Engine, Replacement D11H, D13H, D16H VN VHD VAH

Vo l v o Tru c k s N o r t h
S erv ic e B ulletin
A me ri c a
Greensboro, NC USA
Tr u c k s
Date Group No. Release Page
8.2012 210 146 01 1(66)
Engine, Replacement
D11H, D13H, D16H
VN, VHD, VAH
E ngi ne, Replacement
This information covers the proper procedure for replacing a VOLVO engine in VN, VHD and
VAH chassis, without optional PTO.
Contents
• “Special Tools”, page 2
• “Engine, Replacement”, page 4
N o t e : Information is subject to change without notice.

Illustrations are used for reference only, and may differ slightly from the actual engine
version. However, key components addressed in this information are represented as
accurately as possible.
P V776-89059132
USA53692 English
Vo l v o Tru c k s N o r t h A m e r i c a Date Group No. Release Page
S e rv ic e B u ll e ti n 8.2012 210 146 01 2(66)
To o l s
S p e c i a l To o l s
For special tools ordering instructions, refer to Tools Informa-
tion, group 08.
W0001874
W0002370
W2004191
D B T2 V 7 0 0 , 8 5 11 2 7 4 0 J44773 J 4 703 8-1

Coolant Injector/Extractor Air Line Release Tool Engine Lifting Plate
W0002371
W0002369
W0002421
J 470 38 -2 J 47 03 8-3 J 4 703 8-6

Engine Lifting Bracket Rear Engine Lifting Extension Engine Lifting Fixture
W0002411
W0002412 W0002179
J 470 38 -7 J 47 03 8-8 85104846

Front Engine Lifting Bracket Engine Lift Front STC Fitting Release Tool
W0001795
W4002806 W4002807
85108826 85108827 9996049

Transmission Line Tool, 15 mm Transmission Line Tool, 18 mm Coolant Drain Hose
T0012612
W0002422
W0001817
88800014 J 47 03 8-4 J 44392

Flywheel Turning Tool Engine Lifting Tool Drive Belt Tensioner Tool
W0001774
W0001797
T0013033
9996950 9996956 88800031

Flywheel Stop Tool Flywheel Turning Tool Cam Sensor Setting Tool
S ervic e P roc edures

E ngine, Repl acement
See also:
• “Engine, Replacement”, page 1
• “Special Tools”, page 2
You must read and understand the precautions and guide-

lines in Service Information, group 20, "General Safety
Practices, Engine" before performing this procedure. If you
are not properly trained and certified in this procedure, ask
your supervisor for training before you perform it.
Special tools: DBT2V700, 85112740, J44392,

