Engine Mechanical ECHO 2002

EM-1
ENGINE MECHANICAL CO/HC
CO/HC
EM167-01
INSPECTION
HINT: This check is used only to determine whether or not the idle CO/HC complies with regulations. 1. INSTALL CONDITIONS (a) Engine at normal operating temperature (b) Air cleaner installed (c) Air pipes and hoses of air induction system connected (d) All accessories switched OFF (e) All vacuum lines properly connected (f) SFI system wiring connectors fully plugged (g) Ignition timing check correctly (h) Transmission in neutral position (i) Tachometer and CO/HC meter calibrated by hand 2. START ENGINE 3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SECONDS 4. INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE DURING IDLING 5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM Complete the measuring with 3 minutes. HINT: When doing the 2 mode (idle and 2,500 rpm) test, these measurement order prescribed by the applicable local regulations.
A11216
2002 ECHO (RM884U)
Author :
Date :
615
EM-2
ENGINE MECHANICAL CO/HC
If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below. S Check heated oxygen sensor operation. (See page DI-48 ) S See the table below for possible causes, and then inspect and correct the applicable causes if necessary.
CO Normal High HC Problems Rough idle Causes 1. Faulty ignitions: S Incorrect timing S Fouled, shorted or improperly gapped plugs S Open or crossed high-tension cords 2. Incorrect valve clearance 3. Leaky intake and exhaust valves 4. Leaky cylinders 1. Vacuum leaks: S PCV hoses S Intake manifold S Throttle body S IAC valve S Brake booster line 2. Lean mixture causing misfire 1. Restricted air filter 2. Plugged PCV valve 3. Faulty SFI systems: S Faulty pressure regulator S Defective ECT sensor S Defective IAT sensor S Faulty ECM S Faulty injectors S Faulty throttle position sensor
Low
High
Rough idle (Fluctuating HC reading)
High
High
Rough idle (Black smoke from exhaust)
2002 ECHO (RM884U)
Author :
Date :
616
EM-3
ENGINE MECHANICAL COMPRESSION
COMPRESSION
EM168-01
INSPECTION
HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating temperature. 2. REMOVE NO. 2 CYLINDER HEAD COVER 3. REMOVE IGNITION COIL (See page IG-6 ) 4. REMOVE SPARK PLUGS
5. (a) (b) (c)
INSPECT CYLINDER COMPRESSION PRESSURE Insert a compression gauge into the spark plug hole. Fully open the throttle. While cranking the engine, measure the compression pressure.
A11217
HINT: Always use a fully charged battery to obtain engine speed of 250 rpm or more. (d) Repeat steps (a) through (c) for each cylinder. NOTICE: This measurement must be done in as short a time as possible. Compression pressure: 1,471 kPa (15.0 kgf/cm2, 213 psi) Minimum pressure: 1,079 kPa (11.0 kgf/cm2, 156 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm2, 14 psi) or less (e) If the cylinder compression in one more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps (a) through (c) for cylinders with low compression. S If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged. S If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket.
2002 ECHO (RM884U)
Author :
Date :
617
EM-4
ENGINE MECHANICAL COMPRESSION
6. 7. 8.
REINSTALL SPARK PLUGS REINSTALL IGNITION COIL (See page IG-7 ) REINSTALL NO. 2 CYLINDER HEAD COVER
2002 ECHO (RM884U)
Author :
Date :
618
EM-61
ENGINE MECHANICAL CYLINDER BLOCK
CYLINDER BLOCK
EM17B-01
COMPONENTS
Water Bypass Pipe
9.0 (90, 80 in.lbf)
9.0 (90, 80 in.lbf)
9.0 (90, 80 in.lbf)
z Gasket
L Engine Coolant Drain Union
Knock Sensor
z Gasket
Oil Pressure Switch

9.0 (90. 80 in.lbf)
Thermostat
Water Inlet Nm(kgfcm, ftlbf) : Specified torque zNon-reusable part LPrecoated part
A11250
2002 ECHO (RM884U)
Author :
Date :
675
EM-62
No.1 Compression Ring No.2 Compression Ring z Connecting Rod Bushing Oil Ring (Expander) Oil Ring (Side Rail) Connecting Rod
Piston Piston Pin

See page EM-78 1st 15 (150,11) 2nd Turn 90
Connecting Rod Bearing Connecting Rod Cap
Cylinder Block
Upper Main Bearing Crankshaft Thrust Washer z O-ring Crankshaft Thrust Washer z Crankshaft Rear Oil Seal Crankshaft Lower Main Bearing Crankshaft Bearing Cap
See page EM-78 1st 22 (220,16) 2nd Turn 90
x10
z O-ring
Oil Pan No.1 z Gasket z O-ring x10
Oil Filter Union

30 (306, 22)
Oil Filter Oil Pan No.2

24 (245, 18)
Oil strainer
11 (112, 8) 38 (387, 28)
z Gasket Nm(kgfcm, ftlbf) : Specified torque zNon-reusable part

2002 ECHO (RM884U) 9.0 (92, 80 in.lbf)
A11251
Author :
Date :
676
EM-63
EM17C-01
DISASSEMBLY
1. 2. 3. 4. 5. 6. M/T: REMOVE FLYWHEEL A/T: REMOVE DRIVE PLATE INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY REMOVE TIMING CHAIN (See page EM-15 ) REMOVE CYLINDER HEAD (See page EM-28 ) REMOVE ENGINE WIRE
A10451
7. REMOVE WATER BYPASS PIPE Remove the 2 nuts, bolt and water bypass pipe. 8. REMOVE THERMOSTAT (See page CO-8 ) 9. REMOVE KNOCK SENSOR (See page SF-57 ) 10. REMOVE OIL PRESSURE SWITCH (See page LU-1 ) 11. REMOVE ENGINE COOLANT DRAIN UNION 12. REMOVE OIL FILTER (See page LU-2 ) 13. REMOVE OIL FILTER UNION Using a 12 mm hexagon wrench, remove the oil filter union.
A11268
14. (a) (b)
A11269
REMOVE OIL PAN NO. 2 Remove the 9 bolts and 2 nuts. Insert the blade of SST between the oil pan No. 1 and oil pan No. 2, and cut off applied sealer and remove the oil pan. SST 09032-00100 NOTICE: S Be careful not to the damage the oil pan contact surface of the oil pan No. 1. S Be careful not to damage the oil pan No. 2 flange.
Author : Date : 677
2002 ECHO (RM884U)
EM-64
15. REMOVE OIL STRAINER Remove the 2 nuts, oil strainer and gasket.
A11270
16. (a)
REMOVE OIL PAN NO. 1 Uniformly loosen and remove the 13 bolts, in several passes, in the sequence shown.
A11271
(b) (c)
Using screwdriver remove the oil pan No. 1 by prying the portions between the cylinder block and oil pan No. 1. Remove the 2 O-rings from cylinder block.
A11272
A10452
17. CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.16 - 0.36 mm (0.0063 - 0.0142 in.) Maximum thrust clearance: 0.36 mm (0.0142 in.) If the thrust clearance is greater than maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft. 18. REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE (a) Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly. (b) Remove the 2 connecting rod cap bolts.
A10453
2002 ECHO (RM884U)
Author :
Date :
678
EM-65
(c)
Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.
A10454
HINT: Keep the lower bearing inserted with the connecting rod cap. (d) Clean the crank pin and bearing. (e) Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. (f) Lay a strip of Plastigage the crank pin.
Plastigage
A10455
Install the connecting rod cap with the 2 bolts. (See page EM-78 ) Torque: 1ST 15 Nm (150 kgfcm, 11 ftlbf) 2ND Turn 90 NOTICE: Do not turn the crankshaft.
A10456
(g)
(h)
A10457
Remove the 2 bolts, connecting rod cap and lower bearing. (See procedure (b) and (c) above) (i) Measure the Plastigage at its widest point. Standard oil clearance: 0.016 - 0.040 mm (0.0006 - 0.0016 in.) Maximum oil clearance: 0.06 mm (0.0024 in.) If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft.
2002 ECHO (RM884U)
Author :
Date :
679
EM-66
Mark 1, 2 or 3
HINT: If replacing a bearing, replace it with one having the same number as marked on the connecting rod. There are 3 sizes of standard bearings, marked 1, 2 and 3 accordingly. Reference Standard bearing center wall thickness
Mark 1 2 3 1.488 - 1.492 (0.0586 - 0.0587) 1.492 - 1.496 (0.0587 - 0.0589) 1.496 - 1.500 (0.0589 - 0.0591) mm (in.)
Mark 1, 2 or 3
A01198
(j)
Completely remove the plastigage.
19. (a) (b) HINT:

