Parts Requiring Angular Tightening
- Use an angle wrench for the final tightening of the following engine parts. Cylinder head bolts Lower cylinder block bolts Connecting rod cap bolts Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular tightening)
- Do not use a torque value for final tightening.
- The torque value for these parts are for a preliminary step.
- Ensure thread and seat surfaces are clean and coated with engine oil.
GENERAL SPECIFICATIONS
General Specifications Table Cylinder arrangement 4 in-line Displacement cm 3 (cu in) 2,488 (151.82) Bore and stroke mm (in) 89.0 x 100 (3.50 - 3.94) Valve arrangement DOHC Firing order 1-3-4-2 Number of piston rings Compression 2 Oil 1 Compression ratio 9.5 Compression pressure kPa (kg/cm 2 , psi) / 250 rpm Standard 1,250 (12.8, 182) Minimum 1,060 (10.8,154) Differential limit between cylinders 100 (1.0, 14) Valve timing Unit: degree a b C d e f 224 244 0 64 3 41
Scheme 1
Scheme 2
Scheme 3
Scheme 4
Scheme 5
Scheme 6
Scheme 7
Scheme 8
Scheme 9
Scheme 10
Scheme 11
Scheme 12
Scheme 13
Scheme 14
Scheme 15
Scheme 16
Scheme 17
Scheme 18
Scheme 19
Scheme 20
Scheme 21
Scheme 22
Scheme 23
Scheme 24
Scheme 25
Scheme 26
Scheme 27
ENGINE SPECIFICATIONS
| Application | Specification |
|---|---|
| Displacement | 151.8 Cu. In. (2.5L) |
| Bore | 3.50 In. (89 mm) |
| Stroke | 3.94 In. (100 mm) |
| Compression Pressure | 154-181 psi (10.8-12.8 kg/cm 2 ) |
| Compression Ratio | 9.5:1 |
| Fuel System | SFI |
GENERAL SPECIFICATIONS
VALVE CLEARANCE SPECIFICATIONS
| Application | In. (mm) | |
|---|---|---|
| Cold | ||
| Exhaust | .010-.013 (.26-.34) | |
| Intake | .009-.013 (.24-.32) | |
| Hot | ||
| Exhaust | .013-.016 (.33-.41) | |
| Intake | .013-.016 (.32-.40) | |
VALVE CLEARANCE SPECIFICATIONS
MAIN BEARING SPECIFICATIONS (MATCHED SET)
| Grade Number (1) | ID Color (2) | Thickness - In. (mm) |
|---|---|---|
| 0 | Black | .0777-.0778 (1.973-1.976) |
| 1 | Red (Brown) | .0778-.0779 (1.976-1.979) |
| 2 | Green | .0779-.0780 (1.979-1.982) |
| 3 | Yellow | .0780-.0781 (1.982-1.985) |
| 4 | Blue | .0781-.0783 (1.985-1.988) |
| 5 | Pink | .0783-.0784 (1.988-1.991) |
| 6 | Purple | .0784-.0785 (1.991-1.994) |
| 7 | Orange (White) | .0785-.0786 (1.994-1.997) |
| (1) Grade is the same for lower and upper bearings. (2) Color Mark in parenthesis are for 2004 model. | ||
| (1) | Grade is the same for lower and upper bearings. |
| (2) | Color Mark in parenthesis are for 2004 model. |
MAIN BEARING SPECIFICATIONS (MATCHED SET)
MAIN BEARING SPECIFICATIONS (MISMATCHED SET)
| Grade Number (1) | ID Color (2) | Thickness - In. (mm) | |
|---|---|---|---|
| 01 | |||
| Lower | Black/Red (Black/Brown) | .0778-.0779 (1.976-1.979) | |
| Upper | Black/Red | .0777-.0778 (1.973-1.976) | |
| 12 | |||
| Lower | Red/Green | .0779-.0782 (1.979-1.982) | |
| Upper | Red/Green | .0778-.0779 (1.976-1.979) | |
| 23 | |||
| Lower | Green/Yellow | .0780-.0781 (1.982-1.985) | |
| Upper | Green/Yellow | .0779-.0782 (1.979-1.982) | |
| 34 | |||
| Lower | Yellow/Blue | .0793-.0794 (1.985-1.988) | |
| Upper | Yellow/Blue | .0780-.0781 (1.982-1.985) | |
| 45 | |||
| Lower | Blue/Pink | .0783-.0784 (1.988-1.991) | |
| Upper | Blue/Pink | .0793-.0794 (1.985-1.988) | |
| 56 | |||
