Page 1462 of 2870

ME(H4DOTC)-6
MECHANICAL
General Description
2. 2.5 L MODEL
NOTE:
STD: Standard I.D.: Inner Diameter O.D.: Outer Diameter OS: Oversize US: Undersize
EngineModel2.5 L
Ty p eHorizontally opposed, liquid cooled, 4-cylinder,
4-stroke gasoline engine
Valve arrangement Belt driven, double overhead camshaft, 4-valve/cylinder
Bore×Stroke mm (in) 99.5×79.0 (3.92×3.11)
Piston displacement
cm
3 (cu in)2,457 (149.94)
Compression ratio 8.2
Compression pres-
sure (at 200 — 300
rpm)kPa (kgf/cm
2, psi)981 — 1,177 (10 — 12, 142 — 171)
Number of piston rings Pressure ring: 2, Oil ring: 1
Intake valve timingOpeningMax. retard ATDC 5°
Min. advance BTDC 15°
ClosingMax. retard ABDC 65°
Min. advance ABDC 45°
Exhaust valve timingOpening BBDC 55°
Closing ATDC 5°
Valve clearanceIntake mm (in) 0.20±0.02 (0.0079±0.0008)
Exhaust mm (in) 0.35±0.02 (0.0138±0.0008)
Idling speed
[At neutral position on MT, or “P” or “N”
range on AT]
rpmNo loadMT: 700±100
AT : 7 0 0±100
A/C ONA/C Refrigerant pressure
(LOW)MT: 725±100
AT : 7 5 0±100
A/C Refrigerant pressure
(HIGH)MT: 800±100
AT : 8 2 5±100
Firing order 1 → 3 → 2 → 4
Ignition timing BTDC/rpmMT model 17°±10°/700
AT model 17°±10°/700
Page 1478 of 2870

ME(H4DOTC)-22
MECHANICAL
General Description
C: CAUTION
Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
Keep the disassembled parts in order and pro-
tect them from dust or dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
Be careful not to burn yourself, because each
part in the vehicle is hot after running.
Be sure to tighten fasteners including bolts and
nuts to the specified torque.
Place shop jacks or rigid racks at the specified
points.
Before disconnecting electrical connectors of
sensors or units, be sure to disconnect the ground
cable from battery.
All parts should be thoroughly cleaned, paying
special attention to the engine oil passages, pis-
tons and bearings.
Rotating parts and sliding parts such as piston,
bearing and gear should be coated with oil prior to
assembly.
Be careful not to let oil, grease or coolant contact
the timing belt, clutch disc and flywheel.
All removed parts, if to be reused, should be re-
installed in the original positions and directions.
Bolts, nuts and washers should be replaced with
new ones as required.
Even if necessary inspections have been made
in advance, proceed with assembly work while
making rechecks.
Remove or install the engine in an area where
chain hoists, lifting devices, etc. are available for
ready use.
Be sure not to damage coated surfaces of body
panels with tools or stain seats and windows with
coolant or oil. Place a cover over fenders, as re-
quired, for protection.
Prior to starting work, prepare the following:
Service tools, clean cloth, containers to catch cool-
ant and oil, wire ropes, chain hoist, transmission
jacks, etc.
Lift-up or lower the vehicle when necessary.
Make sure to support the correct positions.
Page 1480 of 2870
ME(H4DOTC)-24
MECHANICAL
General Description
398744300 PISTON GUIDE Used for installing piston in cylinder for 2.0 L
engine.
498747300 PISTON GUIDE Used for installing piston in cylinder for 2.5 L
engine.
498857100 VALVE OIL SEAL
GUIDEUsed for press-fitting of intake and exhaust valve
guide oil seals.
499017100 PISTON PIN GUIDE Used for installing piston pin, piston and con-
necting rod. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-398744300
ST-498747300
ST-498857100
ST-499017100
Page 1485 of 2870
ME(H4DOTC)-29
MECHANICAL
General Description
18332AA010 OIL FILTER
WRENCHUsed for removing and installing the oil filter.
(Outer diameter: 65 mm (2.56 in))
499587100 OIL SEAL
INSTALLERUsed for installing oil pump oil seal.
499587600 OIL SEAL
INSTALLERUsed for installing camshaft oil seal for DOHC
engine.
499597200 OIL SEAL GUIDE Used for installing camshaft oil seal for DOHC
engine.
Used with OIL SEAL GUIDE (499587600). ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST18332AA010
ST-499587100
ST-499587600
ST-499597200
Page 1491 of 2870