J44773, J47038-1, J47038-2, J47038-3,
J47038-6, J47038-7, J47038-8, 85104846,
85108826, 85108827, 88800014, 9996049,
88800031, J47038-4, 9996950, 9996956
Removal
1
Apply parking brake and place shift lever in neutral.
2
Connect to Premium Tech Tool and save the old parameters.
These saved parameters will be transferred to the new en-
gine control module (ECM).
3
Disconnect all battery cables from the negative (ground) bat-
tery terminals to prevent personal injury from electrical shock
and prevent damage to electrical components.
W2003815
4
Using a suitable container drain the oil. Discard of the oil
drain plug gasket. Dispose of the use oil in accordance with
all state, local and/or federal regulations.
N o t e : Use only hand tools when removing and tightening the
drain plug. Do not use an air ratchet or similar air tool.
5
Remove the threshold plates on both sides.
6
Remove the fasteners and remove the center dash trim pan-
el. Then remove the engine cover fasteners and remove cov-
er from the cab.
N o t e : Depending on chassis, the passenger seat may need
to be removed first to allow for engine cover removal.
W8003859
7
If equipped, remove the engine cover seal ring from the
bulkhead.
8
Unlatch and raise the hood.
9
If equipped, remove the rock guard from underneath the
radiator.
W2006077
10
Connect the coolant injector/extractor to the radiator and
drain the engine coolant.
N o t e : An alternate method is to connect the drain hose to
the drain fitting and drain the coolant into an approved
container.
DBT2V700, 85112740, 9996049
W2004191
11
Remove the fasteners securing the radiator/hood grille and
remove the grille.
12
Disconnect the wiring harnesses for the headlights and fog/
running lights and remove the nylon ties securing the
harness.
13
Mark the locations of the bumper mounting fasteners for re-
assembly purposes.
14
Remove three of the four bumper fasteners on each side.
Loosen the remaining nut, but do not remove it at this time.
W2004694
15
Close the hood in preparation of bumper removal.
16
With the help of an assistant to hold the bumper, remove the
two remaining fasteners and take off the bumper.
W2004743
17
Raise the hood.
18
Cut wiring harness tie straps and disconnect the cable har-
ness on the left and right side of the hood hinge. Disconnect
the hood harness and lay to the side.
19
Mark the locations of the hood hinge mounting flange nuts on
the frame mounts. Marking the position on the frame mount
slotted holes will aid in hood alignment during reassembly.
W2004695
20
Remove the hood restraint cylinders from both sides of the
radiator supports and support the hood in the open position.
21
With the help of an assistant, remove the hinge mounting fas-
teners that hold the hood hinge to the frame. Use a pallet with
a protective covering to support the hood as the hinge fasten-
ers are removed.
22
Set the hood aside in a protected location.
23
Remove both right and left inner splash guards as
assemblies.
N o t e : Some models may be equipped with fender extenders,
attached to the inner splash guard. Remove these as an
assembly.
24
Remove the AC condenser line bracket bolts from the left
side of the radiator.
N o t e : Do not disconnect the refrigerant lines from the AC
condenser.
W2006084
25
Remove the bolts securing the AC condenser to the front of
the charge air cooler (CAC).
W8003667
26
Lift and move the AC condenser (with lines attached) over
the charge air cooler and radiator to the left fender area. Se-
cure out of the way to prevent damage.
W2006199
27
Remove upper coolant hoses including the pipe at the
radiator.
28
Disconnect the de-aeration line between the engine and the
expansion tank from the engine, remove rear hose clamp
and loosen coolant hose to expansion tank from pipe.
29
Disconnect the engine coolant level sensor located on the ra-
diator right side. Cut tie straps to release sensor harness.
30
Loosen the clamps at the outlet of the engine charge air cool-
er (CAC) and the inlet of the mixing chamber. Remove the
CAC pipe between the mixing chamber and cooler.
31
Loosen the clamps securing the air inlet pipe at the air
cleaner and at the turbocharger inlet elbow. Remove the
main air inlet pipe.
W2006005
32
If equipped, disconnect and remove the air cleaner differen-
tial pressure gauge wiring harness from the air cleaner
housing.
W2003861
33
Loosen the air compressor intake air hose clamp.
34
Remove the fasteners and lift the air cleaner housing away
from the cab.
W2003858
35
Remove the engine turbocharger inlet elbow.
W2075313
36
Disconnect the engine turbocharger compressor outlet tem-
perature sensor harness.
W2075314
37
Remove the CAC pipe from between the engine turbocharg-
er and engine CAC.
W2075348
38
Remove all the fasteners securing the front closing cross
member and remove the cross member.
W2006086
39
Remove the transmission cooler line clamps.
40
Loosen the clamps for the lower radiator hoses, position the
clamps out of the way and remove the lower radiator hoses.
Also, remove the pipe from the engine.
N o t e : Use a suitable receptacle to collect any residual cool-
ant as hoses are removed from the radiator.
41
Disconnect and plug the transmission oil cooler lines from
the bottom of the radiator using the correct size special tool.
N o t e : Use a suitable receptacle to collect any transmission
oil that may leak as the cooler lines are removed. Dispose of
the used oil in accordance with all state, local and/or federal
regulations.
85108826, 85108827
42
Support the weight of the cooling package using a mobile
floor crane such as OTC 16-1815 or equivalent crane capa-
ble of safely lifting the cooling package. Position the crane
and attach a chain using bolts, nuts and washers or strap to
the lifting eyes of the radiator frame.
WA R N I N G
Failure to use a crane of sufficient capacity may allow the
coolant package to fall or suddenly shift out of position
causing damage to equipment or personal injury.
43
Disconnect the upper radiator hose, by-pass hose and static
fill hose from the engine side of each connection.
N o t e : D13 engine shown for reference.
W2075311
44
Remove the radiator lower rubber isolator mount bolts and
remove the isolators from each side of the radiator.
