GENERAL DATA (ENGINE CAPACITIES)
| B5204T5 | B5234T3 | B5244T2 | B5244T3 | B5254T2 | B5254T4 | |
|---|---|---|---|---|---|---|
| Output (kw at rpm) | 132/5280 | 184/5220 | 195/5700 | 147/6000 | 154/5000 | 220/5500 (man) / 6000 (aut) |
| Maximum torque (Nm at rpm) | 240/2220-5280 | 330/2520-5220 | 350/2400-5100 | 285/1800-4980 | 320/1500-4500 | 400/2100-5100 (man) |
| 350/1900-6000 (aut) | ||||||
| Max rpm | 6200 | 6200 | 6200 | 6200 | 6500 | 6500 |
| Idling (rpm) | 670 | 670 | 850 | 670 | 670 | 720 |
| No. of cylinders | 5 | 5 | 5 | 5 | 5 | 5 |
| Cylinder bore (mm) | 81 | 81 | 83 | 83 | 83 | 83 |
| Stroke (mm) | 77 | 90 | 90 | 90 | 93.2 | 93.2 |
| Cylinder displacement (dm 3 =litres) | 1984 | 2319 | 2435 | 2435 | 2521 | 2521 |
| Firing sequence | 1-2-4-5-3 | 1-2-4-5-3 | 1-2-4-5-3 | 1-2-4-5-3 | 1-2-4-5-3 | 1-2-4-5-3 |
| Compression ratio | 9.5:1 | 8.5:1 | 8.5:1 | 9.0:1 | 9.0:1 | 8.5:1 |
| Weight, complete, including oil (kg) | Approximately 177 | Approximately 177 | Approximately 177 | Approximately 177 | Approximately 177 | Approximately 177 |
Scheme 475
| Standard | B5204Tx | B5234Tx | B5244Tx | B5254Tx |
|---|---|---|---|---|
| C-marked 1 | 81.000-81.010 | 81.000-81.010 | 83.000-83.010 | 83.000-83.010 |
| D-marked 1 | 81.010-81.020 | 81.010-81.020 | 83.010-83.020 | 83.010-83.020 |
| E-marked 1 | 81.020-81.030 | 81.020-81.030 | 83.020-83.030 | 83.020-83.030 |
BORE (D) IN MM
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.
Scheme 476
| Standard | B5204T5 Measured 16 mm from the bottom of the piston | B5234T3 Measured 42 mm from the top of the piston | B5244T2 Measured 42 mm from the top of the piston | B5244T3 Measured 38 mm from the top of the piston | B5254Tx |
|---|---|---|---|---|---|
| C-marked 1 | 80.980-80.990 | 80.980-80.990 | 82.980-82.990 | 82.980-82.990 | |
| D-marked 1 | 80.990-81.000 | 80.990-81.000 | 82.990-83.000 | 82.990-83.000 | |
| E-marked 1 | 81.000-81.010 | 81.000-81.010 | 83.000-83.010 | 83.000-83.010 |
BORE (D) IN MM
1 Classification is marked on the top of the piston.
Scheme 477
| Measured cylinder diameter | 83.015 mm |
|---|---|
| Measured piston diameter | 82.995 mm |
| The piston running clearance is | 0.020 mm |
| Piston running clearance must be | .010-0.030 mm |
PISTON RUNNING CLEARANCE (EXAMPLE)
Piston rings
Scheme 478
| 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, 200 -0.010/-0.030 mm |
|---|
| Lower........1, 500 -0.010/-0.030 mm |
COMPRESSION RING DIMENSION
| Spring........1.510 ± 0.020 mm |
|---|
| Rail........0.460 ± 0.011 mm |
DIMENSION, THREE PIECE OIL RING
Piston pin
| B52x4Tx (excluding B5244T3) | B5244T3 | |
|---|---|---|
| Diameter (mm) | 23.000 +0/-0.004 | 21.000 +0/-0.004 |
| Length (mm) | 61.000 +0/-0.200 | 60.000 +0/-0.200 |
Scheme 479
| Inlet........31.00 ± 0.15 mm |
|---|
| Exhaust........27.00± 0.15 mm |
VALVE CROWN DIAMETER (A)
| Inlet (early versions)........6.970 +0/-0.015mm |
|---|
| Inlet (late versions)........5.970 +0/-0.015mm |
VALVE STEM DIAMETER (B)
| Exhaust (early versions) | |
|---|---|
| H1 = 22.7 mm | B1 = 6, 962 ± 0.007 mm |
| H2 = 65.1 | B2 = 6, 954 ± 0.007 mm |
| Exhaust (late versions) | |
| H1 = 22.7 mm | B1 = 5.962 ± 0.007 mm |
| H2 = 65.1 | B2 = 5954 ± 0.007 mm |
VALVE STEM DIAMETER (B1/B2)
| Inlet........102.00 ± 0.07 mm |
|---|
| Exhaust........101.05± 0.07 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° |
VALVE ANGLE
Scheme 480
| Valve stem height........48.4± 0.5 mm |
|---|
| Maximum machining of the valve stem........0.5 mm |
VALVE STEM VERTICAL POSITION
Scheme 481
| Upper reduction angle (A) |
|---|
| Inlet........20° |
| Exhaust........15° |
| Matching surface angle (B) |
| Inlet/Exhaust........45° |
| Lower reduction angle (C) |
| Inlet/Exhaust........60° |
