2004 Volvo VN TSBs
112 Technical Service Bulletins across 15 categories
Categories
Engine
23 bulletinsCBR - 11 Liter Engines - Fuel In Oil.
Barksdale Leveling Valve, Leak Test
CBR: Programming Failure - Chassis With Cummins Engine And An Allison Transmission
Volvo Chassis - D12C, D12D, D11F, D13F, D16D, D16F Engines - Copper Injector Sleeves, Replacement Procedure And...
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Information ( Flat Tip Injectors ) - US04 To US07 Emissions
Engine Control Module (EMS) Software (MSW) Information August 2022; Improvement List (Change Log) - US21+OBD22 (13L...
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VGT, TC) And US17+OBD22 (11L) Emissions
Programming Failure - Chassis With Cummins Engine And An Allison Transmission
Volvo Chassis - Discharge Recirculation Valve (DRV) - FSB 258-029 , Engine Turbocharger Compressor Bypass Valve...
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Deletion Kit , Installation
In the event that an EGR temperature sensor replacement is required on a VOLVO D13H engine, a new routing configuration...
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is required.
Turbocharger Outlet Pipe
Engine Coolant Thermostat Software Update
Engine Control Module (ECM) Software Update
Exhaust Gas Recirculation (EGR) Valve Oil Supply Line, updated part
In some instances the exhaust rocker piston cap screw may become loose and back out causing loss of engine compression,...
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or a mechanical injector Diagnostic Trouble Code (DTC).
THIS COMMUNICATION IS TO RETURN UNSOLD INVENTORY BECAUSE SOME PRODUCT MAY HAVE POROSITY THAT CAN CAUSE A SLOW COOLANT...
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LEAK THAT WOULD DISSATISFY CUSTOMERS
VOLVO: LOW OIL PRESSURE, ON CERTAIN VEHICLES, DURING LONG HARD PULL CONDITIONS, DIAGNOSTIC TROUBLE CODES (DTCS) PID 100...
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FM1, SPN 100 FMI 1 OR P252400, CAN LOG ON, WITH OR WITHOUT ENGINE SHUT DOWN LAMP. MODEL VN, VT. NO YEARS LISTED. *PE
VOLVO: ON SOME TRUCKS, THERE IS AN OIL CONTAMINATION INTO THE ENGINE WIRE HARNESS BECAUSE OF A FAILURE OF THE OIL LEVEL SENSOR.
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MODELS VAH, VHD, VN, VT. NO MODEL YEARS LISTED. *PE
VOLVO TRUCKS: CONNECTOR PIN, REPLACEMENT.
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SEVERE FRETTING DAMAGE OF THE ENGINE VARIABLE GEOMETRY TURBOCHARGER ACTUATOR (ENGINE VGT ACTUATOR) HARNESS AND TURBINE SHAFT SPEED SENSOR (TSS) CONNECTOR MAY CAUSE AN UNRELIABLE SIGNAL TO THE ENGINE VGT ACTUATOR. *JS
VOLVO TRUCKS: SOME ENGINES LEAK OIL THROUGH THE GROMMET.
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INFORMATION ON THE WIRING HARNESS, UNIT INJECTOR REPLACEMENT. *RM UPDATED 9/9/11. *PE
MACK TRUCKS: THERE IS REVISED MOUNTING HARDWARE FOR THE EXHAUST MANIFOLD AND TURBOCHARGER.
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*RM
VOLVO TRUCK: ENGINE ECU AND ACM SOFTWARE UPDATES.
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NEW SOFTWARE UPDATES WITH ENHANCEMENTS ARE AVAILABLE FOR THE ENGINE CONTROL MODULE (ECM) AND AFTERTREATMENT CONTROL MODULE (ACM). MODEL VN. NO MODEL YEARS LISTED. *PE
VOLVO TRUCK: TO REDUCE THE POTENTIAL FOR CAB WATER INTRUSION, A CAB COWL SEAL HAS BEEN RELEASED BY ENGINEERING.
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THE SEAL PART NUMBER 8083305 IS POSITIONED ABOVE THE TOP EDGE OF THE COWL PANEL TO DIVERT WATER FLOW ONTO THE COWL PANEL RATHER THAN BETWEEN THE COWL PANEL AND CAB. NO MODEL YEARS LISTED. *PE
VOLVO TRUCK: REPORTS PROMPTED THE RELEASE OF A REPLACEMENT CONNECTOR FOR THE CAB HVAC MOTOR RESISTOR.