A01166
REMOVE PISTON AND CONNECTING ROD ASSEMBLIES Using a ridge reamer, remove all the carbon from the top of the cylinder. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
A10458
Keep the bearings, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order. 20. CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the crankshaft back and forth. Standard thrust clearance: 0.09 - 0.19 mm (0.0035 - 0.0075 in.) Maximum thrust clearance: 0.3 mm (0.012 in.) If the thrust clearance is greater than maximum, replace the thrust washer as a set. Thrust washer thickness: 2.430 - 2.480 mm (0.09567 - 0.09764 in.)
S S
2002 ECHO (RM884U)
Author :
Date :
680
EM-67
21. (a)
REMOVE BEARING CAPS AND CHECK OIL CLEARANCE Uniformly loosen and remove the 10 bearing cap bolts in several passes in the sequence shown.
A10459
(b)
Using the 2 removed bearing cap bolts, remove the bearing cap and lower bearing by wiggling the bearing cap right and left.
A10460
HINT: Keep the lower bearing inserted with the bearing cap. (c) Lift out the crankshaft. HINT: Keep the upper bearings and thrust washers together with the cylinder block. (d) Clean each main journal and bearing. (e) Check each main journal and bearing for pitting and scratches. If the journal or bearing is damaged, replace the bearing. If necessary, grind or replace the crankshaft. (f) Place the crankshaft on the cylinder block.
A10461
Lay a strip of plastigage acrose each journal. Install the bearing caps (See page EM-44 ). Torque: 1ST 22 Nm (220 kgfcm, 16 ftlbf) 2ND Turn 90 NOTICE: Do not turn the crankshaft. (i) Remove the bearing caps (See procedure (a) and (b) above). (j) Measure the plastigage at its widest point. Standard oil clearance: 0.010 - 0.023 mm (0.0004 - 0.0009 in.) Maximum oil clearance: 0.07 mm (0.0028 in.) If the oil clearance is greater then maximum, replace the bearings. If necessary, replace the crankshaft.
(g) (h)
A10462
2002 ECHO (RM884U)
Author :
Date :
681
EM-68
No. 1 No. 3 No. 5
No. 2 No. 4
HINT: If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then selecting the bearing with the same number as the total. There are 4 sizes of standard bearings, marked 1, 2, 3 and 4 accordingly.
Total number Cylinder block (A) + Crankshaft (B) Use bearing Number Mark EXAMPLE: 0-2 1 3-5 2 : Number mark 6-8 3 9 -11 4
No. 1 No. 3 No. 5
Cylinder block 4 (A) + Crankshaft 3 (B) = Total number 7 (Use bearing 3)
No. 2 No. 4
A10463
Reference
Item Cylinder block main journal bore diameter (A) Mark 0 1 2 3 4 5 6 0 1 2 3 4 5 1 2 3 4 50.000 - 50.003 (1.96850 - 1.96862) 50.003 - 50.005 (1.96862 - 1.96870) 50.005 - 50.007 (1.96870 - 1.96878) 50.007 - 50.010 (1.96878 - 1.96889) 50.010 - 50.012 (1.96889 - 1.96897) 50.012 - 50.014 (1.96897 - 1.96905) 50.014 - 50.016 (1.96905 - 1.96913) 46.000 - 46.002 (1.81102 - 1.81110) 46.002 - 46.004 (1.81110 - 1.81118) 46.004 - 46.006 (1.81118 - 1.81126) 46.006 - 46.008 (1.81126 - 1.81133) 46.008 - 46.010 (1.81133 - 1.81141) 46.010 - 46.012 (1.81141 - 1.81149) 1.992 - 1.995 (0.07843 - 0.07854) 1.995 - 1.998 (0.07854 - 0.07866) 1.998 - 2.001 (0.07866 - 0.07878) 2.001 - 2.004 (0.07878 - 0.07890) mm (in.)
Crankshaft main journal diameter (B)
Standard bearing center wall thickness
(k) 22. (a) (b)
Completely remove the Plastigage. REMOVE CRANKSHAFT Lift out the crankshaft. Remove the 5 upper main bearings and 2 thrust washers from the cylinder block.
HINT: Arrange the main bearings and thrust washers in the correct order.
2002 ECHO (RM884U)
Author :
Date :
682
EM-69
23. CHECK FIT BETWEEN PISTON AND PISTON PIN Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set.
A12947
24. (a)
(b) HINT: Arrange the piston rings in the correct order only.
REMOVE PISTON RINGS Using a piston ring expander, remove the 2 compression rings. Remove the 2 side rails and oil ring by hand.
A12948
SST
SST
SST
A12963
25. DISCONNECT CONNECTING ROD FROM PISTON Using SST, press out the piston pin from the piston. Remove the piston. SST 09221- 25026 (09221- 00021, 09221- 00030, 09221-00190, 09221-00141, 09221-00150) HINT: S The piston and pin are a matched set. S Arrange the pistons, pins, rings, connecting rods and bearings in correct order.
2002 ECHO (RM884U)
Author :
Date :
683
EM-70
EM17D-01
INSPECTION
1. REMOVE GASKET MATERIAL Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block. 2. CLEAN CYLINDER BLOCK Using a soft brush and solvent, thoroughly clean the cylinder block. NOTICE: If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block, so always wash the cylinder block at a temperature of 45C (133F) or less.
A01165
3.
INSPECT TOP SURFACE OF CYLINDER BLOCK FOR FLATNESS Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage. Maximum warpage: 0.05 mm (0.0020 in.) If warpage is greater than maximum, replace the cylinder block.
A01169
4. INSPECT CYLINDER BORE DIAMETER Visually check the cylinder for vertical scratches. If deep scratches are present, replace the cylinder block.
A01167
2002 ECHO (RM884U)
Author :
Date :
684
EM-71
5. INSPECT CYLINDER BORE DIAMETER Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions. Standard diameter: 75.000 - 75.013 mm (2.95275 - 2.95326 in.) Maximum diameter: 75.013 mm (2.95326 in.) If the diameter is greater than maximum, replace the cylinder block.
1 Front 2 1 Thrust Direction 2 Axial Direction A B
A01168 EM2548
10 mm (0.39 in.)
10 mm (0.39 in.)A01467
6. REMOVE CYLINDER RIDGE If the wear is less than 0.2 mm (0.008 in,), using a ridge reamer, grind the top of the cylinder.
A01166
7.
INSPECT 12 POINTED HEAD BEARING CAP SUBASSEMBLY BOLTS Using vernier calipers, measure the tension portion diameter of the bolt. Standard diameter: 7.3 - 7.5 mm (0.287 - 0.295 in.) Minimum diameter: 7.3 mm (0.287 in.) If the diameter is less than minimum, replace the bolt.
A01194
8. (a)
CLEAN PISTON Using a gasket scraper, remove the carbon from the piston top.
A12949
2002 ECHO (RM884U)
Author :
Date :
685
EM-72
(b)
Using a groove cleaning tool or broken ring, clean the piston ring grooves.
A12950
(c) Using solvent and a brush, thoroughly clean the piston. NOTICE: Do not use a wire brush.
A12951
9. (a)
27 mm
A12952
INSPECT PISTON OIL CLEARANCE Using a micrometer, while placing the piston up side down, take measurement at the position of 27 mm (1.06 in.). Piston diameter: 74.945 - 74.955 mm (2.95058 - 2.95098 in.) (b) Measure the cylinder bore diameter in the thrust directions. (See procedure in step 5) (c) Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.045 - 0.068 mm (0.00177 - 0.00268 in.) Maximum oil clearance: 0.08 mm (0.0031 in.) If the oil clearance is greater than maximum, replace all the 4 pistons. If necessary, replace the cylinder block.
10. INSPECT PISTON RING END GAP Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove. Ring groove clearance: 0.030 - 0.070 mm (0.0012 - 0.0028 in.) If the clearance is not as specified, replace the piston.
A12953
2002 ECHO (RM884U)
Author :
Date :
686
EM-73
11. (a) (b)
110 mm
A12954
INSPECT PISTON RING END GAP Insert the piston ring into the cylinder bore. Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block. (c) Using a feeler gauge, measure the end gap. Standard end gap: No.1 0.25 - 0.35 mm (0.0098 - 0.0138 in.) No.2 0.35 - 0.50 mm (0.0138 - 0.0197 in.) Oil (Side rail) 0.10 - 0.35 mm (0.0039 - 0.0138 in.) Maximum end gap: No.1 0.91 mm (0.0358 in.) No.2 1.06 mm (0.0417 in.) Oil (Side rail) 0.82 mm (0.0323 in.) If the end gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum, even with a new piston ring, replace the cylinder block.
EM7639
12. INSPECT CONNECTING ROD ALIGNMENT Using a rod aligner and feeler gauge, check the connecting rod alignment. S Check for out-of-alignment Maximum out-of alignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If out-of alignment is greater than maximum, replace the connecting rod assembly.
Z00064
S Check for twist Maximum twist: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If twist is greater than maximum, replace the connecting rod assembly.
Z00065
13. (a)
INSPECT PISTON PIN OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing inside diameter: 18.010 - 18.019 mm (0.7091 - 0.7094 in.)
A01185
2002 ECHO (RM884U)
Author :
Date :
687
EM-74
(b)
EM0227
Using a micrometer, measure the piston pin diameter. Piston pin diameter: 17.988 - 18.007 mm (0.7086 - 0.7089 in.) (c) Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance: 0.009 - 0.015 mm (0.0003 - 0.0006 in.) Maximum oil clearance: 0.05 mm (0.0020 in.) If the oil clearance is greater than maximum, replace the bushing. If necessary, replace the piston and piston pin as a set.
14. INSPECT CONNECTING ROD BOLTS Using a vernier calipers, measure the tension portion diameter of the bolt. Standard diameter: 6.6 - 6.7 mm (0.260 - 0.264 in.) Minimum diameter: 6.4 mm (0.252 in.) If the diameter is less than minimum, replace the bolt.
A01470
15. (a) (b)
INSPECT CRANKSHAFT FOR CIRCLE RUNOUT Place the crankshaft on V-blocks. Using a dial indicator, measure the circle runout, as shown in the illustration. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than maximum, replace the crankshaft.
A11241
2002 ECHO (RM884U)
Author :
Date :
688
EM-75
16. (a)
INSPECT MAIN JOURNALS AND CRANK PINS Using a micrometer, measure the diameter of each main journal and crank pin. Main journal diameter: 46.000 - 46.012 mm (1.81102 - 1.81149 in.) Crank pin diameter: 39.992 - 40.000 mm (1.5745 - 1.5748 in.) If the diameter is not as specified, check the oil clearance (See page EM-63 ). If necessary, replace the crankshaft. (b) Check each main journal and crank pin for taper and outof-round as shown. Maximum taper and out-of-round: 0.02 mm (0.0008 in.) If the taper and out-of round is greater than maximum, replace the crankshaft.
A11242
2002 ECHO (RM884U)
Author :
Date :
689
EM-78
EM17F-01
REASSEMBLY
HINT:
S S S
1. (a)
Thoroughly clean all parts to be assembled. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. Replace all gaskets, O-rings and oil seals with new parts. ASSEMBLE PISTON AND CONNECTING ROD Gradually heat the piston side of connecting rod to 80 90C (176 - 194F). Coat the piston pin and pin holes of the piston with engine oil. Align the cavity on the piston with the protrusion on the connecting rod. Using SST, press in the piston pin. SST 09221- 25026 (09221- 00021, 09221- 00030, 09221-00190, 09221-00141, 09221-00150)
(Cavity)
(b) (c)
Front Mark
(d)
(Protrusion)
SST SST
SST
A12957
No.2
2. (a) (b)
INSTALL PISTON RINGS Install the oil ring expander and 2 side rails by hand. Using a piston ring expander, install the 2 compression rings.
A12958
No.1 Compression and Expander Front
Lower Side Rail
(c)
Position the piston rings so that the ring ends are as shown. NOTICE: Do not align the ring ends.
Upper Side Rail No. 2 Compression A12959