| Lower | Pink/Purple | .0784-.0785 (1.991-1.994) | |
| Upper | Pink/Purple | .0783-.0784 (1.988-1.991) | |
| 67 | |||
| Lower | Purple/Orange (Purple/White) | .0785-.0786 (1.994-1.997) | |
| Upper | Purple/Orange | .0784-.0785 (1.991-1.994) | |
| (1) Grade is different for lower and upper bearings. (2) Color mark in parenthesis is 2004 model. | |||
| (1) | Grade is different for lower and upper bearings. |
| (2) | Color mark in parenthesis is 2004 model. |
MAIN BEARING SPECIFICATIONS (MISMATCHED SET)
CONNECTING ROD BEARING SPECIFICATIONS
| Grade Number | ID Color (1) | Thickness - In. (mm) |
|---|---|---|
| 0 | Black | .0590-.0589 (1.499-1.495) |
| 1 | Brown (Red) | .0592-.0590 (1.503-1.499) |
| 2 | Green | .0593-.0592 (1.507-1.503) |
| 3 | Yellow | .0595-.0593 (1.511-1.507) |
| (1) Color mark in parenthesis is for 2004 model. | ||
| (1) | Color mark in parenthesis is for 2004 model. |
CONNECTING ROD BEARING SPECIFICATIONS
OIL PUMP SPECIFICATIONS
| Application | In. (mm) |
|---|---|
| Pump Body-To-Outer Rotor Clearance | .0045-.0070 (.114-.179) |
| Rotor Tip Clearance | Less Than .0087 (.220) |
| Inner Rotor-To-Body Clearance | .0012-.0028 (.030-.070) |
| Inner Rotor-To-Brazed Portion Of Housing Clearance | .0014-.0028 (.035-.070) |
| Outer Rotor-To-Body Clearance | .0024-.0043 (.060-.110) |
| Regulator Valve-To-Pump Body Clearance | .0016-.0039 (.040-.100) |
OIL PUMP SPECIFICATIONS
TORQUE SPECIFICATIONS
| Application | Ft. Lbs. (N.m) | |||
|---|---|---|---|---|
| Auxiliary Drive Belt Auto Tensioner Bolt | 15-18 (20-25) | |||
| Balancer Unit Mounting Bolt (1) (2) | ||||
| Step 1 | 33-38 (45-51) | |||
| Step 2 | Tighten Additional 90-95 Degrees | |||
| Step 3 | Fully Loosen Bolts | |||
| Step 4 | 33-38 (45-51) | |||
| Step 5 | Tighten Additional 90-95 Degrees | |||
| Camshaft Sprocket Bolt | 94-115 (128-156) | |||
| Connecting Rod Bolt (3) | ||||
| Step 1 | 14-15 (19-20) | |||
| Step 2 | Tighten Additional 85-95 Degrees | |||
| Coolant Temperature Sensor | 15-21 (20-29) | |||
| Crankshaft Pulley Bolt | ||||
| Step 1 | 27-35 (37-47) | |||
| Step 2 | Tighten Additional 60-66 Degrees | |||
| Cylinder Block Coolant Drain Plug | 25-32 (34-44) | |||
| Cylinder Head Bolt (4) (5) | ||||
| Step 1 | 72 (98) | |||
| Step 2 | Fully loosen Bolts | |||
| Step 3 | 25-32 (34-44) | |||
| Step 4 | Tighten Additional 75-80 Degrees | |||
| Step 5 | Tighten Additional 75-80 Degrees Again | |||
| Drive Plate/Flywheel Bolt | 76-83 (103-113) | |||
| Engine Coolant Inlet & Outlet Bolt | 16-21 (22-28) | |||
| Engine Mounting | ||||
| Center Member Bolt | 57-72 (77-98) | |||
| Front Engine Mount-To-Center Member | 44-52 (60-70) | |||
| Front Engine Mount Bracket-To-Engine Bolt | 37-44 (50-60) | |||
| Front Engine Mount Through Bolt | 46-58 (62-78) | |||
| Left Engine Mount Bolt | 32-41 (43-55) | |||
| Left Engine Mount Through Bolt | 47-55 (64-74) | |||
| Rear Engine Mount-To-Center Member Bolt | 57-72 (77-98) | |||
| Rear Engine Mount Bracket-To-Engine Bolt | 57-63 (77-85) | |||
| Rear Engine Mount Through Bolt | 57-72 (77-98) | |||
| Right Engine Mount-To-Right Engine Mount Bracket | 44-52 (60-70) | |||
| Right Engine Mount Bracket-To-Engine Bolt | 32-41 (43-55) | |||
| Engine Slinger Bolt | ||||
