General data
| B5244S | B5244S2 | |
|---|---|---|
| Output (kW at rpm) | 125/5700 | 103/5700 |
| Maximum torque (Nm at rpm) | 230/4500 | 220/3780 |
| Maximum engine speed (rpm) | 6500 | 6500 |
| Idling speed (rpm) | 850 | 850 |
| No. of cylinders | 5 | 5 |
| Bore (mm) | 83.0 | 83.0 |
| Stroke (mm) | 90.0 | 90.0 |
| Cylinder displacement (dm 3 =litres) | 2435 | 2.435 |
| Firing order | 1-2-4-5-3 | 1-2-4-5-3 |
| Compression ratio | 10.3:1 | 10.3:1 |
| Weight, including oil (kg) | Approximately 177 | Approximately 177 |
Scheme 162
| Standard | B5244S/S2 |
|---|---|
| C-marked 1 | 83.000-83.010 |
| D-marked 1 | 83.010-83.020 |
| E-marked 1 | 83.020-83,030 |
| 1 The bore classification is stamped on top of the engine block. For example: 1CCDDE is read as cyl 1=C, cyl 2=C, cyl 3=D, cyl 4=D, cyl 5=E. |
Bore (D) in mm
Scheme 163
| Standard | B5244S/S2 |
|---|---|
| C-marked 1 ........mm | 82.980-82.990 |
| D-marked 1 ........mm | 82.990-83.000 |
| E-marked 1 ........mm | 83.000-83.010 |
| 1 The classification is marked on the top of the piston. |
Piston diameter (D)
Scheme 164
| Measured cylinder diameter ........ | 83.015 mm |
|---|---|
| Measured piston diameter ........ | 82.995 mm |
| The piston running clearance is ........ | 0.020 mm |
| The piston running clearance must be 0.010-0.030 mm. |
Piston running clearance (example)
Piston rings
Scheme 165
| Upper compression ring ........0.030-0.070 mm |
|---|
| Lower compression ring ........0.030-0.070 mm |
| Oil control ring assembly ........0.038-0.142 mm |
Axial clearance
| Upper ........1.20 -0.010/-0.030 mm |
|---|
| Lower ........1.50 -0.010/-0.030 mm |
Compression ring dimension
| Spring ........1.51 0.020 mm |
|---|
| Rail ........0.46 0.011 mm |
Dimension, three piece oil ring
Piston pin
| Diameter ........21.000 +0/-0.004 mm |
Scheme 166
| Inlet ........31.00 0.15 mm |
|---|
| Exhaust ........27.00 0.15 mm |
Valve crown diameter (A)
| Inlet ........6.970 +0/-0.015mm |
Valve stem diameter (B)
| Exhaust |
|---|
| H1 = 17.40 mm ........6.963 0.007 mm |
Valve stem diameter (B1)
| Exhaust |
|---|
| H2 = 70.40 mm ........6.953 0.007 mm |
Valve stem diameter (B2)
| Inlet ........104.25 0.25 mm |
|---|
| Exhaust ........103.30 0.25 mm |
Total valve length (C)
| Inlet and exhaust ........1.50 mm |
|---|
| Minimum height after grinding ........1.20 mm |
Disc edge height (D)
| Inlet and exhaust ........44.5° |
Mating surface angle (E)
Scheme 167
| Valve stem height ........48.4 0.5 mm |
|---|
| Maximum machining of the valve stem ........0.5 mm |
Valve stem vertical position
Scheme 168
| A | Upper inlet reduction angle ........20° Upper exhaust reduction angle ........15° |
|---|---|
| B | Inlet and exhaust matching surface angles ........45° |
| C | Lower reduction angle ........60° |
| A | Width of the intake valve seat ........1.4-1.8 mm Width of the exhaust valve seat ........1.8-2.2 mm |
Angles
Scheme 169
| A | External diameter ........32.000 +0.025/-0.041 mm |
|---|---|
| B | External height ........26.0 0.5 mm |
| C | Solid valve lift shaft length ........15.96 mm at 0.02 mm stages up to 16.16 mm. The dimensions are listed on the inside of each tappet. |
Tappets, dimensions
Valve springs
| Variant | Length | Type |
|---|---|---|
| All | 45.1 +1.5/-0.5 | Conical |
Valve springs, dimensions
Scheme 170