2002 ECHO (RM884U)
Author :
Date :
692
EM-79
3.
Supply parts: INSTALL MAIN BEARINGS
A01190
HINT: Upper bearings have an oil groove and oil holes; Lower bearings do not. (a) Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings. NOTICE: Install the bearing with the oil hole in the cylinder block. (b) Align the bearing claw with the claw grove of the main bearing cap, and push in the 5 lower bearings.
Block Side: A B C
Cap Side: D
4.
Manufacture parts: INSTALL MAIN BEARINGS
A10470
HINT: Upper bearings have an oil groove and oil holes; Lower bearings do not. Measure the clearance on both sides of the bearing and install it so that the difference between measured values will be within the specified bellow. Specified clearance: A - B = 0.8 mm (0.032 in.) C - D = 0.4 mm (0.016 in.) 5. PLACE CRANKSHAFT ON CYLINDER BLOCK
6. INSTALL BEARING CAPS (a) Install the 5 bearing caps. HINT: Each bearing cap has a number and front mark. (b) Apply a light coat of engine oil on the threads and under the head of the bearing cap bolts.
10
8
A10459
2002 ECHO (RM884U)
Author :
Date :
693
EM-80
(c)
(d) 7.
Install and uniformly tighten the 10 bolts of the bearing cap is several passes, in the sequence shown. Torque: 1ST 22 Nm (220 kgfcm, 16 ftlbf) 2ND Turn 90 Check that the crankshaft turns smoothly. CHECK CRANKSHAFT THRUST CLEARANCE (See page EM-63 )
8.
A01205
INSTALL PISTON AND CONNECTING ROD ASSEMBLES Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. 9. PLACE CONNECTING ROD CAP ON CONNECTING ROD (a) Match the numbered connecting rod cap with the connecting rod. (b) Align the pin dowels of the connecting rod cap with the pins of the connecting rod, and install the connecting rod. (c) Check that the protrusion of the connecting rod cap is facing in the correct direction. 10. INSTALL CONNECTING ROD CAP BOLTS HINT: S The connecting rod cap bolts are tightened in 2 progressive steps (steps (b) and (d)). S If any of the connecting rod cap bolts is broken or deformed, replace it. (a) Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.
A10456
Install and alternately tighten the 2 connecting rod cap bolts in several passes. Torque: 1ST 15 Nm (150 kgfcm, 11 ftlbf) 2ND Turn 90 If any of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts. 11. CHECK CONNECTING ROD THRUST CLEARANCE (See page EM-63 )
(b)
2002 ECHO (RM884U)
Author :
Date :
694
EM-81
12. (a)
(b)
INSTALL OIL PAN NO. 1 Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the oil pan No. 1 and cylinder block. S Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. S Thoroughly clean all components to remove all the loose material. S Using a non-residue solvent, clean both sealing surfaces. Apply seal packing to the oil pan No. 1 as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent S Install a nozzle that has been cut to a 2 - 3 mm (0.08 - 0.12 in.) opening.
Seal Width 2 - 3 mm
A10464
HINT: Avoid applying an excessive amount to the surface. S Parts must be assembled within 3 minutes of application. Otherwise the material must be remove d and reapplied. S Immediately remove nozzle from the tube and reinstall cap. (c) Install new O-rings to the cylinder block. (d) Using a plastic-faced hammer, lightly tap the oil pan No. 1 to ensure a proper fit.
5 4 3
15 14 2
(e)
13 12
Install and uniformly tighten the 13 bolts, in several passes, in the sequence shown. Torque: 24 Nm (245 kgfcm, 18 ftlbf)
1 9
11 10
A11271
HINT: Each bolt length in indicated in the illustration. A: 49 mm (1.929 in.) B: 88 mm (3.465 in.) C: 144 mm (5.669 in.) 13. INSTALL REAR CRANKSHAFT OIL SEAL (See page EM-76 ) HINT: Wipe seal packing away from the contact surface of the cylinder block assembly and oil seal.
2002 ECHO (RM884U)
Author :
Date :
695
EM-82
A11270
14. INSTALL OIL STRAINER Install a new gasket, and oil strainer with the 2 nuts. Torque: 11 Nm (112 kgfcm, 8 ftlbf) 15. INSTALL OIL PAN (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the main bearing cap and oil pan. S Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. S Thoroughly clean all components to remove all the loose material. S Using a non-residue solvent, clean both sealing surfaces. NOTICE: Do not use a solvent which will affect the painted surfaces.
(b)
Apply seal packing to the oil pan as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent S Install a nozzle that has been cut to a 2.5 - 3.5 mm (0.098 - 0.138 in.) opening.
Seal Width 2.5 - 3.5 mm
A10465
HINT: Avoid applying an excessive amount to the surface. S Parts must be assembled within 3 minutes of application. Otherwise the material must be remove d and reapplied. S Immediately remove nozzle from the tube and reinstall cap.
(c)
16. 17.
Install the oil pan with the 9 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes. Torque: 9.0 Nm (92 kgfcm, 80 in.lbf) INSTALL OIL FILTER UNION Torque: 30 Nm (306 kgfcm, 21 ftlbf) INSTALL OIL FILTER (See page LU-2 )
A11269
2002 ECHO (RM884U)
Author :
Date :
696
EM-83
Adhesive
18. (a)
(b)
INSTALL ENGINE COOLANT DRAIN UNION Apply adhesive to 2 or 3 threads. Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Install the drain union. Torque: 35 Nm (350 kgfcm, 25 ftlbf)
P12477
HINT: After applying the specified torque, rotate the drain union clockwise until its drain port is facing downward. 19. INSTALL KNOCK SENSOR Torque: 39 Nm (400 kgfcm, 29 ftlbf) 20. INSTALL OIL PRESSURE SWITCH (See page LU-1 ) 21. INSTALL THERMOSTAT (See page CO-10 )
22. 23. 24. 25. 26.

