connector.

34

W3004842

Install the “Volvo Action Service”switch and connect the connector.

NOTE: This switch may not be avail-able with all kits.

35

W3004853

1 Two-sided tape2 Volvo Link ECU

Mount the ECU to the underside of theTEC tray with two-sided tape. Be sureto orient the ECU properly so thewiring harness and antenna connec-tions can be easily made.

Page 18

36

W3004849

1 Volvo Link ECU2 Radio3 “RF OUT” Cable to Radio4 “RF IN” Short Jumper Cable5 “RF IN” Cable from RAMI box (previously to

the back of the radio)

Disconnect the radio antenna cablefrom the radio. Plug the antenna cableinto the short antenna adapter cable.Plug the other end of the short an-tenna adapter cable into the ECU “RFIN” connector. Plug the long antennaadapter cable into the ECU “RF OUT”connector, and the opposite end intothe radio antenna receptacle.

Volvo Trucks North America, Inc. Date Group No. Page

Service Bulletin 3.2002 397 002 19(22)

W3004848

1 Volvo Link ECU2 GPS Antenna Cable3 Electrical Connector

37Connect the wiring harness and GPSantenna cable to the ECU.

38Secure all wiring and connectors asneeded.

39Install 5–amp fuses in positions 46and 52 in the TEC panel.

NOTE: If an alternative expansionblock was selected in step 31, add thecorresponding 5–amp fuses.Expansion block and fuse location in-formation is on a decal under the topand front TEC covers.

40Replace all removed panels.

41Install the upper right grab handlemounting bolt. Torque tighten to 24 ± 4Nm (18 ± 2 ft-lb).

42If necessary, program the Volvo LinkECU with the VCADS Pro tool (appliesto late model ECUs only). See theVCADS Pro user manual for program-ming instructions.

NOTE: This step is not included in theVolvo Standard Time (VST) calcula-tions.

43Program the instrument cluster to in-terface with the Volvo Link ECU. Newmain software for the instrument clus-ter may need to be downloaded, also.This step must be performed by adealer with the proper tools and ac-cess to the Volvo database.

NOTE: This step is not included in theVolvo Standard Time (VST) calcula-tions.

Page 20

3970-18-02-01Kit, InstallationVolvo Link System, with Prep KitThe following instructions are for installation of kits20470229 and 20470230, for vehicles with the VolvoLink prep kit already installed.

NOTE: Volvo Link kits should be ordered from Volvo perthe engine type in the vehicle. Early model ECUs will beprogrammed before delivery. Later model ECUs may beprogrammed in the field using the VCADS Pro tool.

NOTE: The instrument cluster must be programmed tointerface with the Volvo Link ECU. It is assumed that allretrofits will be done at dealer locations with the ability toreprogram the instrument cluster.

1

Before working on a vehicle, set theparking brakes, place the transmis-sion in neutral, and block thewheels. Failure to do so can resultin unexpected vehicle movementand can cause serious personal in-jury or death.

Make certain the vehicle ignition isOFF.

ECU and Wiring Harness Installation

2Remove the right upper grab handlemounting bolt.

3

W8001131

Remove the center and right lowerdash panels.

4Remove the top TEC cover.

5

W3004842

If switch is provided, install the “VolvoAction Service” switch in a blankswitch location and connect the con-nector.

NOTE: This switch may not be avail-able with all kits.

6

W3004853

1 Two-sided tape2 Volvo Link ECU

Mount the ECU to the underside of theTEC tray with two-sided tape. Be sureto orient the ECU properly so thewiring harness and antenna connec-tions can be easily made.

Volvo Trucks North America, Inc. Date Group No. Page

Service Bulletin 3.2002 397 002 21(22)

7

W3004849

1 Volvo Link ECU2 Radio3 “RF OUT” Cable to Radio4 “RF IN” Short Jumper Cable5 “RF IN” Cable from RAMI box (previously to

the back of the radio)

Disconnect the radio antenna cablefrom the radio. Plug the antenna cableinto the short antenna adapter cable.Plug the other end of the short an-tenna adapter cable into the ECU “RFIN” connector. Plug the long antennaadapter cable into the ECU “RF OUT”connector, and the opposite end intothe radio antenna receptacle.

Page 22

W3004848

1 Volvo Link ECU2 GPS Antenna Cable3 Electrical Connector

8Connect the wiring harness and GPSantenna cable to the ECU.

9Secure all wiring and connectors asneeded.

10Replace all removed panels.

11Install the upper right grab handlemounting bolt. Torque tighten to 24 ± 4Nm (18 ± 2 ft-lb).

12If necessary, program the Volvo LinkECU with the VCADS Pro tool (appliesto later model ECUs only). See theVCADS Pro user manual for program-ming instructions.

NOTE: This step is not included in theVolvo Standard Time (VST) calcula-tions.

13Program the instrument cluster to in-terface with the Volvo Link ECU. Newmain software for the instrument clus-ter may need to be downloaded, also.This step must be performed by adealer with the proper tools and ac-cess to the Volvo database.

NOTE: This step is not included in theVolvo Standard Time (VST) calcula-tions.