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REPLACEMENT CONNECTOR IS SUPPLIED AS KIT PART, WHICH CONTAINS THE CONNECTOR BODY AND THE NECESSARY TERMINALS. MODEL YEARS UNKNOWN. *PE
VOLVO TRUCKS: ENGINE UPDATE CAMPAIGN FOR CERTAIN D13F ENGINES (VN-2, VHD-2) CONSISTS OF INSPECTING THE CAMSHAFT AND...
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REPLACING THE INTAKE ROCKER ARMS, EXHAUST ROCKER ARMS, INJECTOR ROCKER ARMS, INJECTOR HOLD DOWNS, AND THE INJECTOR SEALING WASHERS. *PE UPDATED 12/17/09. *PE
Other
22 bulletinsCBR - A significant GPS reporting issue is affecting fleet operations, with trucks maintaining back-office communication...
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but failing to transmit GPS location data.
AMT Control Housing Bench Testing - False Failures
The Diagnostic Process
Volvo Chassis Ghost Codes Due To Poor Grounding
VIDA QR Scanner Mobile App
Volvo Chassis - Driveline (Driveshaft, Propeller Shaft) Ride Height And Angle, Measurement And Calculation; Pinion Angle...
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Measurement - Model Year 1996 And Newer
Volvo Chassis - Volvo Hill Start Assist System Information
Volvo Chassis - Fusion 2 Adaptive Cruise Function Document
Volvo Chassis - Volvo Active Driver Assist (VADA)
On some trucks with the Telematics Gateway (TGW) system, the TGW control unit may not correctly communicate with the...
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vehicle systems after restarting.
Hill Start Assist Solenoid, Replacement
Oil Filter Housing
Aftertreatment DEF Tank Vent Filter
Hill Start Assist Solenoid, Replacement
AMT High Range Cone Replacement
Oil Filter Housing
High Soot Output
Timing Plate Flange Screw
Hill Start Assist Solenoid, Replacement
Timing Plate Leak Repair
Range Synchronizer, Repair
Hill Start Assist Solenoid, Replacement
Electrical
18 bulletinsOverheating has been observed at the alternator power cable and ground cable connection, resulting in melted insulation around the terminal area.
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The alternator power cable connection should maintain a stable electrical contact without overheating or insulation damage during normal vehicle operation. The alternator power cable shows signs of overheating and melted insulation at the connection point, which may affect electrical conductivity and charging system performance.
DEF Level (UQLS) Sensor Troubleshooting Guide - US17+OBD16 Emissions and Newer
NOx Sensor Troubleshooting Guide - US10+OBD13 And Newer Emissions
(Back Office) - Cruise Control Inoperative After Updating Software VECU5 Without ESP Package (UESP)
Temperature Sensor Troubleshooting Guide - US10+OBD13 And Newer
Unable To Retrieve "On Request" Messages For PeopleNet Or Omnitracs Modules Installed On The DL5 Data Link; Third Party...
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Electronic Log Device Not Reporting Certain Data
Particulate Matter (PM) Sensor Troubleshooting Guide - US14+OBD16 And Newer Emissions
DEF Level (UQLS) Sensor Troubleshooting Guide - US17+OBD16 Emissions and Newer
Shipping and Handling of Volvo Lithium-ion 48V Mild Hybrid Battery to Global Battery Solutions (GBS)
Volvo Chassis - Rain Sensor Bracket Removal And Installation Procedure when Using An Aftermarket Windshield
DEF Sensor Assembly Routing
Exhaust Gas Recirculation (EGR) Differential Pressure Sensor
Seat Harness Routing (Swivel) wires pulling away from clipping points
Seat Harness Routing (Non-Swivel) wires pulling away from clipping points
Fuel Management Module, Replacement, incorrect calibration
Battery Cable, Routing
Oil Level Sensor Harness Wire Splice
VOLVO: LIGHT CONTROL MODULE (LCM), REPROGRAMMING.
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ON SOME VOLVO UNITS EQUIPPED WITH CLEAR LED CLEARANCE LIGHTS IN THE SUN VISOR, THE MAY EXHIBIT AN ACTIVE FAULT CODE MID 216 PSID 49 FMI 5. THIS FAULT INDICATES A TRAILER MARKER OPEN ISSUE WHICH IS INCORRECT FOR THE ISSUE PRESENT ON THE VEHICLE. *JS
Transmission
11 bulletinsCBR: Volvo Chassis - Timing Gear Plate Repair.
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This solution provides supplementary information to be used when installing a Timing Gear Plate with Integrated Seal.