ME(H4DOTC)-35
MECHANICAL
Engine Oil Pressure
6. Engine Oil Pressure
A: INSPECTION
1) Remove the oil pressure switch from engine cyl-
inder block.
Pressure Switch.>
2) Connect the oil pressure gauge hose to cylinder
block.
3) Connect the battery ground cable to battery.
4) Start the engine, and then measure the oil pres-
sure.
Oil pressure:
98 kPa (1.0 kg/cm
2, 14 psi) or more at 800 rpm
294 kPa (3.0 kg/cm2, 43 psi) or more at 5,000
rpm
If the oil pressure is out of specification, check oil
pump, oil filter and lubrication line.
LU(H4SO)-24, INSPECTION, Engine Lubrication
System Trouble in General.>
If the oil pressure warning light is turned ON and
oil pressure is in specification, replace the oil pres-
sure switch.
Engine Lubrication System Trouble in General.>
NOTE:
The specified data is based on an engine oil tem-
perature of 80°C (176°F).
5) After measuring the oil pressure, install the oil
pressure switch.
LATION, Oil Pressure Switch.>
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
FU-00009
ME-00009
Page 1493 of 2870

ME(H4DOTC)-37
MECHANICAL
Valve Clearance
8. Valve Clearance
A: INSPECTION
Inspection and adjustment of the valve clearance
should be performed while engine is cold.
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Remove the air intake duct.
IN(H4DOTC)-8, REMOVAL, Air Intake Duct.>
4) Remove the bolts which secure the timing belt
cover (RH).
5) Lift-up the vehicle.
6) Remove the under cover.
7) Loosen the remaining bolts which secure the
timing belt cover (RH), and then remove the timing
belt cover.
8) Lower the vehicle.
9) When inspecting the #1 and #3 cylinders:
(1) Pull out the engine harness connector with
bracket from air cleaner upper cover.
(2) Remove the air cleaner case.
IN(H4DOTC)-7, REMOVAL, Air Cleaner.>
(3) Disconnect the ignition coil connector.
(4) Remove the ignition coil.
(5) Place a suitable container under the vehicle.
(6) Disconnect the PCV hose from rocker cover
(RH).
(7) Remove the bolts, and then remove the
rocker cover (RH).10) When inspecting the #2 and #4 cylinders:
(1) Disconnect the battery cable, and then re-
move the battery and battery carrier.
(2) Remove the bolt which secures the engine
harness bracket onto body.
(3) Disconnect the washer motor connectors.
(4) Remove the washer tank mounting bolts.
FU-00009
ME-00012
ME-00013
ME-00014
ME-00015
ME-00016
Page 1498 of 2870

MECHANICAL
ME(H4DOTC)
Page
1. General Description ....................................................................................2
2. Compression .............................................................................................31
3. Idle Speed .................................................................................................32
4. Ignition Timing ...........................................................................................33
5. Intake Manifold Vacuum............................................................................34
6. Engine Oil Pressure ..................................................................................35
7. Fuel Pressure ............................................................................................36
8. Valve Clearance ........................................................................................37
9. Engine Assembly ......................................................................................41
10. Engine Mounting .......................................................................................50
11. Preparation for Overhaul ...........................................................................51
12. V-belt .........................................................................................................52
13. Crank Pulley ..............................................................................................55
14. Timing Belt Cover......................................................................................57
15. Timing Belt Assembly................................................................................58
16. Cam Sprocket ...........................................................................................67
17. Crank Sprocket .........................................................................................68
18. Camshaft ...................................................................................................69
19. Cylinder Head Assembly ...........................................................................76
20. Cylinder Block ...........................................................................................84
21. Intake and Exhaust Valve .......................................................................115
22. Piston ......................................................................................................116
23. Connecting Rod ......................................................................................117
24. Crankshaft ...............................................................................................118
25. Engine Trouble in General ......................................................................119
26. Engine Noise ...........................................................................................124
Page 1503 of 2870

ME(H4DOTC)-45
MECHANICAL
Engine Assembly
26) Support the transmission with a garage jack.
NOTE:
Before moving the engine away from transmission,
check to be sure no work has been overlooked. Do-
ing this is very important in order to facilitate re-in-
stallation and because transmission lowers under
its own weight.
27) Separation of the engine and transmission.
(1) Remove the starter.
REMOVAL, Starter.>
(2) Install the ST to torque converter clutch
case. (AT model)
ST 498277200 STOPPER SET
(3) Remove the bolts which hold the right upper
side of transmission to engine.
28) Remove the engine from vehicle.
(1) Slightly raise the engine.
(2) Raise the transmission with garage jack.
(3) Move the engine horizontally until the main-
shaft is withdrawn from clutch cover.
(4) Slowly move the engine away from engine
compartment.NOTE:
Be careful not to damage adjacent parts or body
panels with crank pulley, oil pressure gauge, etc.
29) Remove the front cushion rubbers.
B: INSTALLATION
1) Install the clutch release fork and bearing onto
transmission. (MT model)
(1) Remove the release bearing from clutch
cover with flat type screw driver.
(2) Install the release bearing on transmission.
(3) Install the release fork into release bearing
tab.
ME-00048
ST
ME-00049
ME-00050
(A) Release fork
(B) Release bearing
ME-00051
ME-00052
(A)
(B)