| Valve seat, width (a) |
| Inlet........1.4-1.8 mm |
| Exhaust........1.8-2.2 mm |
Scheme 482
| Tappets, dimensions |
|---|
| External diameter (A)........32.000 +0.025/-0.041 mm |
| External height (B)........26.0± 0.5 mm |
| Solid valve lifter shaft length (C) |
| 15.96 mm at 0.02 mm intervals up to 16.16 mm. The dimensions are listed on the inside of each valve lifter. |
TAPPETS, DIMENSIONS
GENERAL TIGHTENING TORQUE
Note. Screws coated with a locking fluid or self locking nuts must be replaced with new when reinstalled.
See the table below to find the tightening torques for components not included in the summary.
Nuts and screws which are not self locking can be reused provided that they are in good condition.
| Applies to screwed joint with strength class 8.8. | |
|---|---|
| Thread | Tightening torque (Nm) |
| M5 | 5 |
| M6 | 10 |
| M7 | 17 |
| M8 | 24 |
| M10 | 50 |
| M12 | 80 |
| M14 | 130 |
SUMMARY OF SPECIFIC COMPONENTS AND TIGHTENING TORQUES
Note. Screws coated with locking fluid or sealant must always be replaced with new screws during reinstallation.
Always use new screws and nuts when angle tightening. Any exceptions to this rule will be indicated in the method.
Angle-tightening in tight spaces. See SCREWED JOINT, TORQUE/ANGLE TIGHTENING .
| Exhaust system (to the turbocharger (TC)) | 24 Nm |
|---|---|
| Cylinder head Tighten the screws in sequence from the center and outwards. | Stage 1........20 Nm Stage 2........60 Nm Stage 3........130° |
| Manifold (cylinder head side) | 25 Nm |
| Pipe screw (coolant pipe / turbocharger (TC)) | 26 Nm |
| Pipe screw (water heated crankcase ventilation.) | 26 Nm |
| Pipe screw (oil pressure line / turbocharger (TC)) | 26 Nm |
| Pipe screw (oil pressure line / engine block) | 38 Nm |
| Sub-frame nut (lower torque rod) | Stage 1........65 Nm Stage 2........60° |
| Subframe screws (start on the left-hand side, then the right-hand side) | Stage 1........105 Nm Stage 2........120° |
| Subframe bracket | 50 Nm |
| Intake manifold | 19 Nm |
| Catalytic converter (to the turbocharger (TC)) (to the exhaust system) | 25 Nm 24 Nm |
| Knock sensor (KS) | 20 Nm |
| Piston cooling valve (piston cooling oil duct, in cylinder block) | 36 Nm |
| Timing gear pulley (camshafts without variable valve timing) | 20 Nm |
| Timing gear pulley (camshafts with variable valve timing) | 10 Nm |
| Heated oxygen sensor (HO2S) | 45 Nm |
| Carrier plate | Stage 1........45 Nm Stage 2........50° |
| Intermediate section Tighten the screws in sequence from the center and outwards. | Stage 1 M10........20 Nm Stage 2 M10........45 Nm Stage 3 M8........24 Nm Stage 4 M7........17 Nm Stage 5 M10........90° |
| Torque converter | 50 Nm |
| Engine mounting Right side (M10x35 to cylinder block) | Stage 1........35 Nm Stage 2........60° |
| Engine mounting Right side (M8x23 to cylinder block) | Stage 1........20 Nm Stage 2........60° |
| Right-hand engine pad for the subframe (Only applies to XC90) | Stage 1........120 Nm Stage 2........40° |
| Lower torque rod, transmission screw | Stage 1........35 Nm Stage 2........40° |
| Lower torque rod, sub-frame nut | Stage 1........65 Nm Stage 2........60° |
| Oil filter (environmental filter) | 25 Nm |
| Oil trap | 15 Nm |
| Oil pan plug | 38 Nm |
| Oil pump (countersunk Allen, M6x20, holds the pump housing together) | 6 Nm |
| Oil return line (turbocharger (TC)) | 12 Nm |
| Oil pan (Applies to B5254T4) | The screws (1, 2, 3 and 4). Tighten to........3 Nm the screws (5). Tighten to........25 Nm. Then tighten to 48 Nm |
| Oil pressure switch | 27 Nm |
| Stud (at exhaust port, manifold, turbocharger (TC)) | 20 Nm |
| Plug (check hole for gauging valve clearance) | 20 Nm |