Volvo Chassis - Equipped with An Automated Manual Transmission (AMT, iShift) - SNV 19-002 - AMT Oil Filter Housing...
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Corrosion
Warranty Automated Manual Transmission ( AMT, I-Shift, mDrive ) Control Housing Assembly; Guidelines For Filing A Claim...
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For Chassis Return Visit With Transmission Issues After A Repair Requiring Control Housing Removal And Reinstallation - US07 And Newer
Volvo Chassis - Equipped With An I-Shift Automated Manual Transmission ( AMT ) - Flywheel Resurfacing And Reuse...
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Guidelines
Flywheel Resurfacing Guidelines, I-Shift
Transmission ECU Programming
Twin Mass Flywheel Conversion, Transmission Removed
Transmission ECU Compatibility
VOLVO TRUCKS: DURING OPERATION OF DRIVER SIDE SWIVEL SEAT AND I SHIFT TRANSMISSION, THE HARNESS RUBBING OR WIRES, ARE PULLED OUT OF CONNECTORS.
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THIS CAUSES SEAT HARNESS DROPPING OR PULLING AWAY FROM CLIPPING POINTS. *PE
VOLVO TRUCK: I SHIFT TRANSMISSION WITH MIXED COMPONENTS.
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INSTALLATION OF REPLACEMENT PARTS IN AN I SHIFT TRANSMISSION (VERSION-C) MAY RESULT IN DIAGNOSTIC TROUBLE CODES (DTCS) MID 130 PID 160 FMI1 OR FMI2. NO MODEL YEARS LISTED. *PE
VOLVO TRUCK; CLUTCH SWITCH CLIP; IT HAS BEEN FOUND THAT VN, VHD AND VT VEHICLES USE A SPRING CLIP TO RETAIN THE CLUTCH...
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SWITCH, MAY HAVE AN ISSUE WITH THE CLUTCH SWITCH MOVING OR DETACHING FROM IT'S MOUNT. *PE
Fuel System
10 bulletinsDEF Pump Troubleshooting Guide - US10+OBD13 And Newer Emissions
Fuel Level Gauge Reading Incorrect In The Instrument Cluster
Volvo Chassis - Fuel Level Sending Unit Specification Information
Coolant Hose, EGR Cooler, Replacement
Dual Fuel Tanks Ventilation Filter Kit
Single Fuel Tank Ventilation Filter Kit
EGR Mass Flow Rate Low, diagnostic trouble code
VOLVO TRUCK: FUEL TANK MOUNTING.
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FUEL TANK STRAPS OVER TIME MAY LOSE TORQUE AND ALLOW THE FUEL TANK TO ROTATE. MODELS VN, VHD, VT, VAH. NO MODEL YEARS LISTED. *PE UPDATED 2/21/12. *PE
VOLVO TRUCK: ON SOME VEHICLES, COOLANT OVERFLOW OUT OF THE OVERFLOW TUBE OCCURS DURING THE DIESEL PARTICULATE FILTER REGENERATION CYCLE.
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EXCESSIVE COOLANT FLOW FROM THE RADIATOR TOP TANK AND THERMOSTAT VENT LINES PREVENTS FLOW INTO THE DE-AERATION PROCESS. VN-2, VHD-2 VT MODELS ONLY. NO MODEL YEARS LISTED. *PE
VOLVO: LEAKAGE DETECTION DIAGNOSTICS IMPROVEMENTS TO REMEDY DTC'S.
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ALL MODELS FROM MODEL YEARS 2003-2008. DIAGNOSTIC MONITOR FOR THE EVAPORATIVE EMISSION SYSTEM SMALL LEAK, HAS USED A SOFTWARE FUNCTION THAT CALCULATES LEAKAGE BASED ON A PRESSURE INFERRED FROM THE CURRENT CONSUMED BY AN ELECTRIC PUMP THAT PUMPS AIR INTO THE FUEL TANK SYSTEM. *PE
Body & Paint
7 bulletinsVolvo Chassis - Model VN, Hood Release Cable Interference
Volvo Chassis - Model VN - Water Intrusion In Back Of Cab, Back Wall Of Bunk Leaking
Service Door Rust Prevention
Floor Cracks Repair (Rear Panel)
Floor Cracks Repair (Front Panel)
VOLVO TRUCKS: VEHICLES WITH PARTIAL CHASSIS FAIRINGS MAY EXPERIENCE DAMAGE TO THE FAIRINGS LOWER SUPPORT RAIL.
