Volvo B5244S4 Manual Download Page 20 | Manualshive

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TURBOCHARGER INTAKE SYSTEM

Intake Manifold Lower Section

The intake system is divided into upper and lower sections.

The injectors are located on the lower manifold to mix the fuel with the turbulent air as efficiently as
possible.

The position of the injectors is optimized to minimize fuel film formation and improve emissions.

The lower intake manifold is aluminum to protect the fuel injection nozzles in the event of an accident.

There are individual ducts to each intake port to distribute the crankcase gases evenly between the
cylinders.

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Summary of Contents for B5244S4

Page 1: ... air cleaner housing and control module box are integrated The intake manifold is also used as a cover for the engine the turbocharged engine has a separate cover The engines have two drive belts one for the alternator and one for the air conditioning compressor The naturally aspirated B5244S4 engine has a Denso engine management system The turbocharged B5254T3 engine has a Bosch engine management...

Page 2: ...B5244S ULEV engine I ntroduced in the S40 and V50 only Uses Denso engine management system Meets U S ULEV emissions standards Uses automatic transmission AW55 51 manual transmission M66 will be introduced later When cold the engine warm up uses the Wide Range concept ...

Page 3: ...TECHNICAL DATA ...

Page 4: ...bearings are aluminum Pistons Graphite coated pistons Wrist pin diameter length 21 mm 57 mm Weight 397 grams with piston rings snap rings and wrist pins Weight piston alone 282 grams Graphite coated pistons have a play of approximately 0 04 mm between the piston and cylinder before the graphite coating The graphite coating is approximately 0 01 mm on either side of the piston The graphite coating ...

Page 5: ...de in through the filter To ensure that oil still flows even if the filter is clogged there is an overflow valve in the cover that opens at 11 kPa and when starting the vehicle from cold 20 C to 25 C Oil Separation The oil trap is manufactured in die cast aluminum and consists of one chamber 3 cyclonic separators 1 spring loaded membrane and a plastic cover The chamber roughly separates oil and ga...

Page 6: ...Poly V and are tensioned by their own mechanical tensioners The tensioner consists of a spring and a friction element Catalytic Converter The catalytic converter under the floor Under Floor Catalyst UFC has double oval ceramic monoliths The flow through the catalytic converter is optimized to reduce resistance Exhaust Pipe The exhaust system has been developed to reduce wind resistance under the c...

Page 7: ...ssible The position of the injectors is optimized to minimize fuel film formation and improve emissions The lower intake manifold is aluminum to protect the fuel injection nozzles in the event of an accident There are individual ducts to each intake port to distribute the crankcase gases evenly between the cylinders To better control the exact volume of crankcase gases used in combustion the gaske...

Page 8: ...n pressure and to be as compact as possible The air cleaner housing has a volume of 9 1 liters The air cleaner housing and control module box are integrated into one unit The air cleaner is a cassette that is inserted vertically The cover above the filter is mounted using two bolts The air cleaner unit is mounted on 3 brackets A fine net is located behind the ECM to reduce the cyclone effect in th...

Page 9: ...sed on the B5254T2 Uses Bosch ME 9 0 engine management system Meets U S ULEV emission standards Uses M66W manual transmission Uses AW55 51 automatic transmission When cold the engine warm up uses the Wide Range concept B5254T3 Engines ...

Page 10: ...Technical Data ...

Page 11: ...rods forged using split caps Center to center length 143 mm weight 644 grams Both the upper and lower bearings are copper lead alloy Pistons Graphite coated pistons Wrist pin diameter length 21 mm 60 mm Weight 412 grams with piston rings snap rings and wrist pin Piston weight alone 290 grams Graphite coated pistons have a play of approximately 0 04 mm between the piston and cylinder before the gra...

Page 12: ...es The filter and cover are the same as those used on Volvo s own diesel engine D5244T T2 Oil flows from the outside in through the filter To ensure that oil flows even if the filter is clogged there is an overflow valve in the cover that opens at 11kPa and when starting the vehicle from cold 20 C to 25 C Oil Separation The same as in B524454 In addition in the turbocharged engines the gases go fr...

