NHTSA ID Number: 10128180
Manufacturer Communication Number: TJ32978 2 0-2017
TSB/Document Date: 2018-02-05
Summary
This is a Technical Journal: *Added VST Operation No. If the vehicle is equipped with air suspension and if customer is complaining over a knock/rattle/clatter noise from the front suspension when driving on roughroads or over a road hump, then follow the advice under Service. Note: Vehicles with Air suspension can be identified by the following VDN code: RI03 Service: Too high tire pressure could produce noise that could be misinterpreted as noise from the front air suspension system. First ensure that the tire pressure is matching the Correct tire pressure, refer to the Tire Label (located in left side B-pillar) or Owners Manual. It is required that workshop test drive the vehicle with Correct tire pressure in order to verify the customers complaints regarding unacceptable noise from the front suspension. If the noise is confirmed, replace front shock absorbers according to TJ Instruction VCC-503532-2 (see also movie, special tool 9997644_v3.mp4) and perform a SUM upgrade. Note:The Hose coupling (31429025) should be used as a tool when filling the shock absorber during reassembly, should be reused.
VOLVO
CAR
SERVICE AND PARTS BUSINESS
Technical Journal
TITLE:
Front Air Suspension, knock/rattle/clatter noise
REF NO:
ISSUING DEPARTMENT:
CAR MARKET:
TJ 32978.2.0
Technical Service
United States and Canada
PARTNER:
ISSUE DATE:
STATUS DATE:
3 US 7510 Volvo Car USA
2017-10-09
2017-10-23
FUNC DESC:
FUNC GROUP:
FR SPR, HYD/GAS/AIR,
BELLOWS, CYLINDER
7251
Page 1 of 25
“Right first time in Time”
Attachment
File Name
TJ 32978.wmv
TJ 32978.m4a
TJI-503532-2_1_0_en-US.pdf
File Size
2.6571 MB
0.2825 MB
7.4435 MB
Vehicle Type
Type
Eng
256
256
256
256
256
08
10
A2
BA
BC
Eng
Desc
B4204T20
B4204T23
B4204T27
B1APHEV
B1BPHEV
Sales
Body
Gear
Steer
Model Year Plant
Chassis range
2016-2017
2016-2017
2016-2017
2016-2017
2016-2017
0000001-0114847
0000001-0114847
0000001-0114847
0000001-0140101
0000001-0140101
Struc Week
Range
201505-201621
201505-201621
201505-201621
201526-201640
201526-201640
CSC Customer Symptom Codes
Code
WV
WY
X1
8J
Description
Suspension/Clicking/clonking noise/At start/stop
Suspension/Clicking/clonking noise/Unsure when/at all times
Suspension/Unusual noise
Shock absorption/Unusual noise
Produced in the USA and available as an electronic document. Hard copy documents are printed in USA on recycled paper containing
a minimum of 50% wastepaper and 10% post-consumer waste.
© 2017 VOLVO CAR USA, LLC
Technical Journal 32978.2.0
VST Operation Number
VST Operation Number
97194-2
Description
Shock absorber, front, air suspension replace acc. to TJ32978
DTC Diagnostic Trouble Codes
Rows beginning with * are modified
Note! If using a printed copy of this Technical Journal, first check for the latest online version.
Text
DESCRIPTION:
*Added VST Operation No.
If the vehicle is equipped with air suspension and if customer is complaining over a knock/rattle/clatter
noise from the front suspension when driving on rough roads or over a road hump, then follow the
advice under Service.
Note: Vehicles with Air suspension can be identified by the following VDN code: RI03.
SERVICE:
Too high tire pressure could produce noise that could be misinterpreted as noise from the front air
suspension system.
First ensure that the tire pressure is matching the Correct tire pressure, refer to the Tire Label (located in
left side B-pillar) or Owner’s Manual.
It is required that workshop test drive the vehicle with Correct tire pressure in order to verify the
customer’s complaints regarding unacceptable noise from the front suspension.