W2006097
45
Remove both radiator support bolts and isolators from the
upper portion of the radiator.
W2006098
46
Lift straight up on the radiator assembly, then move the cool-
ant package forward and away from the chassis. Secure the
coolant package in an upright position to protect the cooling
fins of the radiator and engine CAC.
N o t e : Install protective covers on the radiator and engine
CAC openings.
W2006269
47
Remove the fasteners securing the fan ring to the fan ring
supports and remove the ring from the engine.
48
Remove the fasteners securing the fan blade to the fan hub
and remove the fan from the engine.
W2006089
49
Using tool J44392, pry the belt tensioner away from the fan
and water pump drive belt and remove the belt.
J44392
W2006031
50
Place a 1/2 inch ratchet or special tool in the accessory drive
belt tensioner, relieve the tension on adjuster and slip belt off
the AC compressor pulley. Do not remove the belt from the
engine.
J44392
W2006093
51
Remove the AC compressor by first cutting the harness ties
and disconnecting AC harness plug. Remove AC suction line
support bracket bolt from the inlet manifold and remove the
compressor mounting bolts to free the compressor from the
engine brackets. Secure the AC compressor to the chassis
frame.
N o t e : Allow AC compressor hoses to remain connected.
52
On D13 engines, loosen the V-clamps and remove the EGR
crossover tube.
W2073632
1 Crossover Tube
2 Mixer Inlet Tube
53
Disconnect the line to the aftertreatment hydrocarbon doser.
54
Remove the exhaust pipe from between the diffuser pipe and
the aftertreatment diesel particulate filter inlet pipe. Lift the
pipe over the diffuser and out from under the cab.
N o t e : It may be necessary to remove the aftertreatment hy-
drocarbon doser line for clearance before removing the ex-
haust pipe.
W2005952
55
Remove the coupling hose clamp securing the intake air inlet
pipe at the air compressor. Remove the bracket bolts at the
cylinder head and remove air compressor inlet pipe from the
engine.
W5001571
56
Remove the air discharge line from the compressor head.
Remove the support brackets from the discharge line. Dis-
connect the compressor signal line from the compressor.
W5001572
57
Remove aftertreatment diesel exhaust fluid (DEF) heater ho-
ses from the air compressor coolant pipes, some engines
may have one of the heater hoses routed to the side of the
engine.
58
Loosen hose clamps on cab heater pipes and remove hoses
from pipes.
N o t e : Collect any residual coolant in a suitable catch
container.
59
If equipped, loosen hose clamps on coolant hoses connect-
ing to the fuel filter heater. Remove coolant hoses from filter.
N o t e : Use a suitable receptacle to collect any residual cool-
ant that may leak as the hoses are removed.
60
Partially withdraw the dipstick and remove the cap screw se-
curing the oil dipstick tube and remove the dipstick tube from
the side of the oil pan.
W2005086
61
Remove the fasteners securing the oil filler tube to the oil pan
and remove the tube.
W2004884
62
If equipped, remove the fan clutch air line from the fan clutch
hub using the air line release tool and cut tie straps to posi-
tion the line out of the way.
J44773
W2006094
63
Disconnect the fuel inlet and return lines from the fuel pump.
N o t e : Use a suitable fuel collection container to catch any re-
sidual fuel that may be in the fuel lines.
64
Remove the power steering pump mounting bolts and secure
the pump (with lines attached) to the suspension leaf spring.
N o t e : Fuel pump remains attached to rear of power steering
pump.
65
Disconnect all wiring from the starter motor. Remove cable
supports on the engine right side.
W2004714
66
Disconnect fuel lines on engine left side (utilize quick discon-
nects). Cut any wire ties securing the fuel lines.
N o t e : Use a suitable fuel collection container to catch any re-
sidual fuel that may be in the fuel lines.
85104846
67
Remove the battery cable loom brackets on the bell housing
and move both negative and positive battery cables out of
the way.
68
Cut the nylon ties securing the wiring harness to the left front
and left side, then disconnect the interface harness
connector.
69
Cut all ties securing the harness across the top of the trans-
mission, then disconnect all switches.
70
If equipped, disconnect the block heater harness and remove
the ties securing the harness.
71
Disconnect ground cable from left side of engine, cut tie
straps securing cable to engine wiring harness. Position ca-
ble out of the way.
72
Remove the ties securing the transmission cooler hoses to
the support brackets at the oil pan.
W2004874
73
Remove the front section of the drive shaft from between the
transmission and the back section of the front drive shaft,
then secure the drive shaft to the frame.
74
If equipped, remove the slave cylinder or actuator housing
line bracket.
75
If equipped, remove the slave cylinder or actuator housing.
Secure clutch cylinder to frame rail.
N o t e : Do not disconnect the lines.
W2004757
76
If equipped, disconnect the shifter/splitter air lines and supply
air line, then remove the retainer bolt and lift the shift lever off
the tower.
W2004755
77
Remove the lower bell housing bolts.
78
Remove the clip from the release bearing grease line, then
position a transmission jack with a suitable capacity under
the transmission and secure it.
79
Remove the top bell housing bolts. Lower transmission down
slightly, then move back and away from the rear of the
engine.
80
Loosen the rear motor mount bolts. Do not remove the bolts
at this time.
W2005367
81
Slide center engine lifting bar over the valve cover and install
clevis pin. Connect center lifting bar clevis to chain on hoist.
Slide rear lifting plate into center lifting bar and install pin. Bolt
on front section of the engine lifting bracket to cylinder head
and install pin in bar. Tighten lifting bracket bolts to
specification.
DANGER
Use only the chains, clevis and lifting plate provided with
these special tools. Failure to use the correct special tool
components may allow the engine to fall, causing serious
personal injury or death.
N o t e : See steps 82–84 for the appropriate lifting tools. En-