| Front | 38-48 (51-65) | |||
| Rear | 18-23 (25-31) | |||
| Exhaust Manifold Nut (6) | 29-32 (39-44) | |||
| Generator Bolt | ||||
| Adjustment Bolt | 18-23 (25-31) | |||
| Lower Mounting Bolt | 33-38 (45-52) | |||
| Heater Pipe-To-Cylinder Block Bolt | 16-21 (22-28) | |||
| Intake Manifold-To-Cylinder Head Bolts/Nuts (7) | 13-16 (18-22) | |||
| Intake Manifold Collector-To-Intake Manifold Bolt (8) | 13-16 (18-22) | |||
| Intake Manifold Support Bolt | 13-16 (18-22) | |||
| Knock Sensor Bolt | 12-20 (16-27) | |||
| Lower Cylinder Block Bolt (9) (10) | ||||
| Step 1 - Bolts 1-10 | 27-31 (36-42) | |||
| Step 2 - Bolts 1-10 | Tighten Additional 60-65 Degrees | |||
| Step 3 - Bolts 11-22 | 15-18 (20-25) | |||
| Oil Dipstick Tube Bolt | 15-18 (20-25) | |||
| Oil Drain Plug | 22-29 (30-39) | |||
| Oil Pan-To-Transaxle Bolt | 30-34 (40-46) | |||
| Oil Pressure Regulator Plug | 29-50 (39-68) | |||
| Oil Strainer Bolts | 15-18 (20-25) | |||
| Oxygen Sensor | 30-37 (40-50) | |||
| Spark Plug | 15-21 (20-29) | |||
| Starter Bolt | 72-94 (98-127) | |||
| Timing Chain Slack Guide Bolt | 12-13 (16-17) | |||
| Transaxle-To-Engine Bolt | ||||
| Automatic (11) | ||||
| Bolts 2, 3, 4, 5 & 6 | 52-58 (70-79) | |||
| Bolts 1, 7, 8, 9, 10 & 11 | 23-30 (31-40) | |||
| Manual (12) | ||||
| Bolts 2, 3, 4 & 5 | 52-58 (70-79) | |||
| Bolts 1, 6, 7, 8, 9 & 10 | 23-30 (31-40) | |||
| Upper Oil Pan-To-Cylinder Block Bolt (13) | ||||
| 6 mm Bolts | 71-89 INCH Lbs. (8-10) | |||
| 8 mm Bolts | 15-18 (20-25) | |||
| Water Pipe-To-Water Pump Housing Bolts | 16-21 (22-28) | |||
| Water Pump Bolts | 16-21 (22-28) | |||
| Water Pump Housing Bolt | 16-21 (22-28) | |||
| INCH Lbs. (N.m) | ||||
| Air Cleaner Assembly Bolt | 35-44 (4-5) | |||
| Balancer Unit Timing Chain Tensioner Bolt | 53-71 (6-8) | |||
| Camshaft Bracket Bolt (14) | ||||
| Step 1 - Bolts 9-11 | 18 (2) | |||
| Step 2 - Bolts 1-8 | 18 (2) | |||
| Step 3 - All Bolts | 53 (6) | |||
| Step 4 - All Bolts | 80-106 (9-12) | |||
| Camshaft Position Sensor Bolt | 44-62 (5-7) | |||
| Crankshaft Position Sensor Bolt | 44-62 (5-7) | |||
| Crankshaft Signal Plate Bolt | 106-124 (12-14) | |||
| Electric Throttle Control Actuator Bolts | 62-89 (7-10) | |||
| EVAP Canister Purge Volume Control Solenoid Bolt | 44-53 (5-6) | |||
| Exhaust Manifold Heat Shield Bolt | 44-62 (5-7) | |||
| Front Cover Bolt (15) | 106-115 (12-13) | |||
| Ignition Coil Bolt | 44-62 (5-7) | |||
| Intake Valve Timing Control Cover Bolts (16) | 106-115 (12-13) | |||
| Intake Valve Timing Control Solenoid Valve Bolt | 62-89 (7-10) | |||
| Lower Oil Pan-To-Upper Oil Pan Bolts (17) | 53-71 (6-8) | |||
| Oil Pressure Switch | 106-150 (12-17) | |||
| Oil Pump Mounting Bolt | 53-71 (6-8) | |||
| Oil Strainer Bracket Bolt | 71-89 (8-10) | |||
| Radiator Drain Plug | 80-106 (9-12) | |||
| Rocker Cover Bolt (18) | ||||
| Step 1 | 9-27 (1-3) | |||
| Step 2 | 62-80 (7-9) | |||
| Timing Chain Tensioner Bolt | 80-97 (9-11) | |||
| Vacuum Reservoir Tank Bolt | 62-89 (7-10) | |||