A10451
INSTALL WATER BYPASS PIPE Torque: 9.0 Nm (92 kgfcm, 80 in.lbf) INSTALL ENGINE WIRE INSTALL CYLINDER HEAD (See page EM-44 ) INSTALL TIMING SPROCKETS AND TIMING CHAIN (See page EM-20 ) REMOVE ENGINE STAND
M/T
27.
M/T: INSTALL FLYWHEEL
6 3 5
1 4 2
A09012
HINT: The flywheel bolts are tightened in 2 progressive steps, (a) and (c). (a) Install and uniformly tighten the 6 mounting bolts, in several passes, in the sequence shown. Torque: 49 Nm (500 kgfcm, 36 ftlbf) (b) Mark the flywheel bolt with paint. (c) Retighten the flywheel bolts by an additional 90. (d) Check that the painted mark in now at a 90 angle to (b).
2002 ECHO (RM884U)
Author :
Date :
697
EM-84
A/T
28. (a) (b)
A/T: INSTALL DRIVE PLATE Install the front spacer, drive plate and rear plate on the crankshaft. Apply adhesive to 2 or 3 threads of the mounting bolt end, Adhesive: Part No. 08833-00070, THREE BOND or equivalent
Adhesive
P08755
A/T 6 1 4 3 2 5
A09018
(c)
Install and uniformly tighten the 6 mounting bolts, in several passes, in the sequence shown. Torque: 88 Nm (890 kgfcm, 65 ftlbf)
2002 ECHO (RM884U)
Author :
Date :
698
EM-76
EM17E-01
REPLACEMENT
SST
1. (a)
REPLACE CONNECTING ROD BUSHINGS Using SST and a press, press out the bushing. SST 09222-30010
A01182
(b) (c)
Oil Hole
Align the oil hoses of a new bushing and the connecting rod. Using SST and a press, press in the bushing. SST 09222-30010
A01184
(d)
Using a pin hole grinder, hone the bushing to obtain the standard specified clearance (See page EM-70 ) between the bushing and piston pin.
EM6535
(e)
Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.
A01443
Cut Position
2. REPLACE CRANKSHAFT REAR OIL SEAL If rear oil seal is installed to cylinder block (a) Using a knife cut off the oil seal lip. (b) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip.
A12955
2002 ECHO (RM884U)
Author :
Date :
690
EM-77
SST
(c) (d)
Apply MP grease to a new oil seal lip. Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-15030, 09950-70010 (09951-07100)
A12956
2002 ECHO (RM884U)
Author :
Date :
691
EM-24
ENGINE MECHANICAL CYLINDER HEAD
CYLINDER HEAD
EM16H-01
COMPONENTS
PS Oil Pressure Switch Connector VSV for EVAP Connector MAF Sensor Connector
Generator PS Pump
Air Cleaner Cap
Air Filter Generator Wire

7.5 (76, 66 in.lbf)
Generator Connector Air Cleaner Case A/C Compressor

7.5 (76, 66 in.lbf)
Liquid Tube Accelerator Cable

52 (530, 38) 45 (459, 33)
RH Engine Mounting Insulator
52 (530, 38)
Front Exhaust Pipe RH Engine Under Cover
z Gasket
62 (630, 46)
A11277
Nm (kgfcm, ftlbf) : Specified torque z Non-reusable part
2002 ECHO (RM884U)
Author :
Date :
638
EM-25
Wiper Arm
Wiper Arm Head Cap
Cowl Top Ventilator Lower RH

20 (205, 15)
Hood to Cowl Top Seal Cowl Top Ventilator Lower LH
5.4 (55, 48 in.lbf)
Wiper Motor and Wiper Link Assembly
7.8 (80, 69 in.lbf)
Outer Front Cowl TOp Panel
Nm (kgfcm, ftlbf)
2002 ECHO (RM884U)
: Specified torque
A11283
Author :
Date :
639
EM-26
No. 2 Cylinder Head Cover Heat Insulator

8.0 (82, 71 in.lbf)
Engine Wire
Exhaust Manifold
27 (280, 20)
Ignition Coil (w/ Igniter) z Gasket PCV Valve
37 (377, 27)
Exhaust Manifold Stay ECT Sensor Camshaft Position Sensor Connector z Gasket
Camshaft Position Sensor
Oil Filter Oil Dipstick and Oil Guide z O-Ring Oil Control Valve Engine Wire
z Gasket
z Gasket
Throttle Body
Intake Manifold
30 (300, 22)

2002 ECHO (RM884U)
A11248
Author :
Date :
640
EM-27
Cylinder Head Cover
RH Engine Mounting Bracket
PCV Hose
55 (561, 41)
Timing Chain Cover
No. 1 Camshaft Bearing Cap Camshaft Timing Sprocket
No. 2 Camshaft Bearing Cap z Gasket
Spring Retainer
Valve Lifter Keeper
Crankshaft Pulley Pin Spring Seat Valve Timing Controller Assembly Valve Spring Oil Seal Valve Guide Bushing
Valve
128 (1,300, 94)
Front Crankshaft Oil Seal

15 (150, 11)
1st: 29.4 (300, 22) 2nd: 90 3rd: 90 (See page EM-44 ) z Gasket Cylinder Head
11 (110, 8)
z Gasket
Water Pump Pulley Water Pump
Chain Tensioner Slipper
Timing Chain Tensioner
z O-Ring Injector
Tinming Chain Nm (kgfcm, ftlbf) : Specified torque z Non-reusable part

2002 ECHO (RM884U)
z O-Ring Chain Vibration Damper

A11275
Author :
Date :
641
EM-31
EM16J-01
DISASSEMBLY
1. REMOVE VALVE LIFTERS HINT: Arrange the valve lifters in the correct order.
2. (a)
SST
(b) (c) (d)