gine lifting tools will vary depending on engine size.
N o t e : Refer to Specifications in Group 200 for component

torque and sequence specifications.
82
Install the correct lifting tools for removing the D11 engine.
N o t e : See illustrations for the appropriate engine lifting tools.
W2075983
W2075982
E n g i n e L i f t i n g To o l s , F r o n t a n d R e a r, D 11
1. J47038–7, Front Engine Lifting Bracket

2. J47038–6, Engine Lifting Fixture
3. J47038–3, Rear Engine Lifting Fixture
4. J47038–4, Flywheel Housing Lifting Bracket
83
W2075981
W2075980
E n g i n e L i f t i n g To o l s , F r o n t a n d R e a r, D 1 3

3. J47038–3, Rear Engine Lifting Fixture
4. J47038–4, Flywheel Housing Lifting Bracket
84
W2075979
W2075978
E n g i n e L i f t i n g To o l s , F r o n t a n d R e a r, D 1 6

3. J47038–1, Rear Engine Lifting Plate
(Chains and Clevis Hooks Included)
85
Support the weight of the engine using a mobile floor crane
capable of safely lifting the engine. Position the crane and
hook up to the bar as close as possible. Raise the crane
slightly to apply tension to the chain.
86
Remove the front engine mount bolts.
W2004716
87
Remove the rear engine mount bolts. Engine may need to be
lifted slightly to allow the bolts to be released.
W2005365
88
With the help of an assistant, lift the engine up off the sup-
ports, and remove the engine from the chassis out the front
of the frame.
N o t e : Carefully move the engine out away from transmission
making sure that lines or wires are not damaged during en-
gine removal.
DANGER
The engine is very heavy and extreme caution must be ex-
ercised while it is being removed. Failure to use proper
equipment and failure to keep your body clear may result
in serious personal injury or death if the engine should fall
or suddenly shift out of position.
89
Position the old engine on a suitable engine stand capable of
safely supporting the engine's weight. This will allow for a
safe parts transfer to the new engine.
90
Remove the engine lifting tools.
N o t e : See 7/8 Component Transfer section for replacing a 7/
8 basic US2010 Vovlo engine in a VN, VHD, and VAH truck
without optional power takeoff (PTO).
N o t e : See 3/4 Component Transfer section for replacing a 3/

4 basic US2010 Vovlo engine in a VN, VHD, and VAH truck
without optional power takeoff (PTO).
7/8 Component Transfer

N o t e : Refer to Specifications in Group 200 for component
torque and sequence specifications.
1
Remove the fan ring brackets, left upper, right and left lower
fan ring mounts.
W2004751
2
Remove the upper fan hub mounting fastener and install
alignment stud.
W2006095
3
Remove the remaining mounting fasteners securing the fan
hub to the front of the engine and remove the fan hub.
4
Remove the ground and positive cables from the alternator.
5
Remove the clutch pressure plate bolts and separate the
pressure plate and clutch discs from the flywheel.
N o t e : Loosen the bolts in a crisscross pattern in order to pre-
vent pressure plate from bending.
W4002944
I-Shift pressure plate shown (typical)
6
On D13 and D16 engines, remove the rubber dust plug and
install the flywheel turning tool. Lock the flywheel using the
turning tool and a breaker bar.
88800014
W0002368
7
On the D11 engines, remove the dust cover and install tool
9996950 to lock flywheel.
9996950
8
Remove the flywheel bolts and washers. Next, using a pry
bar, tip the flywheel away from the crankshaft and remove
the flywheel from the rear of the engine.
W2005379
9
Remove the special oil pan mounting fasteners with mount-
ing studs and transmission cooler line brackets from the old
engine. Install the oil pan mounting fasteners with studs and
transmission cooler line brackets on the new engine.
10
If equipped, remove the intake air heater relay, wiring and
bracket from the old engine.
W2006196
11
If equipped, remove mounting fastener and the engine block
heater from the old engine.
W2075312
1 Mounting Fasteners
2 Engine Block Heater
12
If equipped, remove the front idler and bracket from the old
engine.
13
Remove the starter from the old engine.
14
Remove the crankcase breather assembly and hoses from
the old engine.
N o t e : Make sure to save the original fasteners for reinstalla-
tion to prevent damage to valve cover.
W2034062
15
Remove the alternator and brackets from the old engine.
16
Remove the air compressor from the old engine.
17
Remove CCV oil supply line, if equipped.
N o t e : This step applies to the D11 engine only.
18
Remove all shipping cover and plugs from the new engine.
19
Remove fasteners and valve cover. Record unit injector trim
codes for programming.
20
Install the valve cover to new engine and torque fasteners to
specification.
21
Remove protective cover from engine fuel filter housing on
new engine and install a new fuel filter separator.
22
If equipped, install the crankcase ventilation oil supply pipe.
N o t e : This step applies to the D11 engine only.
23
Install the air compressor onto the new engine.
24
Install the alternator and brackets onto the new engine.
25
Install the crankcase ventilation assembly and hoses onto
the new engine.
N o t e : Make sure to install original bolts.
W2034062
26
Install the starter onto the new engine.
27
If equipped, install the front idler and bracket onto the new
engine.
28
If equipped, install the intake air heater relay, wiring and
bracket on the new engine.
W2006196
29
If equipped, install the engine block heater onto the new en-
gine and tighten mounting fastener to specification.
W2075312
1 Mounting Fasteners
2 Engine Block Heater
30
Carefully clean the flywheel and crankshaft contact surfaces,
then position the flywheel on the crankshaft and hand-tighten
the flywheel bolts snug.
W2005379
31
On D13 and D16 engines, remove the flywheel housing dust
plug from the new engine and install flywheel turning tool
88800014. Lock the flywheel in position using the turning tool
and a breaker bar.
88800014
W0002368
32
On the D11 engines, remove the dust cover install tool
9996950 to lock flywheel.
9996950
33
Tighten flywheel bolts in sequence shown in the
specifications.
N o t e : Refer to Specifications in Group 200 for torque and se-
quence specifications.
34
Remove the flywheel turning tool and reinstall the dust plug.
88800014
35
On the D11 engines, remove the lock tool 9996950 and in-
stall the dust cover.
9996950
36
Install any needed covers or plugs to the old engine.
37
Check condition of the pilot bearing, clutch disc, clutch throw
out bearing and clutch pressure plate. Replace worn parts as
necessary.
38
Install the clutch and pressure plate assembly onto the fly-
wheel. Tighten the clutch-to-flywheel bolts to specifications.
Ensure the caging bolts are removed from the clutch/pres-
sure plate assembly.
W4002944
39
Remove the clutch and pressure plate installation tools.
40
Install the ground and positive cables onto the alternator.
41
Install an alignment stud in the fan hub upper mounting loca-
tion, and position the fan hub from the old engine onto this
stud.
W2006095
42
Install the fan hub lower mounting fasteners and remove the
alignment stud from the upper location.
43
Install the fan hub upper fastener and torque-tighten all fan
hub fasteners to specification.
44
Check the condition of both of the original AC/alternator and
water pump/fan belts. Check for dry cracks or scuff marks
and replace with new belts if any of these conditions are
present.
45
Install the fan ring brackets, left upper, right and left lower fan
ring mounts.
W2004751
3/4 Component Transfer