| Inlet/Exhaust ........0.03-0.06 mm |
Clearance between new components
| Inlet/Exhaust ........0.15 mm |
Maximum play for used components
Camshafts
| Engine type | Camshaft | |||
|---|---|---|---|---|
| Marking | Maximum lift height | |||
| Inlet | Exhaust | Inlet | Exhaust | |
| B5244S | 9207938 | 9465138 | 8.65 | 8.80 |
| B5244S2 | 9207938 | 9465138 | 8.65 | 8.80 |
Scheme 171
| Front-rear ........0.50 mm |
|---|
| Lateral ........0.20 mm |
| Cylinder head height ........129.0 0.05 mm |
| Maximum machining ........0.30 mm |
Maximum out-of-true
| CAUTION | Scratches and corrosion to the cylinder head gasket face should only be machined on a flat cylinder head. |
Scheme 172
| Main bearing journal radial runout ........maximum 0.040 mm |
|---|
| Axial play (Measured in the engine with the intermediate section tightened) ........0.08-0.19 mm |
| Main bearing journal radial runout ........0.019-0.043 mm |
Crankshaft
Scheme 173
| Diameter, standard 1 ........50.000 0/-0.016 |
|---|
| Bearing recess width ........26.0 0.1 mm |
| Maximum out-of-round ........0.004 mm |
| Maximum taper ........0.004 mm |
| 1 The variation in diameter for each bearing journal must not exceed 0.008 mm. |
Big end journals
| Diameter, standard 1 ........65.000 +0.003/-0.016 mm |
|---|
| Axial bearing width ........26.00 +0/-0.04mm |
| Maximum out-of-round ........0.004 mm |
| Maximum taper ........0.004 mm |
| 1 The variation in diameter for each bearing journal must not exceed 0.008 mm. |
Main bearing journals
Scheme 174
| Diameter, bearing recesses |
|---|
| Big end ........53.00 -0/+0.013 mm |
| Small end ........21.00 +0.005/+0.011 mm |
| Maximum ovality in the bearing recesses ........0.006 mm |
| Length |
| Big end - Small end ........147 mm |
Connecting rods
| CAUTION | If the cap is turned the wrong way and tightened, the structure of the fracture surface will be damaged and the connecting rod must then be discarded. |
Note. Blow the fracture surface clean using compressed air before reinstalling the cap.
Engine oil
Filling with oil after reconditioning.
| B5202-5254 ........6.6 litres |
Oil volume including oil filter
| According to API Service ........lowest SG |
|---|
| According to CCMC ........class G4/G5. |
| According to ACEA ........class A2/A3. |
Oil grade
| 13.3 r/s (800 rpm) ........0.10 Mpa 1 |
|---|
| 14.2 r/s (850 rpm) ........0.10 Mpa 1 |
| 66.7 r/s (4000 rpm) ........0.35 Mpa 1 |
| Maximum oil pressure (the relief valve opens) ........0.48 Mpa |
| 1 The oil pressure listed is for an oil temperature of 100°C, which is reached after 10-15 minutes driving. |
Oil pressure (minimum)
| Marking ........90 |
|---|
| Starts to open at ........90°C |
| Fully open at ........105°C |
Thermostat
Fuel line pressure
| Desired value | |
|---|---|
| Relative pressure | 380 kPa |
| Absolute pressure | 480 kPa |
Removing the front timing cover
Note. Since the illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.
Scheme 175
Loosen hose thermostat housing-expansion tank from the thermostat housing by pressing in the locks, then press in the connection against the thermostat housing, then pull out the connection.
Scheme 176
Note. Make sure that the belt cover has cleared the nipple on the thermostat housing before the cover is pulled up, to prevent damaging the nipple.