| Plug (gauge hole / crankshaft seal) | 38 Nm |
| Belt tensioner (mechanical) | 20 Nm |
| Flywheel | Stage 1........45 Nm Stage 2........65° |
| Vibration damper -2002 (flanged screws x4) | Stage 1........25 Nm Stage 2........30° |
| Vibration damper 2002- /flanged screws x4 | Stage 1........25 Nm Stage 2........60° |
| (center nut) | 180 Nm |
| Temperature sensor (coolant) | 22 Nm |
| Timing cover, (front/rear) | 12 Nm |
| Timing cover, (upper) | 8 Nm |
| Turbocharger (TC) (to manifold, without gasket) | 25 Nm |
| Turbocharger (TC) (to manifold, with gasket) | 37 Nm |
| Spark plugs | 30 Nm |
| Connecting rod cap (connecting rod with treated toothed surface between the connecting rod and cap, screw with waist) | Stage 1........20 Nm Stage 2........90° |
| Connecting rod cap (connecting rod with fracture surface between the connecting rod and cap, fully threaded screw) | Stage 1........30 Nm Stage 2........90° |
| Transmission screw (lower torque rod) | Stage 1........35 Nm Stage 2........40° |
| Variable valve timing center screw | 120 Nm |
| Variable valve timing center plug | 35 Nm |
Note. The illustrations in this service information are used for different model years and / or models. Therefore there may be some variation. However, the essential information in the illustrations is always correct.
Scheme 483
The engine serial number and type are stamped on the left side of the cylinder block at the top of the mounting for the water pump.
There is also a decal on the timing cover with the engine type, manufacture number and serial number.
Note. Screws coated with a locking fluid or self locking nuts must be replaced with new when reinstalled.
See the table below to find the tightening torques for components not included in the summary.
Nuts and screws which are not self locking can be reused provided that they are in good condition.
| Applies to screwed joint with strength class 8.8. | |
|---|---|
| Thread | Tightening torques (Nm) |
| M5 | 5 |
| M6 | 10 |
| M7 | 17 |
| M8 | 24 |
| M10 | 50 |
| M12 | 80 |
| M14 | 130 |
Torque Specifications
SUMMARY OF TIGHTENING TORQUES FOR SPECIFIC COMPONENTS
Note. Screws coated with locking fluid or sealant must always be replaced with new screws during reinstallation.
Always use new screws and nuts when angle tightening. Any exceptions to this rule will be indicated in the method.
Angle-tightening in tight spaces. See SCREWED JOINT, TORQUE/ANGLE TIGHTENING .
| Exhaust bend (to the turbocharger (TC)) | 24 Nm |
|---|---|
| Cylinder head Tighten the screws in sequence from the center and outwards. | Stage 1........20 Nm Stage 2........60 Nm Stage 3........130° |
| Manifold (cylinder head side) | 25 Nm |
| Sub-frame nut (lower torque rod) | Stage 1........65 Nm Stage 2........60° |
| Pipe screws (water heated crankcase ventilation.) | 26 Nm |
| Pipe screws (coolant pipe / turbocharger (TC)) | 26 Nm |
| Pipe screws (oil pressure line / turbocharger (TC)) | 18 Nm |
| Pipe screws (oil pressure line / engine block) | 38 Nm |
| Subframe screws (start on the left-hand side, then the right-hand side) | Stage 1........105 Nm Stage 2........120° |
| Intake manifold (joint upper / lower section) | 19 Nm |
| Intake manifold (cylinder head side) | 19 Nm |
| Centre screw for the timing belt | 25 Nm |
| Knock sensor (KS) | 20 Nm |
| Piston cooling valve (piston cooling oil duct) | 35 Nm |
| Timing gear pulley (camshafts without variable valve timing) | 20 Nm |
| Timing gear pulley (camshafts with variable valve timing) | 10 Nm |
| Carrier plate | Stage 1........45 Nm Stage 2........ angle-tighten 50° |
| Intermediate section Tighten the screws in sequence from the center and outwards. | Stage 1 M10........20 Nm Stage 2 M10........45 Nm Stage 3 M8........24 Nm Stage 4 M7........17 Nm Stage 5 M10........90° |