N o t e : Refer to Specifications in Group 20 for component tor-
que and sequence specifications.
1
Remove the fan ring brackets, left upper, right and left lower
fan ring mounts.
W2004751
2
Remove the upper fan hub mounting fastener and install
alignment stud.
W2006095
3
Remove thermostat cover and thermostat.
4
Remove the remaining mounting fasteners securing the fan
hub to the front of the engine and remove the fan hub.
5
Remove the negative and positive cables from the alternator.
6
Remove the clutch pressure plate bolts and separate the
pressure plate and clutch discs from the flywheel.
N o t e : Loosen the bolts in a crisscross pattern in order to pre-
vent pressure plate from bending.
W4002944
7
On D13 and D16 engines, remove the rubber dust plug. In-
stall the flywheel turning tool. Lock the flywheel using the
turning tool and a breaker bar.
N o t e : Not applicable to D11 engines.
88800014, 9996956
W0002368
8
Remove the flywheel bolts and washers. Using a pry bar, tip
the flywheel away from the crankshaft and remove the fly-
wheel from the rear of the engine.
W2005379
9
Remove the flywheel turning tool. On D13 and D16 engines,
reinstall the dust plug.
W0002368
10
Remove the oil pan mounting fasteners and transmission
cooler line brackets from the old engine. Install the oil pan
mounting fasteners and transmission cooler line brackets on
the new engine.
11
If equipped, remove the intake air heater (IAH) wiring and
bracket from the old engine.
W2006196
12
If equipped, remove mounting fastener and the engine block
heater from the old engine.
W2075312
13
Remove the fuel separator coolant hoses from the old
engine.
14
Remove the front idler and bracket from the old engine.
15
Remove the heater brackets from the harness cover on the
old engine.
16
Remove the vibration damper and pulley from the old engine
crankshaft hub.
W2005536
1 Fan Pulley
2 Vibration Damper
3 Crankshaft Hub
17
Remove the coolant manifold, pump, housing and piping
from the old engine.
18
Remove mounting fasteners and the EGR valve from the old
engine.
W2005695
19
Remove the turbocharger and exhaust manifold from the old
engine.
20
Remove the EGR cooler from the old engine.
W2005970
21
If equipped, remove the EGR cooler brackets from the old
engine.
W2005901
22
Remove the starter from the old engine.
23
Remove the mounting fasteners and the oil filter housing
W2006184
24
Remove the crankcase breather assembly and hoses from
the old engine.
N o t e : Make sure to save the original fasteners for reinstalla-
tion to prevent damage to valve cover.
W2034062
25
Remove the mounting fasteners and the intake manifold from
the old engine.
W2006117
26
Remove the alternator and brackets from the old engine.
27
Remove the air compressor from the old engine.
28
Remove the engine control module (ECM) and cooling plate
29
Remove the engine fuel filter housing from the old engine.
W2005861
30
Remove the aftertreatment fuel shutoff valve from the old
engine.
31
Remove the crankcase pressure (CCP) sensor from the old
engine.
32
Remove the engine oil pressure (EOP) sensor from the old
engine.
33
Remove the engine wiring harness from the old engine.
34
Remove the camshaft position (CMP) sensor from the old
engine.
35
Remove the crankshaft position (CKP) sensor from the old
engine.
36
Remove the air compressor coolant pipes from the old
engine.
37
Remove the EGR valve oil return line from the old engine.
38
Remove all shipping cover and plugs from the new engine.
39
Transfer the engine coolant temperature (ECT) sensor to the
new engine.
40
Install the EGR valve oil return line onto the new engine.
41
Install the air compressor coolant pipes onto the new engine.
42
Install the EOP sensor onto the new engine.
43
Install the engine wiring harness onto the new engine.
44
Record the injector trim codes.
45
Check for proper depth, install the CMP sensor with the cor-
rect shims onto the new engine.
88800031
46
Install the CCP sensor onto the new engine.
47
Install the aftertreatment fuel shutoff valve onto the new
engine.
48
Install the fuel filter housing onto the new engine.
W2005861
49
Install the ECM and cooling plate onto the new engine.
50
Install the air compressor onto the new engine.
51
Install the alternator and brackets onto the new engine.
52
Install the intake manifold onto the new engine and tighten
mounting fasteners to specification. Refer to Function Group
20, Specifications.
W2006117
53
Install the crankcase ventilation assembly and hoses onto
the new engine.
W2034062
54
Install the oil filter housing onto the new engine.
55
Install the starter onto the new engine.
56
If equipped, install the EGR cooler brackets onto the new
engine.
W2005901
57
Install the manifold and engine turbocharger onto the new
engine.
W2005970
58
Install the engine turbocharger and exhaust manifold onto
the new engine.
59
Install the EGR valve onto the new engine.
W2005695
60
Install the coolant manifold, pump, housing and piping onto
the new engine.
61
Install the vibration damper and pulley onto the new engine.
W2005536
1 Fan Pulley
2 Vibration Damper
3 Crankshaft Hub
62
Install the front idler and bracket onto the new engine.
63
If equipped, install the IAH wiring and bracket on the new
engine.
W2006196
64
If equipped, install the engine block heater onto the new en-
gine and tighten mounting fastener to specification.
W2075312
65
Install the heater brackets to the harness cover on the new
engine.
66
If equipped, install a new engine coolant filter and bypass
hard pipe.
67
Install the fuel separator coolant hoses onto the new engine.
68
Carefully clean the flywheel and crankshaft contact surfaces.
Position the flywheel on the crankshaft and hand-tighten the
flywheel bolts snug.
W2005379
69
On D13 and D16 engines, remove the flywheel housing dust
plug from the new engine. Install flywheel turning tool. Lock
the flywheel in position using the turning tool and a breaker
bar.
N o t e : Not applicable to the D11 engine.
88800014, 9996956
W0002368
70
Tighten flywheel bolts in sequence to specification.
71
Remove the flywheel turning tool. On D13 and D16 engines,
reinstall the dust plug.
N o t e : Not applicable to the D11 engine.
72
Install any needed covers or plugs to the old engine.
73
Check condition of the pilot bearing, clutch disc, clutch throw
out bearing and clutch pressure plate. Replace worn parts as
necessary.
74
Install the clutch and pressure plate assembly onto the fly-
wheel. Tighten the clutch-to-flywheel bolts to specification.
Ensure the caging bolts are removed from the clutch/pres-
sure plate assembly.
W4002944
I-shift pressure plate shown (typical)
75
Remove the clutch and pressure plate installation tools.
76
Install the ground and positive cables onto the alternator.
77
Install thermostat and torque thermostat cover to
specification.
78
Install an alignment stud in the fan hub upper mounting loca-
tion, and position the fan hub from the old engine onto this
stud.
W2006095
79
Install the fan hub lower mounting fasteners and remove the
alignment stud from the upper location.
80
Install the fan hub upper fastener and tighten all fan hub fas-
teners to specification.
81
Check the condition of both of the original A/C/alternator and
water pump/fan belts. Check for dry cracks or scuff marks
and replace with new belts if any of these conditions are
present.
82
Install the three fan ring brackets, left upper, right and left
lower fan ring mounts.
W2004751
Installation
1
N o t e : Refer to Specifications in Group 20 for component tor-
que and sequence specifications.
Slide center engine lifting bar over the valve cover and install
clevis pin. Connect center lifting bar clevis to chain on hoist.
Slide rear lifting plate into center lifting bar and install pin. Bolt
on front section of the engine lifting bracket to cylinder head
and install pin in bar. Tighten lifting bracket bolts to
specification.
DANGER
Use only the chains, clevis and lifting plate provided with
these special tools. Failure to use the correct special tool
components may allow the engine to fall, causing serious
personal injury or death.
N o t e : See, Removal Section, steps 82–84 for the appropri-