A01061
REMOVE VALVES Using SST, compress the valve spring and remove the 2 keepers. SST 09202-70020 (09202-00010) Remove the spring retainer. Remove the valve spring. Remove the valve.
(e)
Using needle-nose pliers, remove the oil seal.
A01062
(f)
Using compressed air and a magnetic finger, remove the spring seat by blowing air.
HINT: Arrange the valves, valve springs, spring seats and spring retainers in the correct order.
A01064
2002 ECHO (RM884U)
Author :
Date :
645
EM-32
EM16K-01
INSPECTION
1. (a) CLEAN TOP SURFACES OF PISTONS AND CYLINDER BLOCK Turn the crankshaft, and bring each piston to top dead center (TDC). Using a gasket scraper, remove all the carbon from the piston surface.
A01076
(b)
Using a gasket scraper, remove all the gasket material from the cylinder block surface. (c) Using compressed air, blow carbon and oil from the bolt holes. CAUTION: Protect your eyes when using high pressure compressed air.
A01077
2. REMOVE GASKET MATERIAL Using a gasket scraper, remove all the gasket material from the cylinder block contact surface. NOTICE: Be careful not to scratch the cylinder block contact surface.
A01068
3. CLEAN COMBUSTION CHAMBERS Using a wire brush, remove all the carbon from the combustion chambers. NOTICE: Be careful not to scratch the cylinder block contact surface.
A01069
4. CLEAN CYLINDER HEAD Using a soft brush and solvent, thoroughly clean the cylinder head.
A01070
2002 ECHO (RM884U)
Author :
Date :
646
EM-33
5. CLEAN VALVE GUIDE BUSHINGS Using a valve guide bushing brush and solvent, clean all the guide bushings.
A01479
6. INSPECT FOR FLATNESS Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder block and the manifolds for warpage. Maximum warpage: 0.05 mm (0.0020 in.) If warpage is greater than maximum, replace the cylinder head.
Cylinder Block Side
Intake Manifold Side
Exhaust Manifold Side
A01075
7. INSPECT FOR CRACKS Using a dye penetrant, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head.
A01071
8. (a) (b)
CLEAN VALVES Using a gasket scraper, chip off any carbon from the valve head. Using a wire brush, thoroughly clean the valve.
EM0580
2002 ECHO (RM884U)
Author :
Date :
647
EM-34
9. (a)
INSPECT VALVE STEMS AND GUIDE BUSHINGS Using a caliper gauge, measure the inside diameter of the guide bushing. Bushing inside diameter: 5.010 - 5.030 mm (0.19724 - 0.19803 in.)
A01478
(b)
Z00052
Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: Intake 4.970 - 4.985 mm (0.19567 - 0.19626 in.) Exhaust 4.965 - 4.980 mm (0.19547 - 0.19606 in.) (c) Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Standard oil clearance: Intake 0.025 - 0.060 mm (0.00098 - 0.00236 in.) Exhaust 0.030 - 0.065 mm (0.00118 - 0.00256 in.) Maximum oil clearance: Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in.) If the clearance is greater than maximum, replace the valve and guide bushing.
10. (a)
INSPECT VALVES Check the valve is ground to the correct valve face angle. Valve face angle: 44.5 (b) Check that the surface of the valve for wear. If the valve face is worn, replace the valve.
44.5
EM0180
(c)
Check the valve head margin thickness. Standard margin thickness: 1.00 - 1.15 mm (0.0393 - 0.0453 in.) Minimum margin thickness: 0.7 mm (0.028 in.) If the margin thickness is less than minimum, replace the valve.
Margin Thickness
EM0181
2002 ECHO (RM884U)
Author :
Date :
648
EM-35
(d)
Overall Length
EM2534
45 Carbide Cutter
Residuary Width
Check the valve overall length. Standard overall length: Intake 89.25 mm (3.5138 in.) Exhaust 87.90 mm (3.4606 in.) Minimum overall length: Intake 88.75 mm (3.4941 in.) Exhaust 87.40 mm (3.4409 in.) If the overall length is less than minimum, replace the valve. (e) Check the surface of the valve stem tip for wear. If the valve stem tip is worn, replace the valve. 11. INSPECT AND CLEAN VALVE SEATS (a) Using a 45 carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats.
Resurface
A01073
(b)
Width
A01074
20 45
Check the valve seating position. Apply a light coat of prussian blue (or white lead) to the valve face. Lightly press the valve against the seat. Do not rotate valve. (c) Check the valve face and seat for the following: S If blue appears 360 around the face, the valve is concentric. If not, replace the valve. S If blue appears 360 around the valve seat, the guide and face are concentric. If not, resurface the seat. S Check that the seat contact is in the middle of the valve face with the following width: 1.0 - 1.4 mm (0.039 - 0.055 in.) If not, correct the valve seats as follows: (1) If the seating is too high on the valve face, use 20 and 45 cutters to correct the seat.
1.0 - 1.4 mm
EM0185
75 45
(2)
If the seating is too low on the valve face, use 75 and 45 cutters to correct the seat.
1.0 - 1.4 mm 2002 ECHO (RM884U)
EM0186
Author :
Date :
649
EM-36
(d) (e)
Hand-lap the valve and valve seat with an abrasive compound. After hand-lapping, clean the valve and valve seat.
A01072
Deviation
INSPECT VALVE SPRINGS Using a steel square, measure the deviation of the valve spring. Maximum deviation: 1.6 mm (0.063 in.) Maximum angle (reference): 2 If the deviation is greater than maximum, replace the valve spring.
EM0988
12. (a)
(b)
Using vernier calipers, measure the free length of the valve spring. Free length: 45.1 mm (1.776 in.) If the free length is not as specified, replace the valve spring.
EM0801
(c)
EM0281
Using a spring tester, measure the tension of the valve spring at the specified installed length. Installed tension: 149 - 165 N (15.2 - 16.8 kgf, 33.5 - 37.1 lbf) at 32.5 mm (1.280 in.) Maximum working tension: 286 - 316 N (29.1 - 32.2 kgf, 64.2 - 71.0 lbf at 23.9 mm (0.941 in.) If the installed tension is not as specified, replace the valve spring 13. INSPECT CAMSHAFT FOR RUNOUT (a) Place the camshaft on V-blocks. (b) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than maximum, replace the camshaft.
EM1628
2002 ECHO (RM884U)
Author :
Date :
650
EM-37
EM2011
14. INSPECT CAM LOBES Using a micrometer, measure the cam lobe height. Standard cam lobe height: Intake 44.617 - 44.717 mm (1.75657 - 1.76051 in.) Exhaust 44.666 - 44.766 mm (1.75850 - 1.76244 in.) Minimum cam lobe height: Intake 44.47 mm (1.7508 in.) Exhaust 44.52 mm (1.7528 in.) If the cam lobe height is less than minimum, replace the camshaft. 15. INSPECT CAMSHAFT JOURNALS Using a micrometer, measure the journal diameter. No.1 journal diameter: 34.449 - 34.465 mm (1.35626 - 1.35689 in.) Others journal diameter: 22.949 - 22.965 mm (0.90350 - 0.90413 in.) If the journal diameter is not as specified, check the oil clearance.
EM2538
Plastigage
16. (a) (b) (c)
INSPECT CAMSHAFT JOURNAL CLEARANCE Clean the bearing caps and camshaft journals. Place the camshafts on the cylinder head. Lay a strip of Plastigage across each of the camshaft journal.
A01452
Install the bearing caps (See page EM-44 ). Torque: No.1 23 Nm (235 kgfcm, 17 ftlbf) No.2 12.7 Nm (130 kgfcm, 10 ftlbf) NOTICE: Do not turn the camshaft. (e) Remove the bearing caps.
A12943
(d)
(f)
A01453
Measure the plastigage at its widest point. Standard oil clearance: 0.040 - 0.095 mm (0.00157 - 0.00374 in.) Maximum oil clearance: 0.115 mm (0.00453 in.) If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. (g) Completely remove the Plastigage. (h) Remove the camshafts.
Author : Date : 651
2002 ECHO (RM884U)
EM-38
17. (a) (b)
A01455
INSPECT CAMSHAFT THRUST CLEARANCE Install the camshafts (See page EM-44 ). Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.040 - 0.095 mm (0.0016 - 0.0037 in.) Maximum thrust clearance: 0.11 mm (0.0043 in.) If the thrust clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. (c) Remove the camshafts.
18. (a)
INSPECT VALVE LIFTERS AND LIFTER BORES Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Lifter bore diameter: 31.000 - 31.025 mm (1.22047 - 1.22145 in.)
A01080
(b)
P16860
Using a micrometer, measure the lifter diameter. Lifter diameter: 30.966 - 30.976 mm (1.21913 - 1.21953 in.) (c) Subtract the lifter diameter measurement from the lifter bore diameter measurement. Standard oil clearance: 0.024 - 0.059 mm (0.00094 - 0.00232 in.) Maximum oil clearance: 0.1 mm (0.004 in.) If the oil clearance is greater than maximum, replace the lifter. If necessary, replace the cylinder head.
2002 ECHO (RM884U)
Author :
Date :
652
EM-39
19. INSPECT INTAKE MANIFOLD Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.10 mm (0.0039 in.) If warpage is greater than maximum, replace the manifold.
A01078
20. INSPECT EXHAUST MANIFOLD Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.70 mm (0.0276 in.) If warpage is greater than maximum, replace the manifold.
A01079
2002 ECHO (RM884U)
Author :
Date :
653
EM-44
EM16N-01
INSTALLATION
HINT:
S S S
Thoroughly clean all parts to be assembled. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. Replace all gaskets and oil seals with new ones.
Lod No.
1. (a)
PLACE CYLINDER HEAD ON CYLINDER BLOCK Place a new cylinder head gasket on the cylinder block surface with the Lod No. stamp upward. NOTICE: Be careful of the installation direction. (b) Place the cylinder head quietly in order not to damage the gasket with the bottom part of the head.
A11249
10
7
A11228
2. INSTALL CYLINDER HEAD BOLTS HINT: S The cylinder head bolts are tightened in 2 progressive steps (steps (b) and (d)). S If any cylinder head bolt is broken or deformed, replace it. (a) Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts. (b) Using a 8 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts and plate washers, in several passes, in the sequence shown. Torque: 29.4 Nm (300 kgfcm, 22 ftlbf) If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.
90 Front
90
(c) (d) (e) (f)
Mark the front of the cylinder head bolt with paint. Retighten the cylinder head bolts by 90 and 90 in the numerical order shown. Check that the paint mark is now at a 180 angle to the front. Install the bolt holding the water bypass pipe to the cylinder head. Torque: 9.0 Nm (92 kgfcm, 80 in.lbf)
A12126
2002 ECHO (RM884U)
Author :
Date :
658
EM-45
(g) (h)
Connect the upper radiator hose to the water hose unions. Connect the heater hose to the water hose unions.
No.1 Cam Lobe
3. (a)
INSTALL CAMSHAFTS Place the 2 camshafts on the cylinder head with the No.1 cam lobes facing as shown the illustration.
A12945
(b) Install the bearing caps in their proper locations. HINT: No. 2 camshaft bearing cap has a number and front mark. (c) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
A12946
(d)
7 3 1 5 9 9 9
A12943
Install and uniformly tighten the 19 bearing cap bolts. After tightening the No.1 camshaft bearing cap, tighten then in several passes, in the sequence shown. Torque: No. 1 23 Nm (235 kgfcm, 17 ftlbf) No. 2 12.7 Nm (130 kgfcm, 10 ftlbf) 4. INSTALL VALVE TIMING CONTROLLER ASSEMBLY AND CAMSHAFT TIMING SPROCKET (a) Apply engine oil in the rage from the tip of the intake camshaft to 16 mm from that tip. (b) Align the timing mark on the value timing controller assembly with the knock pin, and install the value timing controller assembly to the camshaft. NOTICE: Do not push valve timing controller assembly to the camshaft forcibly when installing it. (c) Align the knock pin hole in the camshaft timing sprocket with the knock pin of the camshaft, and install the sprocket to the camshaft. (d) Temporarily install the timing sprocket bolt.
Author : Date : 659
2002 ECHO (RM884U)
EM-46
(e)
5. 6. 7. 8. 9. 10. 11. 12.
Hold the hexagon head portion of the camshaft with a wrench, and install the bolt. Torque: 64 Nm (650 kgfcm, 47 ftlbf) CHECK AND ADJUST VALVE CLEARANCE (See page EM-5 ) INSTALL CYLINDER HEAD COVER (See page EM-20 ) INSTALL CAMSHAFT TIMING SPROCKETS (See page EM-20 ) INSTALL OIL FILTER CAP INSTALL PCV VALVE INSTALL ECT SENSOR (See page SF-54 ) INSTALL CAMSHAFT POSITION SENSOR (See page IG-10 ) INSTALL TIMING CHAIN COVER (See page EM-20 )
13. (a)
(b) (c)
A11264
INSTALL INTAKE MANIFOLD Install a new gasket, the intake manifold and 2 brackets with the 2 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes. Torque: 30 Nm (300 kgfcm, 22 ftlbf) Connect the EVAP hose for ORVR. Connect the brake booster vacuum hose.
14. (a) (b) (c) (d) (e) (f) 15. 16. 17. 18.
A11265
CONNECT ENGINE WIRE TO CYLINDER HEAD Install the engine wire protector to the 2 brackets on the intake manifold with the 2 bolts. Connect the ECT sensor connector. Connect the camshaft position sensor connector. Connect the oil control valve connector. Connect the 4 injector connectors. Connect the 2 ground wire. INSTALL THROTTLE BODY (See page SF-36 ) INSTALL PCV HOSES INSTALL SPARK PLUGS (See page IG-1 ) INSTALL IGNITION COILS (See page IG-7 )
2002 ECHO (RM884U)
Author :
Date :
660
EM-47
19. (a)
(b)
INSTALL EXHAUST MANIFOLD Install a new gasket and the exhaust manifold with the 3 bolts 2 nuts. Uniformly tighten the nuts in several passes. Torque: 27 Nm (275 kgfcm, 20 ftlbf) Install the upper heat insulator with the 4 bolts. Torque: 8.0 Nm (82 kgfcm, 71 in.lbf)
A11227
20. INSTALL EXHAUST MANIFOLD STAY Install the manifold stay with the 3 bolts. Alternately tighten the bolts. Torque: 37 Nm (377 kgfcm, 27 ftlbf)
A11226
A11263
CONNECT FRONT EXHAUST PIPE TO EXHAUST MANIFOLD (a) Place a new gasket to the exhaust manifold. (b) Install the 2 bolts and 2 springs holding the front exhaust pipe to the exhaust manifold. Torque: 62 Nm (630 kgfcm, 46 ftlbf) 22. CONNECT ACCELERATOR CABLE 23. INSTALL AIR CLEANER ASSEMBLY 24. INSTALL GENERATOR AND DRIVE BELT (See page CH-17 ) 25. INSTALL WATER FILLER Install the water filler with the 2 bolts. Torque: 7.5 Nm (76 kgfcm, 66 in.lbf) 26. FILL WITH ENGINE COOLANT 27. START ENGINE AND CHECK FOR LEAKS 28. RECHECK ENGINE COOLANT LEVEL AND OIL LEVEL
21.
2002 ECHO (RM884U)
Author :
Date :
661
EM-42
EM16M-01
REASSEMBLY
HINT:
S S S
Thoroughly clean all parts to be assembled. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. Replace oil seals with new ones.
15 mm
18 mm
1. INSTALL WATER HOSE UNIONS HINT: When using a new cylinder head, water hose unions must be installed. (a) Mark the standard position away from the edge, onto the water hose union.
For Radiator Hose For Water Bypass Hose