Remove
- the air duct, cover, surround and control module box
- the hose between the thermostat housing and the expansion tank
- the front timing belt cover.
Scheme 177
Note. Make sure that the belt cover is in position before the cover is pressed in against the rear timing casing, to prevent damage to the nipple on the thermostat housing.
Install
- the front timing belt cover
- the hose between the thermostat housing and the expansion tank
- the surround, cover and air ducts for the control module box.
Temperature and pressure sensor, replacing
Manifold absolute pressure (MAP) temperature sensor
C70
- For B5xx4T, see «Intake Air Temperature Sensor (IAT Sensor), replacing»(ref-404035-S20199659872011061000000) .
Thermostat / temperature sensor, engine coolant, replacing
Special tools
9512885
9995722
9997109
9512953
9512957
Note. The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.
Scheme 178
Remove
- the upper timing belt cover. Disconnect the connector for the temperature sensor
- the temperature sensor from the thermostat housing. Use «9512885»(ref-403953-S00557342822011061000000) .
Note. Put paper underneath the sensor to prevent coolant spillage.
Installing the engine coolant temperature (ECT) sensor
Install
- the sensor with a new seal. Tighten. See: «Summary of specific components and tightening torques»(ref-404053-S19490031972011061000000) . Use: «9512885»(ref-403953-S00557342822011061000000)
- the upper timing belt cover.
Scheme 179
Remove the cap from the expansion tank. Install a hose clamp on the upper coolant hose.
The vehicle must be raised for this work. See: Jacking points, body . Remove the lower cover plate.
Position a container under the engine drain cock. Drain 2 liters of engine coolant.
Close the cock. Install the lower protective panel.
Lower the vehicle.
Scheme 180
Ignition off. Wait for 2 minutes.
| CAUTION | Do not touch the terminal pins on the control module with fingers. Static electricity may damage components in the engine control module (ECM). |
Remove the cover over the control module box. Put the cover to one side.
Insert tool 9995722 around the control module.
Move the upper section of the tool backwards as far as it will go. Pull up the tool. Carefully pull up the control module.
For vehicles with automatic transmissions repeat the above work.
Remove the surround from around the control module box.
Scheme 181
Note. Make a note of the routing of the belt.
Remove
- the auxiliaries belt. Use «9997109»(ref-403953-S16738480202011061000000)
- the upper timing belt cover.
Scheme 182
Remove the 3 x screws for the power steering pump. Place the power steering pump to one side.
Scheme 183
Remove
- the hose clamp to the upper radiator hose. Disconnect the hose from the thermostat housing
- the connector from the temperature sensor
- the 2 x screws for the thermostat housing at the section against the cylinder head
- the thermostat housing from the cylinder head
- the hose clamp for the water hose for heating crankcase ventilation.
Transfer the temperature sensor to the new thermostat housing.
Installing the thermostat housing
Install
- the hose for the water heated crankcase ventilation. Before installing the thermostat housing, use a new hose clamp
- a new gasket
- the thermostat housing assembly. Tighten the screws
- the upper radiator hose. Tighten the hose clamp.
Connect the connector for the temperature sensor.
Finishing
Note. Ensure that the auxiliaries belt is correctly positioned on all the pulleys.
Install
- the power steering pump. Tighten the 3 x screws
- the auxiliaries belt. Use «9997109»(ref-403953-S16738480202011061000000)
- the upper camshaft cover.
Scheme 184
| CAUTION | Check that no pins or sockets are damaged on the connector. |
Install the surround for the control module box.
Carefully press the control module down into the grooves on the inside of the control module box. Press to the limit position
Insert tool 9995722 around the control module.
Move the upper section of the tool forwards as far as it will go. Pull up the tool.
Press the cover into place over the control modules. Check that the air ducts are correctly positioned.
Remove the hose clip. Refill with coolant. Use filling equipment 9512957 and cover 9512953 . Install the cap on the expansion tank.
Test drive the engine until the thermostat has opened. Check for leakage. Top-up the coolant.