| Torque converter | 50 Nm |
| Engine mounting Right side (M10x35 to cylinder block) | Stage 1........35 Nm Stage 2........60° |
| Engine mounting Right side (M8x23 to cylinder block) | Stage 1........20 Nm Stage 2........60° |
| Right-hand engine pad for the subframe (Only applies to XC90) | Stage 1........120 Nm Stage 2........40° |
| Lower torque rod, gearbox screw. | Stage 1........35 Nm Stage 2........40° |
| Lower torque rod, sub-frame nut | Stage 1........65 Nm Stage 2........60° |
| Oil filter (environmental filter) | 25 Nm |
| Oil trap | 15 Nm |
| Sump plug | 38 Nm |
| Oil pump (20 countersunk M6 Allen screws hold the pump housing together) | 6 Nm |
| Oil return line (turbocharger (TC)) | 12 Nm |
| Oil pressure switch | 50 Nm |
| Stud (at exhaust port, manifold, turbocharger (TC)) | 20 Nm |
| Plug (check hole for gauging valve clearance) | 20 Nm |
| Plug (gauge hole / crankshaft seal) | 38 Nm |
| Belt tensioner (mechanical belt tensioner) | 25 Nm |
| Tensioner pulley (lever mechanical belt tensioner) | 30 Nm |
| Flywheel | Stage 1........45 Nm Stage 2........65° |
| Vibration damper | Stage 1........35 Nm Stage 2........50° |
| Temperature sensor (coolant) | 22 Nm |
| Front timing cover | 12 Nm |
| Upper timing cover | 8 Nm |
| Pressure control valve (piston cooling oil duct) | 35 Nm |
| Turbocharger (TC) (to manifold) | 25 Nm |
| Spark plugs | 30 Nm |
| Crankshaft center nut | 300 Nm |
| Connecting rod cap | Stage 1........20 Nm Stage 2........90° |
| Variable valve timing / center screw | 120 Nm |
| Variable valve timing / center plug | 35 Nm |
Scheme 484
- P/N
- Cylinder class
- Bearing class
- Engine serial number
- Engine type
Note. Screws coated with a locking fluid or self locking nuts must be replaced with new when reinstalled.
See the table below to find the tightening torques for components not included in the summary.
Nuts and screws which are not self locking can be reused provided that they are in good condition.
| Applies to screwed joint with strength class 8.8. | |
|---|---|
| Thread | Tightening torques (Nm) |
| M5 | 5 |
| M6 | 10 |
| M7 | 17 |
| M8 | 24 |
| M10 | 50 |
| M12 | 80 |
| M14 | 130 |
Note. Screws coated with locking fluid or sealant must be replaced with new when reinstalled.
Always use new screws and nuts when angle tightening. Any exceptions to this rule will be indicated in the method.
Angle-tightening in tight spaces. See SCREWED JOINT, TORQUE/ANGLE TIGHTENING .
| Function group 21 | |
|---|---|
| Center screw, exhaust camshaft | Stage 1........ 75 Nm Stage 2........ 90° |
| Center screw, intake camshaft | 110 Nm |
| Cylinder head The screws are tightened in sequence as described in the method. | Stage 1........ 45 Nm Stage 2........ 45 Nm Stage 3........ 90° Stage 4........ 180° |
| Intermediate shaft drive wheel, alternator side | 44 Nm |
| Intermediate shaft drive wheel, auxiliaries side | 60 Nm |
| Drive wheel, alternator | 75 Nm |
| Drain nipple (on water pipe) | 7 Nm |
| Manifold (toward cylinder head) | 25 Nm |
| Sub-frame screw (start on the left-hand side, then the right) | Stage 1........ 105 Nm Stage 2........ 120° |
| Sleeves under cylinder head screws | 10 Nm (left-threaded) |
| Inner timing cover adjuster screw | 3 Nm |
| Chain wheel | 400 Nm |
| Knock sensor (KS) | 20 Nm |
| Carrier plate | Stage 1........ 45 Nm Stage 2........ 50° |
| Intermediate shaft alternator side | 40 Nm |
| Right-hand engine pad to engine | Step 1........ 30 Nm Stage 2........ 75° |
| Right-hand engine pad to subframe | Stage 1........ 120 Nm Stage 2........ 40° |
| Lower torque rod to subframe | 110 Nm |
| Flywheel | Stage 1........ 45 Nm Stage 2........ 60° |