A11230
(b)
Adhesive
Apply adhesive to the water hose union hole of the cylinder head. Adhesive: Part No.08833-00070, THREE BOND 1324 or equivalent
A11231
(c)
B
A
A11232
Using a press, press in a new water hose union until there is protruding from the cylinder head. Standard protrusion: A 29 mm (1.14 in.) B 44 mm (1.73 in.) NOTICE: Avoid pressing a new water hose union in too far by measuring the amount of protrusion while pressing.
SST
2. (a)
INSTALL VALVES Using SST, push in a new oil seal. SST 09201-41020
A01063
2002 ECHO (RM884U)
Author :
Date :
656
EM-43
Intake Mark NOK
Exhaust
HINT: The intake valve oil seal is light brown and the exhaust valve oil seal is gray. NOTICE: Pay much attention assembling the oil seal for intake and exhaust. Assembling the wrong one may cause a failure.
Gray Surface Light Brown Surface

S05923
(b)
Install the valve (1), spring (2), valve spring (3), and spring retainer (4).
(1) (3) (4) (2)

A01065
(c)
Using SST, compress the valve spring and place the 2 keepers around the valve stem. SST 09202-70020 (09202-00010)
SST
A01061
(d)
Using a plastic-faced hammer and the valve stem (not in use) tip wound with vinyl tape, lightly tap the valve stem tip to ensure a proper fit. NOTICE: Be careful not to damage the valve stem tip. 3. INSTALL VALVE LIFTERS (a) Install the valve lifter. (b) Check that the valve lifter rotates smoothly by hand.
A07307
2002 ECHO (RM884U)
Author :
Date :
657
EM-28
EM16I-01
REMOVAL
1. 2. (a) (b) 3. 4. 5. 6. DRAIN ENGINE COOLANT REMOVE WATER FILLER Disconnect the No. 3 radiator hose. Remove the 2 bolts and water filler. REMOVE OUTER FRONT COWL TOP PANEL (See page BO-31 ) REMOVE DRIVE BELT AND ALTERNATOR (See page CH-7 ) REMOVE AIR CLEANER ASSEMBLY DISCONNECT ACCELERATOR CABLE
7. (a) (b)
DISCONNECT CENTER EXHAUST PIPE FROM EXHAUST MANIFOLD Remove the 2 bolts and 2 springs holding the front exhaust pipe to the exhaust manifold. Remove the gasket.
A11263
8. REMOVE EXHAUST MANIFOLD STAY Remove the 3 bolts and exhaust manifold stay.
A11226
9. (a) (b) 10. 11. 12. 13.

A11227
REMOVE EXHAUST MANIFOLD Remove the 4 bolts and upper heat insulator. Remove the 3 bolts 2 nuts, exhaust manifold and gasket. REMOVE IGNITION COIL (See page IG-5 ) REMOVE SPARK PLUGS (See page IG-1 ) REMOVE PCV HOSES REMOVE THROTTLE BODY (See page SF-34 )
2002 ECHO (RM884U)
Author :
Date :
642
EM-29
14. (a) (b) (c) (d) (e) (f)

A11265
DISCONNECT ENGINE WIRE FROM CYLINDER HEAD Disconnect the ECT sensor connector Disconnect the camshaft position sensor connector Disconnect the oil control valve connector. Disconnect the 4 injector connectors. Disconnect the 2 ground wires Remove the 2 nuts, and disconnect the engine wire protector from the 2 brackets on the intake manifold.
A11264
15. (a) (b) (c) 16. 17. 18. 19. 20. 21. 22. 23. 24.
REMOVE INTAKE MANIFOLD Disconnect the EVAP hose for ORVR Disconnect the brake booster vacuum hose Remove the 3 bolts, 2 nuts, intake manifold and gasket. REMOVE CAMSHAFT POSITION SENSOR REMOVE ECT SENSOR REMOVE OIL CONTROL VALVE REMOVE PCV VALVE REMOVE OIL FILLER CAP REMOVE HEAD COVER (See page EM-15 ) REMOVE INJECTOR (See page SF-20 ) REMOVE TIMING CHAIN COVER (See page EM-15 ) REMOVE CAMSHAFT TIMING SPROCKET AND VALVE TIMING CONTROL ASSEMBLY Hold the hexagonal head portion of the camshaft with a wrench, and remove the 2 bolts and timing sprocket and valve timing controller assembly. NOTICE: S Be careful not to damage the cylinder head and valve lifter with the wrench. S Do not disassembly the valve timing controller assembly.
3 3
A12943
25. REMOVE CAMSHAFTS Uniformly loosen and remove the 19 bearing cap bolts, in several passes, in the sequence shown, and remove the 9 bearing caps, intake and exhaust camshafts. 26. REMOVE CYLINDER HEAD (a) Disconnect the upper radiator hose from the water hose union (b) Disconnect the heater water hose from the water hose union
2002 ECHO (RM884U)
Author :
Date :
643
EM-30
(c)
3 7 9 6 2
10
4
A11228
Using a 8 mm bi-hexagon wrench, uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown. Remove the 10 cylinder head bolts and plate washers. NOTICE: Head warpage or cracking could result from removing bolts in an incorrect order. (d) Remove the bolt holding the water bypass pipe to the cylinder head. (e) Lift the cylinder head from the dowels on the cylinder block and replace the cylinder head on wooden blocks on a bench.
A12944
HINT: If the cylinder head is difficult to lift of, pry between the cylinder head and cylinder block with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
2002 ECHO (RM884U)
Author :
Date :
644
EM-40
EM16L-01
80 - 100C
REPLACEMENT
REPLACE VALVE GUIDE BUSHINGS (a) Gradually heat the cylinder head to 80 - 100C (176 212 F).
A01067
(b)
SST
Using SST and a hammer, tap out the guide bushing. SST 09201-01055, 09950-70010 (09951-07100)
A01066
(c)
Using a caliper gauge, measure the bushing bore diameter of the cylinder head.
A01445
Both intake and exhaust Bushing bore diameter mm (in.) 9.685 - 9.706 (0.38130 - 0.38213) 9.735 - 9.756 (0.38327 - 0.38493) Bushing size Use STD Use O/S 0.05
(d) Select the new guide bushing (STD or O/S 0.05). If the bushing bore diameter of the cylinder head is greater than 9.706 mm (0.38213 in.), machine the bushing bore to the following dimension: 9.735 - 9.756 mm (0.38327 - 0.38493 in.) If the bushing bore diameter of the cylinder head is greater than 9.756 mm (0.38493 in.), replace the cylinder head. (e) Gradually heat the cylinder head to 80 - 100C (176 212 F). (f) Using SST and a hammer, tap in a new guide bushing to the specified protrusion height. SST 09201-01055, 09950-70010 (09951-07100) Protrusion height: 9.0 - 9.4 mm (0.354 - 0.370 in.)
SST
A01446
2002 ECHO (RM884U)
Author :
Date :
654
EM-41
(g)
Using a sharp 5 mm reamer, ream the guide bushing to obtain the standard specified clearance (See page EM-32 ) between the guide bushing and valve stem.
A01447
2002 ECHO (RM884U)
Author :
Date :
655
EM-48
ENGINE MECHANICAL ENGINE UNIT
ENGINE UNIT
EM178-01
COMPONENTS
VSV for EVAP Connector MAF Sensor Connector
Washer Hose Hood Air Cleaner Cap
Air Filter
7.5 (76, 66 in.lbf)
Air Cleaner Case