If the noise is confirmed, replace front shock absorbers according to TJ Instruction VCC-503532-2 (see
also movie, special tool 9997644_v3.mp4) and perform a SUM upgrade.
Note: The Hose coupling (31429025) should be used as a tool when filling the shock absorber during
reassembly, should be reused.
VEHICLE REPORT:
Yes, please submit a Vehicle Report if the service solution described in this TJ has no effect. Use
concern area “Vehicle Report” and sub concern area “Support not needed”, use function group 7251.
The Technical Journals attachments are accessible in TIE.
Page 2 of 25
2017-10-23
Title
Volvo Car Customer Service
Front shock absorber, air suspension
Action
Issue
1
TJ Instruction VCC-503532-2
Replacement
Date
2017-07
Page
1 ( 23 )
Operation number:
97194-2
Reason
First issue
Affected vehicles
Model year Model
2016
XC90 (16-)
Materials
Lubricant
Flange screw
Flange screw
Repair kit
Grease
Grease
Shock absorber
Shock absorber
Qty.
0.1
2.0
2.0
1.0
0.1
0.1
2.0
2.0
Description
Installation/Removal Tool
SOCKET UPPER NUT REAR SHOCK ABSORBER
Designation
Hose coupling (31429025)
Materials
Part No.
31400016
988926
30670571
31681930
31400019
31400020
31476852
31658905
Special tools
Part No.
999 7644
999 5500
Equipment
Part No.
Notes
US/CAN;
CN;
For T8;
TJ Instruction VCC-503532-2
Page 2 ( 23 )
Color symbols
Note! This colour chart displays (in colour
print and electronic version) the importance
of the different colours used in the images
of the method steps.
1 . Used for focused component, the
component with which you will do
something.
2 . Used as extra colors when you need to show
or differentiate additional parts.
3 . Used for attachments that are to be
removed/installed. May be screws, clips,
connectors, etc.
4 . Used when the component is not fully
removed from the vehicle but only hung to
the side.
5 . Used for standard tools and special tools.
6 . Used as background color for vehicle
components.
TJ Instruction VCC-503532-2
Page 3 ( 23 )
Removal
Deactivate the Air suspension control in
Settings, which is found in Center Console
Display top view or by way of VIDA: Diagnostics/
Components/ECU/SUM/Diagnostic sequences/
Enable leveling control
Remove the front wheel , refer to:
Removal, replacement and installation
7 - Springs and wheels
77 - Wheels, tyres, hubs
771 - wheel and wheel trim
Empty air springs according to: Diagnostics/
Components/ ECU / SUM / Diagnostic
Sequences / Deflating and filling air springs and
reservoir
On both sides.
Disconnect the connector.
TJ Instruction VCC-503532-2
Page 4 ( 23 )
Remove the nut.
Torque:
Front stabilizer bar link to strut and spring
assembly , 80 Nm
Remove the screw.
TJ Instruction VCC-503532-2
Page 5 ( 23 )
Remove the screw.
Loosen the component indicated. Do not
remove it.
Caution! Make sure that the area around
the component is clean and free of foreign
material.
1.
Caution! Hold the marked component in
position to keep it from moving.
2 . Loosen the nut.
TJ Instruction VCC-503532-2
Page 6 ( 23 )
Remove the marked detail/details.
Note! Make sure that the component is
clean and free of foreign material.
TJ Instruction VCC-503532-2
Page 7 ( 23 )
Repair
Remove the part carefully
Caution! The component must not be
disassembled.
TJ Instruction VCC-503532-2
Page 8 ( 23 )
Special Tool: T9997644, Installation/Removal
Tool
Place the component where indicated in the
graphic.
TJ Instruction VCC-503532-2
Page 9 ( 23 )
Install the screws.
Torque:
M8 , 24 Nm
TJ Instruction VCC-503532-2
Page 10 ( 23 )
Note! Do not fully tighten the bolts.