Page 13: ...e camshaft is fixed in the rotor 3 The rotor and with it the camshaft can rotate in relation to the timing belt pulley 1 within a limited range When the unit is in the camshaft 0 position the timing belt pulley 1 and rotor 3 are secured by the lock pin 2 which locks the timing belt pulley 1 to the rotor 3 The lock mechanism works by pushing the spring loaded lock pin into a hole milled into the co...

Page 14: ...Camshaft Reset Valve The camshaft reset valve controls the flow of oil to the CVVT unit The engine control module ECM controls the valve using a pulse width modulated PWM signal ...

Page 15: ...into the valve in the camshaft oil duct A Oil flows via oil ducts in the camshaft to the top of lock pin 2 The lock pin is pressed in by the oil pressure and the CVVT unit is released Chamber A1 fills with oil Due to the oil pressure in the chamber the rotor 3 rotates counterclockwise Return oil flows from chamber B1 via the camshaft duct D to the valve and back to the oil pan ...

Page 16: ...he rotor wing 4 reaches its limit position and the lock pin is pushed out into a hole on the inside of the front of the timing belt pulley Return oil flows from chamber A1 via the camshaft valve and back to the oil pan This process takes place very rapidly The reset valve is controlled by the ECM for advancing and retarding at a very high frequency which allows for quick and exact control The amou...

Page 17: ...l module s environment temperature vibration water tightness etc At the same time the processor has been replaced with a more powerful version with more memory The processor load for the ME 9 0 is approximately 80 85 this figure would have been higher in the ME 7 01 and left too small a margin The ME 9 0 also has 1 5 MB of flash memory 2MB available The ME 7 01 only has 1 MB of memory The ME 9 0 h...

Page 18: ...ht of the turbocharger The exhaust manifold has a MLS Multi Layer Steel gasket Two slits have been machined into the manifold to deal with heat expansion The turbocharger has been matched and designed by Volvo together with the sub contractor 3k Warner Turbo Systems from Germany The catalytic converter under the floor UFC Under Floor Catalyst has double oval ceramic monoliths The flow through the ...

Page 19: ...e turbocharger with a V clamp Intake The intake has short pipes and a double gasket with built in non return valves reed type for crankcase ventilation ETB The electronic throttle body is the same as the B5254T2 the only difference is it has a shortened hose connector Auxiliary Equipment The design of the auxiliary equipment has been changed to make the engine shorter The A C compressor and altern...

Page 20: ...x the fuel with the turbulent air as efficiently as possible The position of the injectors is optimized to minimize fuel film formation and improve emissions The lower intake manifold is aluminum to protect the fuel injection nozzles in the event of an accident There are individual ducts to each intake port to distribute the crankcase gases evenly between the cylinders ...

Page 21: ...t comes off a plenum chamber Air Cleaner The air cleaner and air cleaner housing are designed to minimize drops in pressure and to be as compact as possible The air cleaner housing and control module box are integrated into one unit The air cleaner is a cassette that is inserted vertically and secured with 2 bolts The air cleaner unit is mounted on three brackets A spring loaded valve is located b...

Page 22: ...nipple is integrated into the fuel tank with a hose up to the fuel filler pipe The EVAP system has a round EVAP canister using one chamber filled with activated charcoal EVAP SYSTEM The EVAP system is connected to a recirculation pipe on the fuel filler pipe to reduce the volume of hydro carbons in the EVAP canister when filling the fuel tank The EVAP system has a larger EVAP canister in which the...

Page 23: ...el consumption The pump unit flow is approximately 90 I h at 400 kPa corresponds to 380 kPa at the fuel rail for naturally aspirated engines and 115 I h for turbocharged engines at full load At idle speed flow is approximately 1 2 I h to 2 0 I h Power consumption varies from approximately 8 A at full capacity to approximately 2 A when the engine is idling ...

Page 24: ...cur are when engine braking and when the engine is switched off due to power loss The ECM raises the pressure in the system so the PVV opens approximately 600 kPa This flushes the valve free of particles Pressure Relief Valve PRV Applies Only to B5244S4 The safety valve is integrated into the fuel pump The valve opens in the range 550 kPa 850 kPa First Filling Valve FFV Allows fuel into the pump r...

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