| (1) Measure diameter of balancer unit mounting bolt 10 mm and 70 mm from first thread of bolt. If the difference between bolt diameter measurement is more than 0.15 mm, replace bolt. (2) Tighten balancer unit bolts in sequence. see scheme 253 (3) Measure diameter of connecting rod bolt 19 mm from tip of bolt. If diameter of bolt is less than 7.75 mm, replace bolt. (4) Measure diameter of cylinder head bolt 12 mm and 55 mm from tip of bolt. If the difference between bolt diameter measurements is less than 0.23 mm, replace bolt. (5) Tighten cylinder head bolts in sequence. see scheme 254 (6) Tighten exhaust manifold nuts in sequence. see scheme 255 (7) Tighten intake manifold bolts/nuts in sequence. see scheme 256 (8) Tighten intake manifold collector bolts/nuts in sequence. see scheme 257 (9) Measure diameter of lower cylinder block bolt 10 mm and 50 mm from tip of bolt. If the difference between bolt diameter measurements is more than 0.13 mm, replace bolt. (10) Tighten lower cylinder block bolts in sequence. see scheme 258 (11) Tighten automatic transaxle-to-engine bolts in sequence. see scheme 259 (12) Tighten manual transaxle-to-engine bolts in sequence. see scheme 260 (13) Tighten upper oil pan bolts in sequence. see scheme 261 (14) Tighten camshaft bracket bolts in sequence. see scheme 262 (15) Tighten front cover bolts in sequence. see scheme 263 (16) Tighten intake valve timing control cover bolts in sequence. see scheme 264 (17) Tighten lower oil pan bolts in sequence. see scheme 265 (18) Tighten rocker cover bolts in sequence. see scheme 266 | ||||
| (1) | Measure diameter of balancer unit mounting bolt 10 mm and 70 mm from first thread of bolt. If the difference between bolt diameter measurement is more than 0.15 mm, replace bolt. |
| (2) | Tighten balancer unit bolts in sequence. see scheme 253 |
| (3) | Measure diameter of connecting rod bolt 19 mm from tip of bolt. If diameter of bolt is less than 7.75 mm, replace bolt. |
| (4) | Measure diameter of cylinder head bolt 12 mm and 55 mm from tip of bolt. If the difference between bolt diameter measurements is less than 0.23 mm, replace bolt. |
| (5) | Tighten cylinder head bolts in sequence. see scheme 254 |
| (6) | Tighten exhaust manifold nuts in sequence. see scheme 255 |
| (7) | Tighten intake manifold bolts/nuts in sequence. see scheme 256 |
| (8) | Tighten intake manifold collector bolts/nuts in sequence. see scheme 257 |
| (9) | Measure diameter of lower cylinder block bolt 10 mm and 50 mm from tip of bolt. If the difference between bolt diameter measurements is more than 0.13 mm, replace bolt. |
| (10) | Tighten lower cylinder block bolts in sequence. see scheme 258 |
| (11) | Tighten automatic transaxle-to-engine bolts in sequence. see scheme 259 |
| (12) | Tighten manual transaxle-to-engine bolts in sequence. see scheme 260 |
| (13) | Tighten upper oil pan bolts in sequence. see scheme 261 |
| (14) | Tighten camshaft bracket bolts in sequence. see scheme 262 |
| (15) | Tighten front cover bolts in sequence. see scheme 263 |
| (16) | Tighten intake valve timing control cover bolts in sequence. see scheme 264 |
| (17) | Tighten lower oil pan bolts in sequence. see scheme 265 |
| (18) | Tighten rocker cover bolts in sequence. see scheme 266 |
TORQUE SPECIFICATIONS
Scheme 28
Scheme 29
Scheme 30
Scheme 31
Scheme 32
Scheme 33
Scheme 34
Scheme 35
Scheme 36
Scheme 37
Scheme 38
Scheme 39
Scheme 40
Scheme 41
See also:
• FUEL PRESSURE RELEASE