7.5 (76, 66 in.lbf)
Accelerator Cable Battery Clamp
Battery LH Engine Under Cover Battery Tray
RH Engine Under Cover
Nm (kgfcm, ftlbf)
: Specified torque
A11278
2002 ECHO (RM884U)
Author :
Date :
662
EM-49
PS Oil Pressure Switch Connector
PS Pump Generator Upper Radiator Support
Generator Wire
Horn Connector Generator Connector Radiator Cover

25 (250, 18)
Radiator Reservoir Hose
Radiator Support Cushion
Radiator Assembly A/C Compressor Grommet
Lower Radiator Hose
Liquid Tube
45 (459, 32)
52 (530, 38)
Fuel Tube
J/B Cover
Oil Cooler Hose for A/T

52 (530, 38)
Brake Booster Vacuum Hose Heater Hose Fuel Tube Clamp
Fusible Link
Nm (kgfcm, ftlbf)
: Specified torque
A11279
2002 ECHO (RM884U)
Author :
Date :
663
EM-50
Glove Compartment Door
ECM
Cover
B07685
2002 ECHO (RM884U)
Author :
Date :
664
EM-51
Wiper Arm
Wiper Arm Head Cap
Cowl Top Ventilator Lower RH

20 (205, 15)
Hood to Cowl Top Seal Cowl Top Ventilator Lower LH
5.4 (55, 48 in.lbf)
Wiper Motor and Wiper Link Assembly
7.8 (80, 69 in.lbf)
Outer Front Cowl TOp Panel
Nm (kgfcm, ftlbf)
2002 ECHO (RM884U)
: Specified torque
A11283
Author :
Date :
665
EM-52
Rear Engine Mounting Insulator Rear Engine Mounting Bracket Suspension Member
A/T: Transmission Control Cable
49 (500, 36)
M/T: Transmission Control Cable Clutch Release Cylinder

32 (330, 24)
RH Drive Shaft RH Engine Under Cover
LH Drive Shaft
z Gasket Center Brace
LH Engine Under Cover
z Gasket
Nm (kgfcm, ftlbf)
: Specified torque
62 (630, 46)
Front Exhaust Pipe

A11280
z Non-reusable part
2002 ECHO (RM884U)
Author :
Date :
666
EM-57
INSTALLATION
1. ASSEMBLY ENGINE AND TRANSAXLE (M/T: See page MX-8 ) (A/T: See page AX-33 ) INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN VEHICLE Attach the engine sling device to the engine hangers.
EM17A-01
2. (a)
(b) (c)
Slowly lower the vehicle, and raise the engine into the engine compartment. Keep the engine level, and align RH and LH mountings with the body bracket.
A11267
(d)
A A B A B
A11221
(e)
Install the RH engine mounting insulator with the 5 bolts and nut. Torque: Bolt A 45 Nm (459 kgfcm, 33 ftlbf) Bolt B and nut 52 Nm (530 kgfcm, 38 ftlbf) Install the liquid tube with the bolt.
(f) 3. (a) (b)
Connect the LH engine mounting, and install the 2 bolts. Torque: 49 Nm (500 kgfcm, 36 ftlbf) INSTALL REAR ENGINE MOUNTING Install the rear engine mounting bracket with the 3 bolts. Torque: 49 Nm (500 kgfcm, 36 ftlbf) Temporarily install the rear engine mounting insulator with the through bolt and lock nut.
A11243
4.
5.
INSTALL SUSPENSION MEMBER (Manual steering: See page SR-43 ) (Power steering: See page SR-61 ) INSTALL DRIVE SHAFT (See page SA-24 )
A11518
2002 ECHO (RM884U)
Author :
Date :
671
EM-58
6. (a)
A11266
(b) (c) (d) 7. 8. (a)
INSTALL CENTER EXHAUST PIPE Install new 2 gaskets and center exhaust pipe with the 2 springs, pipe clamp and 3 bolts. Torque: Bolt A 62 Nm (630 kgfcm, 46 ftlbf) Bolt B 32 Nm (330 kgfcm, 24 ftlbf) Install the floor brace with the 2 bolts. Connect the connector for front heated oxygen sensor. Install the rear heated oxygen sensor. CONNECT PS PUMP TO ENGINE (See page SR-32 ) CONNECT ENGINE WIRE TO CABIN Push in the engine wire to the cabin.
(b) (c) (d)
Connect the 2 cowl wire connectors to the connectors on the bracket. Connect the 4 ECM connectors. Install the lower panel (See page BO-84 ).
A11281
9. (a) (b)
CONNECT ENGINE WIRE TO ENGINE COMPARTMENT Connect the positive cable to the positive terminal. Connect the connector to the fusible link.
A11239
(c) (d) 10.
Connect the cable clamp to the relay box. Connect the connector to the relay box. CONNECT TRANSAXLE CONTROL CABLE(S) TO TRANSAXLE
A11237
2002 ECHO (RM884U)
Author :
Date :
672
EM-59
11.
(a) (b)
M/T: CONNECT CLUTCH RELEASE CYLINDER TO TRANSAXLE Connect the clutch release cylinder with the 2 bolts. Torque: 12 Nm (120 kgfcm, 9 ftlbf) Connect the bracket to the transaxle with the bolt. Torque: 4.9 Nm (50 kgfcm, 43 in.lbf)
D08225
12. (a)
(b) 13. 14.

A11236
w/ A/C: CONNECT A/C COMPRESSOR TO ENGINE Connect the A/C compressor to the engine with the 4 bolts. Torque: 25 Nm (250 kgfcm, 18 ftlbf) Connect the A/C compressor connector. INSTALL RADIATOR ASSEMBLY (See page CO-23 ) INSTALL GENERATOR AND DRIVE BELT (See page CH-7 ) CONNECT TUBE, HOSE AND CONNECTOR Connect the heater hose to the water hose union on the cylinder head. Connect the brake booster vacuum hose. Connect the heater hose to the water bypass pipe. Connect the fuel tube to the fuel pipe on vehicle side. Install the fuel pipe clamp.
15. (a) (b) (c) (d) (e)

A11235
16. (a)
(b)
INSTALL AIR CLEANER CASE Install the air cleaner case and air cleaner inlet assembly with the 4 bolts. Torque: 7.5 Nm (76 kgfcm, 66 in.lbf) Install the air filter.
A11234
17. (a) (b) (c) (d) (e) (f) 18.
A11233
INSTALL AIR CLEANER CAP Connect the air cleaner hose to the throttle body with the hose clamp. Install the air cleaner cap to the air cleaner case. Connect the 2 clamps. Connect the 2 hose to the VSV for EVAP. Connect the PCV hose to the cylinder head. Connect the MAF sensor connector. CONNECT ACCELERATOR CABLE
2002 ECHO (RM884U)
Author :
Date :
673
EM-60
19. 20. 21. 22. 23. 24. 25. 26. 27.
INSTALL OUTER FRONT COWL TOP PANEL (See page BO-35 ) INSTALL ENGINE UNDER COVERS INSTALL HOOD INSTALL BATTERY AND TRAY FILL WITH ENGINE COOLANT FILL WITH ENGINE OIL FILL WITH TRANSAXLE OIL START ENGINE AND CHECK FOR LEAKS RECHECK ENGINE COOLANT AND OIL LEVELS
2002 ECHO (RM884U)
Author :
Date :
674
EM-53
EM179-01
REMOVAL
1. 2. 3. 4. 5. 6. 7. 8. REMOVE BATTERY AND TRAY REMOVE HOOD REMOVE OUTER FRONT COWL TOP PANEL (See page BO-32 ) REMOVE ENGINE UNDER COVERS DRAIN ENGINE COOLANT DRAIN ENGINE OIL DRAIN TRANSAXLE OIL DISCONNECT ACCELERATOR CABLE
9. (a) (b) (c) (d) (e)

A11233
(f) 10. (a) (b)
REMOVE AIR CLEANER CAP Disconnect the MAF sensor connector. Disconnect the PCV hose from the cylinder head. Disconnect the 2 hose from the VSV for EVAP. Disconnect the 2 clamps, and disconnect the air cleaner cap from the air cleaner case. Loosen the hose clamp, and disconnect the air cleaner hose from the throttle body. Remove the air cleaner cap and air cleaner hose assembly. REMOVE AIR CLEANER CASE Remove the air filter. Remove the 4 bolts and air cleaner case and air cleaner inlet assembly.
A11234
11. (a) (b) (c) (d) (e) 12.