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IT CAN BE CAUSED BY VIBRATION OF THE FAIRING AGAINST THE FIBERGLASS RAIL. A PROCEDURE HAS BEEN DEVELOPED TO IMPROVE THE SITUATION. *RM
VOLVO TRUCK: DOOR SEAL, OUTER, REPLACEMENT.
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THE OUTER SEAL ON THE CAB DOORS OF VOLVO MODEL TRUCKS MAY PREMATURELY SEPARATE FROM THE CAB SHELL. MODELS VN-2, VHD-2 AND VT. NO MODEL YEARS LISTED. *PE
Brakes
5 bulletinsCBR: Volvo On-Highway Vehicles - Bendix ABS Fault SPN 807 FMI 13 Blink code 19-4.
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The new Central Pressure Control (CPC) system has changed the way that the ABS chuff test is performed.
DTC U012100 - Lost Communication With Anti-Lock Brake System (ABS) Control Module, No Additional Information
Volvo Chassis - Redundant Brake Switch Test - Code MID136 SID55 FMI2, or( DTC ) P1055
VOLVO: ON SOME TRUCKS, AIR DISC BRAKE MAY EXPERIENCE A CONDITION OF THERMAL OVERLOAD.
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THERMAL OVERLOAD REDUCES RUNNING CLEARANCE BETWEEN PAD AND ROTOR BELOW DESIRED LEVEL WHICH IS AN OVER ADJUSTMENT OF NORMAL PAD WEAR COMPENSATION. MODEL VAH, VHD, VN. NO YEARS LISTED. *PE
VOLVO: THE AIR DISC BRAKE, ON SOME TRUCKS, MAY EXPERIENCE THERMAL OVERLOAD DUE TO AN OVER ADJUSTMENT OF NORMAL PAD WEAR...
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COMPENSATION THAT MAINTAINS CLEARANCE RUNNING BETWEEN BRAKE PAD AND ROTOR. MODELS VAH, VHD, VN. NO YEARS LISTED. *PE
Suspension
3 bulletinsCBR - Z Spring Bracket Wear.
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Volvo Chassis
Volvo Chassis - Stemco Hubcap Plug Will Not Stay In
VOLVO: TRUCKS BUILT PRIOR TO 18/8/2011 WERE SHIPPED WITHOUT FOUR (4) SPRING NUTS PRE-INSTALLED FROM THE FACTORY.
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*JS
Infotainment
3 bulletinsCBR: Volvo VHD & VN Models - Vehicle Wil Not Start, PTO Active Message Displayed In Cluster, PTO Light On When PTO...
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Switch Is Turned Off
Instrument Cluster Programming - Programming Fails Or Errors Display When Replacing An Instrument Cluster With A Newer...
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Part Number (Conversion Kit) - US04 To US10 Chassis (9-Pin Diagnostic Connector)
Instrument Cluster Programming - Programming Fails Or Errors Display When Replacing An Instrument Cluster With A Newer...
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Part Number (Conversion Kit) - US04 To US10 Chassis (9-Pin Diagnostic Connector)
Tires & Wheels
3 bulletinsFlywheel Housing Thread Repair
Twin Mass Flywheel Conversion
VOLVO TRUCKS: OIL SEEPAGE AT FLYWHEEL HOUSING.
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THIS PROBLEM HAS ALREADY BEEN SOLVED IN PRODUCTION, BUT THE PRODUCTION SOLUTION IS NOT COMPATIBLE WITH PREVIOUS GENERATION FLYWHEEL HOUSINGS. *JS
Lighting
2 bulletinsVolvo Chassis - Diagnostic Trouble Code ( DTC ) P0420 Illuminating The Malfunction Indicator Lamp (MIL)
Volvo VN Models - Overhead Light Loose, Detaching From Headliner
Steering
2 bulletinsVOLVO TRUCKS: ON THE STEERING AXLE OF THE VOLVO TRUCKS, THE ZERK FITTING ON THE MERITOR SLACK ADJUSTER COMES INTO...
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CONTACT WITH THE BOLT HEAD OF THE STEERING ARM CAUSING THE FITTING TO BREAK. *JS UPDATED 8/17/12. *PE
VOLVO VN VEHICLES BUILT BETWEEN 03/31/2004 AND 04/16/2004 MAY HAVE CRACKS IN THE POWER STEERING PUMP LOWER MOUNTING FLANGE.
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*TT
Pre-Delivery & Maintenance
1 bulletinVolvo Chassis - Drag Link Inspection And Replacement Criteria
Software & Calibration
1 bulletinSoftware Update, revise document
Hybrid & EV
1 bulletinRegeneration in PTO Mode