ate lifting tools. Engine lifting tools will vary depending on en-
gine size.
2
With the lifting tools correctly attached, remove the new en-
gine from the shipping stand. Support the weight of the en-
gine using a mobile floor crane capable of safely lifting the
weight of the new engine.
3
With the help of an assistant, position the engine in the chas-
sis and install new engine mount-to-cushion bolts for the front
mount. Hand-tighten the bolts snug using a socket and
handle.
N o t e : Engine front mounting bolts are one time use only.
New bolts must be obtained at installation.
DANGER
The engine is very heavy and extreme caution must be ex-
ercised while it is being installed. Failure to use proper
equipment and failure to keep your body clear may result
in serious personal injury or death if the engine should fall
or suddenly shift out of position.
W2004716
4
With the help of an assistant, position the rear of the engine
over the rear mounts and lower the rear of the engine until
the rear engine mounts are resting on the frame mounts. In-
stall the vertical rear support bolts and hand-tighten the bolts
snug using a socket and handle.
N o t e : Carefully install the replacement engine to ensure no
lines, hoses or wires are being pinched or damaged.
W2005365
5
Tighten the f r o n t engine mount-to-cushion bracket support
bolts to specification.
N o t e : Refer to Specifications in Group 200 for torque and se-
quence specifications.
6
Tighten the vertical r e a r engine support bolts to specification.
W2005367
7
Remove the engine lifting tools from the engine and back
crane away from area.
8
Connect DEF heater lines.
9
Position the air compressor fresh air inlet pipe in position
over the valve cover and connect the pipe to the coupling
hose at the compressor. Tighten a new coupling hose clamp
and secure the pipe to the cylinder head.
W5001571
10
Connect the air compressor discharge line to the compres-
sor. Install the support brackets for the supply line and AC
line at the intake. Connect the compressor signal line to the
air compressor.
W5001572
11
Position transmission to allow input shaft to align with clutch
release bearing. Connect the release bearing grease line to
the bell housing and secure it with a clip.
12
Push the transmission against the flywheel housing and use
the flywheel turning tool to rotate the engine slightly to allow
the input shaft to align with the clutch disc and pilot bearing.
Install the top mounting bolts and secure.
N o t e : Carefully install input shaft into the clutch disc hub. Do
not force or jam input shaft into the hub.
13
Install and secure the lower mounting bolts and torque-tight-
en all transmission mounting fasteners to specification. Re-
move the transmission jack from gearbox.
14
Connect the front section of the drive shaft to the transmis-
sion and the back section of the front drive shaft. Secure the
drive shaft in place.
15
As applicable, install the slave cylinder or actuator housing.
W2004757
16
As applicable, install the slave cylinder or actuator housing
line brackets.
17
If equipped, connect the shifter/splitter air lines and the sup-
ply air line. Then install the retainer bolt and slide the shift
lever on the tower shaft and secure.
W2004755
18
Route and connect the transmission harness. Secure the
harness in place.
19
Mount the transmission cooler lines.
20
Install battery cable bracket at the bell housing and lay bat-
tery cables toward the starter and secure.
21
Route, connect and secure all wires and cables to the starter
motor. Install all previously removed cable supports.
W2004714
22
Install the ground wire on the engine left side.
23
Position the wiring harness to the left front and left side of the
engine, then connect the interface harness connector. Se-
cure harness using tie straps.
24
Connect fuel lines on engine left side (utilize quick discon-
nects). Secure fuel lines using tie straps.
25
Using a new O-ring, install the power steering pump onto the
engine with inlet and pressure lines still attached. Top off
power steering reservoir as required.
N o t e : Fuel pump remains attached to the rear of the power
steering pump.
26
Using new sealing washers, reconnect the fuel inlet and re-
turn lines to the fuel pump and torque-tighten to
specifications.
27
Reconnect previously disconnected coolant hoses located
under the truck cab. Also, reconnect the heater hoses to the
heater core pipes and tighten with all new clamps securely.
28
If equipped, connect coolant hoses to the fuel filter heater.
Tighten hose with new clamps to secure coolant hoses to the
fuel filter heater.
29
With a new gasket and new V-band clamps, position the ex-
haust pipe between the diffuser pipe and the DEF inlet pipe
and loosely install the V-band clamps. Align all exhaust pipes
and torque-tighten all V-band clamps to specification.
W2006038
30
Connect the afterteatment hydrocarbon doser.
31
Mount the AC compressor to the engine bracket and torque-
tighten all fasteners to specification. Install the AC suction
line support bracket. Reconnect the AC compressor clutch
harness and secure the wires as needed.
32
If equipped, connect the supply air line to the fan hub. Secure
supply air line to the engine harness using tie straps.
W2004687
33
Per the accessory routing decal, route the AC/alternator belt.
Place a 1/2 inch ratchet or special tool in the accessory drive
belt tensioner notch. Install drive belt by prying tensioner
away from the belt to relieve the tension on the adjuster and
allow the belt to slip onto the AC compressor pulley. Release
tension and remove tool.
J44392
W2006093
34
Using tool J44392, pry the belt tensioner away from the fan
and water pump drive belt and install the belt.
J44392
W2006031
35
Install the frame mounting bracket for the dipstick and filler
tube.
36
Install new O-rings and install the oil filler tube onto the side
of the oil pan and secure.
W2004884
37