| Connecting rod cap | Stage 1........ 12 Nm Stage 2........ 20 Nm Stage 3........ 90° |
| Valve cover/cam carrier cover | Standard torque, but to be tightened in sequence. See method. |
| Gear housing | Stage 1........ 10 Nm Step 2........ 24 Nm |
| Pressure line to power steering pump | 30 Nm |
| Outer timing cover | Standard torque, but to be tightened in sequence. See method. |
| Function group 22 | |
| Oil filter cover | 25 Nm |
| Oil pan plug | 38 Nm |
| Piston cooling valve | 32 Nm |
| Cover plug (beneath piston cooling valve) | 38 Nm |
| Function group 25 | |
| Catalytic converter to manifold | 27 Nm |
| Heated oxygen sensor (HO2S) | 45 Nm |
| Throttle body | 8 Nm |
| Function group 28 | |
| Coolant temperature sensor | 20 Nm |
| Spark plugs | 28 Nm |
| Knock sensor (KS) | 20 Nm |
| Function group 33 | |
| Battery positive cable to starter solenoid | 11 Nm |
| Starter motor B+ terminal | 11 Nm |
| Start impulse cable | 8, 5 Nm |
CAPACITIES - ENGINE OIL
| Designation | Liters |
|---|---|
| First fill, including oil filter | 7, 50 |
| Filling during servicing, including oil filter | 5, 5-6, 7 |
| Filling during servicing, no oil filter | 5, 0-6, 2 |
OIL PRESSURE, SPECIFICATIONS
| Designation | Bar |
|---|---|
| Oil pressure at idle | 1, 0 - 2, 0 |
| Oil pressure at 2 000 r/min | 2, 3 - 3, 7 |
Note. Screws coated with a locking fluid or self locking nuts must be replaced with new when reinstalled.
See the table below to find the tightening torques for components not included in the summary.
Nuts and screws which are not self locking can be reused provided that they are in good condition.
| Applies to screwed joint with strength class 8.8. | |
|---|---|
| Thread | Tightening torques (Nm) |
| M5 | 5 |
| M6 | 10 |
| M7 | 17 |
| M8 | 24 |
| M10 | 50 |
| M12 | 80 |
| M14 | 130 |
Note. Screws coated with locking fluid or sealant must be replaced with new when reinstalled.
Always use new screws and nuts when angle tightening. Any exceptions to this rule will be indicated in the method.
Angle-tightening in tight spaces. See SCREWED JOINT, TORQUE/ANGLE TIGHTENING .
| Function group 21 | |
|---|---|
| Cylinder head (NOTE! The screws are tightened in sequence from the center outwards) | Stage 1........ 40 Nm Stage 2........ 90° |
| Manifold (toward cylinder head) | 25 Nm |
| Intake manifold (upper/lower section) | 19 Nm |
| Intake manifold (upper/lower section) | 19 Nm |
| Knock sensor | 20 Nm |
| Sub-frame (start on the left-hand side, then the right) | Stage 1........ 105 Nm Stage 2........ 120° |
| Carrier plate | 80 Nm |
| Intermediate section for engine block step 1 | Stage 1........ 40 Nm Step 2 1 - 10........ 90° 11 - 20........ 110° |
| Intermediate section for engine block step 2 | 21 - 22........ 20 Nm 23 - 36........ 24 Nm |
| Right-hand engine pad to subframe | Stage 1........ 120 Nm Stage 2........ 40° |
| Oscillation damper Center screw (front edge of crankshaft) | Stage 1........ 120 Nm Loosen the screw at least 1 turn Stage 2........ 50 Nm 90° |
| Valve cover | 10 Nm |
| Cap connecting rod | Step 1........ 20 Nm Stage 2........ 85° |
| Function group 22 | |
| Oil filter (environmental filter) | 25 Nm |
| Oil plug | 50 Nm |
| Oil sump | 11 Nm |
| Oil pressure switch | 14 Nm |
| Function group 25 | |
| Heated oxygen sensor (HO2S) | 45 Nm |
| Stud (at exhaust port, manifold, turbocharger) | 10 Nm |
| Auxiliaries/belt tensioner, center screw | 90 Nm |
| Coolant temperature sensor | 20 Nm |
| Spark plugs | 25 Nm |
| Function group 33 | |
| Starter motor B+ terminal | 11 Nm |
| Designation | Bar |
|---|---|
| Oil pressure at idle | 1.0 - 2.0 |
| Oil pressure at 2 000 r/min | 2.3 - 3.7 |
See also:
• SCREWED JOINT, TORQUE/ANGLE TIGHTENING