Install the marked component.
TJ Instruction VCC-503532-2
Page 11 ( 23 )
Tighten each bolt 2 turns at a time.
Remove the marked part.
TJ Instruction VCC-503532-2
Page 12 ( 23 )
Note! Make sure that air can freely escape.
Loosen each bolt 2 turns at a time until all bolts
are removed.
Remove the nut.
Special Tool: T9995500, SOCKET UPPER NUT
REAR SHOCK ABSORBER
TJ Instruction VCC-503532-2
Page 13 ( 23 )
Place the component where indicated in the
graphic.
Remove the part carefully
Caution! Extreme cleanliness must be
exercised when handling these components.
TJ Instruction VCC-503532-2
Page 14 ( 23 )
The part is not to be reused.
Caution! Only use the specified lubricant.
Note! Use new seals.
Note position of components.
Use: Lubricant , 31400016
TJ Instruction VCC-503532-2
Page 15 ( 23 )
Caution! Observe caution when carrying
out this step.
Use hands only.
Place the component where indicated in the
graphic.
Turn in direction of arrow until stop.
TJ Instruction VCC-503532-2
Page 16 ( 23 )
Caution! Make sure that a new nut is
installed.
Tighten the nut.
Torque:
Air suspension to shock absorber , 55 Nm
Caution! Only use the specified lubricant.
Note! Use a new seal.
TJ Instruction VCC-503532-2
Page 17 ( 23 )
1 . Clean the marked area.
2.
Caution! Only use the specified
lubricant.
3 . Install the marked component.
4 . Make sure to replace the marked component
with a new.
Tighten each bolt 2 turns at a time.
TJ Instruction VCC-503532-2
Page 18 ( 23 )
Caution! Make sure that the component is
positioned correctly.
Loosen each bolt 2 turns at a time until all bolts
are removed.
Remove the marked part.
TJ Instruction VCC-503532-2
Page 19 ( 23 )
1 . Install the marked component.
2.
Caution! Make sure that the system
pressure is within specification.
Use: Hose coupling (31429025)
Note! Use soap solution.
TJ Instruction VCC-503532-2
Page 20 ( 23 )
Note! Make sure that the boot is correctly
located.
Repeat all method steps for the other side.
Installation
Note! Make sure that the component is
centred.
Torque:
Front shock absorber bearing, to Body ,
30 Nm
TJ Instruction VCC-503532-2
Page 21 ( 23 )
Note! Make sure that the installation marks
are aligned.
Tighten the nut.
Torque:
Air hose connector, to Connector with metal
thread , 5 Nm
Caution! Make sure that a new bolt is
installed.
Note! Do not fully tighten the bolt.
TJ Instruction VCC-503532-2
Page 22 ( 23 )
Caution! Make sure that a new bolt is
installed.
Caution! Make sure that the component is
positioned correctly.
Tighten the screw.
Torque:
Shock Absorber Fork, to Shock Absorber ,
60 Nm
Note! Only tighten the nuts and bolts
when the suspension is in the normal drive
position.
Tighten the screw.
Torque:
• Stage 1 : Shock Absorber Fork to Front
Lower Control Arm , 140 Nm
• Stage 2 : Shock Absorber Fork to Front
Lower Control Arm , 180°
TJ Instruction VCC-503532-2
Page 23 ( 23 )
Extra information
Fill air springs according to: Diagnostics/
Components/ ECU / SUM / Diagnostic
Sequences / Deflating and filling air springs and
reservoir
Caution! Make sure that the air springs are
inflated before lowering the vehicle.
When necessary, carry out the following instruction.
Order and download software.
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TSB/Document ID: TJ32978 2 0-2017
Replacement Service Bulletin Number:
MFR Communication Date: 2017-10-25
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: BACK OVER PREVENTION
MFR Component System:
MFR Component Subsystem:
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