Install the oil dipstick tube onto the side of the oil pan and
secure.
W2005086
38
If equipped, route and connect the block heater wiring har-
ness. Secure the harness in place.
39
Connect the ground wires to the left side of the engine block
and secure them in place.
40
Connect the interface harness and secure it on the left front
and left side of the block with nylon cable ties.
41
Connect the wires and harnesses to the AC compressor, al-
ternator and preheater relay (if equipped). Secure them in
place.
42
Position the engine fan blade on the front of the fan hub and
install the fan blade fasteners. Tighten all fasteners to
specification.
W2006089
43
Position the fan ring on the mounts and install the fan ring
fasteners. Tighten all fasteners to specification.
44
Using nylon cable ties, route and secure the wiring harness
across the front of the valve cover.
45
Connect a suitable hoist and strap to the coolant package
and position it in front of the vehicle.
W2006269
46
With the help of an assistant, position the coolant package in
the frame and start all radiator bracket fasteners.
47
Install the lower radiator mounts on both sides and tighten
the fasteners securely.
W2006097
48
Install and tighten the radiator upper mounting bolts and
isolators.
W2006098
49
Remove the hoist and lifting chain from the coolant package.
Also, remove the protective covers from the radiator and en-
gine charge air cooler openings.
50
Reconnect the transmission cooler lines to the radiator.
51
Route and secure the transmission cooler lines.
W2004874
52
Using a new O-ring, install and secure the radiator lower
coolant hard pipe and hose. Position new clamps and tighten
the hose clamps securely.
53
Connect the upper radiator hose to the engine and secure
the pipe bracket to the cylinder head. Connect the static fill
and by-pass hoses to the expansion tank. Position new
clamps and tighten the hose clamps securely.
W2075311
54
Connect the coolant level sensor located on the radiator right
side. Secure sensor harness using tie straps.
55
Fill the cooling system with the recommended coolant using
the coolant extractor/injector.
DBT2V700, 85112740
56
Using the recommended oil, replenish the engine oil to the
correct level on the dipstick.
N o t e : Ensure oil pan drain plug is torqued to proper
specification.
57
Install and secure the front closing cross member.
W2006086
58
On D13 engines, position the crossover tube (with new O-
rings) between the venturi tube and the mixer inlet tube. Lu-
bricate new V-band clamp threads and v-inserts and tighten
the clamps to specification.
N o t e : Make sure the O-rings remain in place while position-
ing the tube.
W2073632
1 Crossover Tube
2 Mixer Inlet Tube
59
Replace all the sealing O-rings on the CAC pipe.
60
Install the CAC pipe between the engine turbocharger and
the engine CAC.
W2075348
61
Connect the engine turbocharger compressor outlet tempera-
ture sensor harness.
W2075314
62
Install the engine turbocharger inlet elbow.
W2075313
63
Position the air cleaner housing against the cab and install
fasteners to secure.
W2003858
64
Install the main intake air pipe to the air cleaner housing and
to the turbocharger inlet elbow. Tighten secure with new
clamps.
W2006005
65
Install the air compressor intake air hose to the main intake
air pipe, position a new clamp and tighten secure.
66
If equipped, connect and secure the air cleaner differential
pressure gauge wiring harness to the air cleaner housing.
W2003861
67
Position the deaeration line between the engine and expan-
sion tank. Tighten with a new clamp securely.
68
Using new O-rings, install the CAC pipe between the mixing
chamber and the engine CAC. Lubricate the new clamps v-
inserts and T-bolt threads. Tighten clamps to specification.
69
Lift and move the AC condenser (with lines attached) over
the radiator assembly and into position at the front of the
charge air cooler.
W2006199
70
Install and tighten the bolts to secure the AC condenser to
the CAC.
W8003667
71
Connect the AC condenser line bracket bolts on the left side
of the radiator.
W2006084
72
Install the hood by first moving it into position at the front of
the vehicle.
N o t e : An assistant is required to help lift and support the
hood during installation. Use a pallet with protective covering
to protect and support the hood.
73
Position the hood hinge on the frame mounts and align the
studs with the marks made before removal. Install the flange
nuts and tighten to specification. Close the hood and check
for proper hood alignment. Also, connect the hood restraint
cylinders on both sides of the radiator supports.
W2004695
74
With the help of an assistant, position and align the bumper
with the bumper frame brackets.
W2004743
75
Loosely install one nut on each side to retain the bumper. In-
stall all remaining bumper nuts and tighten to specification.
W2004694
76
Connect the wiring harnesses for the headlights and fog/run-
ning lights. Secure the harnesses using tie straps.
77
Recheck the coolant and oils levels. Replenish the oil and
coolant as necessary.
78
Install the rock guard to the frame underneath the radiator.
W2006077
79
If equipped, install the engine cover seal ring onto the
bulkhead.
80
Install the engine cover.
W8003859
81
If applicable, install the door threshold plates on both sides.
82
Install the center dash trim panel directly over the engine
cover.
N o t e : Install passenger seat, if removed for access.
83
Install the radiator grille.
84
Install the inner splash guard assembly.
85
Install all previously removed cables to the ground (negative)
battery terminals.
W2003815
86
Connect Tech Tool to the diagnostic connector and load the
injector trim code configuration from the new engine.
87
Using the hand primer pump found on the fuel filter housing,
prime the fuel system.
88
Start the engine, check for leaks and proper operation. After
shutdown, replenish fluids as necessary.

