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Service BulletinVolvo Truck CorporationGöteborg, Sweden

Date Group No. Release Page

6.06   210 135 01   1(7)

Trucks

Engine, install

D7E

Engine, install

T0009739

20 046777ENG17024 English

Printed in Sweden

8/16/2019 210-135 Engine, Install

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Volvo Truck Corporation   Date Group No. Release Page

Service Bulletin   6.06   210 135 01   2(7)

Service Procedures

21072-1Engine, install

Note:  As the pictures in the service literature are used formore than one variant, some details can differ in respectof the vehicle you are working with. The essentialinformation in the illustrations is, however, always correct.

Special tools: 9990111, 9998547, 88800046 

1

T2022318

Hang up the engine in the lifting tool.

9998547, 9990111, 88800046

2Carefully lift the engine. Tilt it backwards and thencarefully forwards so that the cooling fan is not damaged.

WARNING

Crushing risk.

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Volvo Truck Corporation   Date Group No. Release Page

Service Bulletin   6.06   210 135 01   3(7)

3

T2022319

Insert the screws for the rear  (18) and front (17) enginemountings and torque tighten them in accordance withthe Function Group 20, Information type Specifications,

Specifications.

Note:   Only torque tighten after all the screws havebeen inserted.

4Remove the lifting equipment.

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Volvo Truck Corporation   Date Group No. Release Page

Service Bulletin   6.06   210 135 01   4(7)

5

T2022316

•   Fit the fuel piping at the fuel pump (16).

•   Fit the charge air hose between the air filter and thecharge air pipe (15).

Note:   Use new sealing rings.

.

•   Fit the relief pipe to the turbocharger. Install the quickrelease connector. Secure the fuel piping and enginemounting (14) with new clamps.

•   Fit the intake hose to the turbocharger from the chargeair pipe attachment in the air filter  (13).

•   Connect the engine cabling (12).

•   Fit the hoses, hose clips and filter holder to thesteering servo hydraulics on the chassis frame (11).

•  Fit all the coolant hoses. Secure the hoses with new

hose clamps. Secure the hose holder (10).

Note:   Secure excess wiring to the chassis frame withnew clamps.

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Volvo Truck Corporation   Date Group No. Release Page

Service Bulletin   6.06   210 135 01   5(7)

6

T2022317

•   Fit the charge air pipe to the intercooler (9).

•   Fit the charge air pipe between the intercooler andthe turbocharger  (8).

•   Fit the air conditioning compressor by installing its

securing screws and electrical connector  (7).

•   Fit the air conditioning compressor drive belt byslackening the belt tensioner (6).

•   Fit the air compressor feed wire (5).

•   Fit the exhaust pipe to the shutter housing. Usethe markings that were made during dismantlingfor best fit  (4).

•   Remove the air hose that connects to the exhaustshutter  (3).

•   Fit the grounding connections, one on each side of

the engine  (2).

•   Fit the terminals on the connection block. Secure theterminals, the holder for the negative terminal andthe plastic cover  (1).

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Volvo Truck Corporation   Date Group No. Release Page

Service Bulletin   6.06   210 135 01   6(7)

7

T2023088

Fit the sound baffles.

8Fill up with servo oil that has been approved by Volvo.

Bleed the system as required.

9Install the gearbox in accordance with Function Group4371, Information type Repair, 43776-1 Transmission,install.

10Fill with coolant in accordance with Function Group 20,Information type Specifications, Specifications.

11Connect the negative cable and switch on the mainelectrical power.

12Bleed the fuel system in accordance with FunctionGroup 2309, Information type Repair, 23003-3 Fuelsystem, bleeding.

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Volvo Truck Corporation   Date Group No. Release Page

Service Bulletin   6.06   210 135 01   7(7)

13Start the engine, perform functional checks and check forleakage. Rectify any fault codes.

WARNING

Make sure that the parking brake has been appliedand that neutral gear is selected.

14Top up with coolant as necessary.

15Wipe and dry off any oil spillage.

16Lower the cab.