Service Bulletin

Volvo Truck Corporation

Göteborg, Sweden Trucks
Date Group No. Release Page
2.06 210 93 02 1(13)

Changing the engine

D6B180, D6B220, D6B250
FL6
Changing the engine D6B

T2015649

This Service Bulletin contains instructions for changing the engine on FL6 from CHID
B265000 -.

Contents:

• “Engine, remove” page 3

• “Engine parts, transferring” page 8

• “Engine, install” page 9

20 061449
ENG21298 English
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 2.06 210 93 02 2(13)

Tools
Special tools
The following special tools are used when changing the engine. The tools are available
to order from Volvo quoting the specified part number.

T2012864

9996049 Drain hose for coolant

9998547 Lifting device

Other special equipment

The following additional special equipment is used when changing the engine. The tools
are available to order from Volvo quoting the specified part number.

T2006804

1159794 Torque wrench 10–100 Nm

1159795 Torque wrench 40–340 Nm
1159796 Torque wrench 150–800 Nm
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 2.06 210 93 02 3(13)

Service Procedures
21070-1
Engine, remove
Special tools: 9996049, 9998547
1

3
Drain hose for coolant

9996049

4
Note: Note where the plastic clamps for electrical cables,
hoses and pipes that are to be removed are located so
that these can be replaced when fitting the engine.
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 2.06 210 93 02 4(13)

T2016932

Note: The hoses to the AC compressor are not to be

loosened.
Remove the AC compressor and place it to one side
according to the picture.

T2016933

7
Note: Remove the gearbox according to the instructions
in service information, group 43.

T2016940
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 2.06 210 93 02 5(13)

T2016941

10

T2016937

11

T2016938
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 2.06 210 93 02 6(13)

12

T2016934

13

T2016939

14
Lifting device

Note: Make sure that the engine is completely free

when venting.
Carefully lift the engine out of the vehicle.

9998547

T2016927
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 2.06 210 93 02 7(13)

15

T2017007
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 2.06 210 93 02 8(13)

21035-4
Engine parts, transferring
In conjunction with changing the engine, the following
components must be transferred to the new engine.

• Rear engine mount brackets

• Flywheel
• Clutch
• Air compressor
• Shutter housing, exhaust pressure governor
• Servo pump
• Coolant resrevoir
• Starter motor
• Alternator
• Fan, pulleys
• Boost air pipe
• Starting heater
• Pipes, brackets, hoses, nipples etc.

Before the components are transferred to the new engine,

they should be thoroughly cleaned and checked with
regard to wear and function.

Use new gaskets and sealing rings.

Note: Never transfer a component to a new engine if it is

suspected that it could cause operational malfunction on
the new engine.

Note: The anti-corrosion additive in the new engine

must be flushed out thoroughly before the engine is
installed in the vehicle.

Programming of control unit

The new control unit must be programmed with the
valid parameters for delivery. For more information
on programming of specific vehicle parameters, see
separate service information “VCADS Pro Instructions”
under group 03.
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 2.06 210 93 02 9(13)

21072-1
Engine, install

T2022556

Before installing a new engine, see the driver’s handbook to find out which coolant to use.

If the new engine has a yellow label “Volvo Coolant VCS” on the valve cover, the
following applies:
Vehicles that require Volvo Coolant (green):
1 Before installation, drain the engine of coolant.
2 Remove the yellow label from the valve cover.
3 Fit a new coolant filter.
4 Install the engine.
5 Fill with Volvo Coolant (green).
Vehicles that require Volvo Coolant VCS (yellow):
1 Before installation, remove the yellow label from the valve cover.
2 Install the engine.
3 Fill with Volvo Coolant VCS (yellow).

If the new engine has no label on the valve cover, the following applies:
Vehicles that require Volvo Coolant (green):
1 Install the engine.
2 Fill with Volvo Coolant (green).
Vehicles that require Volvo Coolant VCS (yellow):
1 Before installation, remove the coolant filter and drain the engine of coolant.
The stopcock on the water pump must be closed.
2 Fit the cover and O-ring. Torque tighten the cover to 45±3 Nm.
Note: Grease in the O-ring with Vaseline.
3 Install the engine.
4 Fill the cooling system with tap water. Set the control for cab heating to “Warm”. Start
the engine and let it run at a high idle speed until normal circulation is obtained or
for at least 5 minutes.
Drain the coolant at all drainage points - radiator, engine and extra radiator if installed.
Loosen the expansion tank cap to facilitate drainage.

WARNING
Pressurised cooling system! Hot coolant can
cause burns. Use suitable protective equipment.

5 Fill the cooling system at once with Volvo Coolant VCS (yellow).
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 2.06 210 93 02 10(13)

Special tools: 9998547

Other special equipment: 1159795
1
Lifting device
Carefully lift the engine in position in the vehicle.

9998547

T2016927

T2016939

T2016934
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 2.06 210 93 02 11(13)

T2016938

T2016937

6
Torque wrench, 40 - 340Nm

1159795
175 ± 30 Nm

T2016941
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 2.06 210 93 02 12(13)

7
Torque wrench, 40 - 340Nm

1159795
70 – 100 Nm

T2016940

T2016933

T2016932

10
Note: Fit the plastic clamps for the electrical cables,
hoses and pipes in the same place that they were
removed from when the engine was removed
Volvo Truck Corporation Date Group No. Release Page
Service Bulletin 2.06 210 93 02 13(13)

11
Fit the gearbox according to the instructions in service
information, group 43.

12

13

14

15

16

17
Note: Check the engine oil level and fill up if necessary.
When bleeding the fuel system, the ignition key must
be in the drive position.

18
Note: Make sure that the parking brake has been applied
and that the gear lever is in neutral.
Start the engine and do the leakage and function check.
Also check that no error codes have been set.