Engine, Replacement D11H, D13H, D16H VN VHD VAH

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Engine, Replacement D11H, D13H, D16H VN VHD VAH

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Vo l v o Tru c k s N o r t h

• “Engine, Replacement”, page 4

N o t e : Information is subject to change without notice.

D B T2 V 7 0 0 , 8 5 11 2 7 4 0 J44773 J 4 703 8-1

J 470 38 -2 J 47 03 8-3 J 4 703 8-6

J 470 38 -7 J 47 03 8-8 85104846

85108826 85108827 9996049

88800014 J 47 03 8-4 J 44392

9996950 9996956 88800031

S ervic e P roc edures

• “Engine, Replacement”, page 1

• “Special Tools”, page 2

You must read and understand the precautions and guide-

Special tools: DBT2V700, 85112740, J44392,

DBT2V700, 85112740, 9996049

N o t e : See steps 82–84 for the appropriate lifting tools. En-

N o t e : Refer to Specifications in Group 200 for component

1. J47038–7, Front Engine Lifting Bracket

1. J47038–8, Front Engine Lifting Bracket

1. J47038–2, Front Engine Lifting Bracket

N o t e : See 3/4 Component Transfer section for replacing a 3/

7/8 Component Transfer

I-Shift pressure plate shown (typical)

I-Shift pressure plate shown (typical)

3/4 Component Transfer

I-Shift pressure plate shown (typical)

I-shift pressure plate shown (typical)

N o t e : See, Removal Section, steps 82–84 for the appropri-

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