A11235
DISCONNECT TUBE, HOSES AND CONNECTORS Remove the fuel pipe clamp. Disconnect the fuel tube from fuel pipe on vehicle side. Disconnect the heater hose from water bypass pipe. Disconnect the brake booster vacuum hose from pipe. Disconnect the heater hose from water hose union on cylinder head. REMOVE DRIVE BELT AND GENERATOR (See page CH-7 )
2002 ECHO (RM884U)
Author :
Date :
667
EM-54
13.
REMOVE RADIATOR ASSEMBLY (See page CO-16 )
w/ A/C
14. (a) (b)
w/ A/C: DISCONNECT A/C COMPRESSOR FROM ENGINE Disconnect the A/C compressor connector. Remove the 4 bolts, and disconnect the A/C compressor from the engine.
HINT: Suspend the A/C compressor securely.

A11236
M/T
15.
(a) (b) 16.

D08225
M/T: DISCONNECT CLUTCH RELEASE CYLINDER FROM TRANSAXLE Remove the bolt, and disconnect the bracket from the transaxle. Remove the 2 bolts, and disconnect the release cylinder from the transaxle. DISCONNECT TRANSAXLE CONTROL CABLE(S) FROM TRANSAXLE DISCONNECT ENGINE WIRE FROM ENGINE COMPARTMENT Disconnect the connector from the relay box. Disconnect the cable clamp from the relay box.
17. (a) (b)
A11237
(c) (d)
Disconnect the connector from the fusible link. Disconnect the positive cable from the positive terminal.
A11239
2002 ECHO (RM884U)
Author :
Date :
668
EM-55
18. (a) (b) (c)
DISCONNECT ENGINE WIRE FROM CABIN Remove the lower panel (See page BO-76 ). Disconnect the 4 ECM connectors. Disconnect the 2 cowl wire connectors from connectors on bracket.
A11281
(d) 19.
Pull out the engine wire from the cabin. DISCONNECT PS PUMP FROM ENGINE (See page SR-24 )
A11240
20. (a) (b) (c) (d) (e) 21. 22.
A11266
23. (a) (b) 24. (a) (b)
REMOVE CENTER EXHAUST PIPE Disconnect the rear heated oxygen sensor. Disconnect the connector for front heated oxygen sensor. Remove the 2 bolts and floor brace. Remove the 3 bolts, 2 springs and pipe clamp. Disconnect the 2 O-ring, and remove the center exhaust pipe and 2 gaskets. REMOVE DRIVE SHAFTS (See page SA-18 ) REMOVE SUSPENSION MEMBER (Manual steering: See page SR-35 ) (Power steering: See page SR-48 ) REMOVE REAR ENGINE MOUNTING Remove the through bolt, lock nut and rear engine mounting insulator. Remove the 2 bolts, nut and rear engine mounting bracket. ATTACH ENGINE SLING DEVICE TO ENGINE HANGERS Remove the bolt, and disconnect the condenser.
D05696
Install the 2 engine hangers in the correct direction. Engine hanger part No.: 12281-21010 Bolt part No.: 91512-B1016 2 pieces Torque: 38 Nm (388 kgfcm, 28 ftlbf) (c) Attach the engine sling device to the engine hangers. CAUTION: Do not attempt to hang the engine by hooking the chain to any other part.
2002 ECHO (RM884U)
Author :
Date :
669
EM-56
25. (a)
REMOVE ENGINE AND TRANSAXLE ASSEMBLY FROM VEHICLE Remove the 2 bolts, and disconnect the LH engine mounting.
A11243
(b) (c) (d)
Remove the 2 bolts and nut, and disconnect the RH engine mounting. Remove the bolt holding the liquid tube to the RH engine mounting insulator. Remove the 3 bolts and RH engine mounting insulator.
A11221
(e) Lift the engine out of the vehicle slowly and carefully. HINT: Make sure the engine is clear of steering gear assembly all wiring, hoses and cables (f) Place the engine and transaxle assembly on to the stand. 26. SEPARATE ENGINE AND TRANSAXLE (M/T: See page MX-4 ) (A/T: See page AX-29 )
A11267
2002 ECHO (RM884U)
Author :
Date :
670
EM-85
ENGINE MECHANICAL EXHAUST SYSTEM
EXHAUST SYSTEM
EM17G-01
COMPONENTS
Heat Insulator Heat Insulator O-Ring
Heat Insulator
Tailpipe
32 (330, 24)
O-Ring
O-Ring z Gasket
Heated Oxygen Sensor (Bank1 Sensor2)
Front Exhaust Pipe
z Gasket
Center Brace O-Ring

Heated Oxygen Sensor HINT: D Before installing oxygen sensor, twist sensor wire counterclockwise 3 and 1/2 turns. D After installing oxygen sensor, check that sensor wire is not twisted. If it is twisted, remove oxygen sensor and reinstall it.
A11282
62 (630, 46)
Heated Oxygen Sensor (Bank1 Sensor1)
2002 ECHO (RM884U)
Author :
Date :
699
EM-12
ENGINE MECHANICAL IDLE SPEED
IDLE SPEED
EM16B-01
INSPECTION
1. (a) (b) (c) (d) (e) (f) (g) (h) (i) INSTALL CONDITIONS Engine at normal operating temperature Air cleaner installed All pipes and hoses of air induction system connected All vacuum lines properly connected SFI system wiring connectors fully plugged All operating accessories switched OFF Ignition timing check correctly Transmission in neutral position Air conditioning switched OFF
TOYOTA Hand-Held Tester
DLC3
D08002
CONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL (a) Connect the TOYOTA hand-held tester or OBDII scan tool to the DLC3. (b) Please refer to the TOYOTA hand-held tester or OBDII scan tool operators manual for further details. 3. INSPECT IDLE SPEED (a) Race the engine at 2,500 rpm for approx. 90 seconds. (b) Check the idle speed. Idle speed (w/ Cooling fan OFF): M/T 650 50 rpm A/T 700 50 rpm If the idle speed is not as specified, check the IAC valve and air intake system. 4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL
2.
2002 ECHO (RM884U)
Author :
Date :
626
EM-1 1
ENGINE MECHANICAL IGNITION TIMING
IGNITION TIMING
EM16A-01
INSPECTION
1. WARM UP ENGINE Allow the engine to warm up to normal operating temperature.
TOYOTA Hand-Held Tester
2. (a) (b) 3.
CONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL Connect the TOYOTA hand-held tester or OBDII scan tool to the DLC3. Please refer to the TOYOTA hand-held tester or OBDII scan tool operators for further details. CONNECT TIMING LIGHT TO ENGINE
DLC3
D08002
Using a timing light, check the ignition timing. Ignition timing: 8 - 12 BTDC @ idle (Transmission in neutral position) 4. DISCONNECT TIMING LIGHT FROM ENGINE 5. DISCONNECT TOYOTA HAND- HELD TESTER OR OBDII SCAN TOOL
A11220
2002 ECHO (RM884U)
Author :
Date :
625
EM-13
ENGINE MECHANICAL TIMING CHAIN
TIMING CHAIN
EM173-01
COMPONENTS
Drive Belt PS Oil Pressure Switch Connector
Generator
Generator Wire
PS Pump
Generator Connector
25 (250, 18)
A/C Compressure
Liquid Tube
45 (459, 33) 52 (530, 38)
52 (530, 38)
RH Engine Under Cover
Nm (kgfcm, ftlbf) : Specified torque

A11276
2002 ECHO (RM884U)
Author :
Date :
627
EM-14
No. 2 Cylinder Head Cover RH Engine Mounting Bracket
Ignition Ciol (w/ Igniter) Timing Chain Cover Cylinder Head Cover
Pin Crankshaft Pulley

128 (1,300, 94)
PCV Hose Front Crankshaft Oil Seal z Gasket

15 (150, 11)
Chain Tensioner Slipper z Gasket
11 (110, 8)
Water Pump Pulley Water Pump z O-Ring
Timing Chain Tensioner
Tinming Chain z O-Ring

2002 ECHO (RM884U)
Chain Vibration Damper

A11273
Author :
Date :
628
EM-18
EM175-01
INSPECTION
123.2 mm
1. (a)
16 Links
P04776
INSPECT TIMING CHAIN AND TIMING SPROCKETS Using a vernier calipers, measure the length of 16 links with the chain dully stretched. Maximum chain elongation: 123.2 mm (4.850 in.) If the elongation is greater than maximum, replace the chain. HINT: Make the same measurements pulling at 3 or more places selected at random. (b) (c) Wrap the chain around the timing sprocket. Using a vernier calipers, measure the timing sprocket diameter with the chain. NOTICE: Vernier calipers must contact the chain rollers for measuring. Minimum sprocket diameter (w/ Chain): Camshaft 96.2 mm (3.787 in.) Crankshaft 50.5 mm (1.988 in.) If the diameter is less than minimum, replace the chain and sprockets.
EM2378
2.
INSPECT CHAIN TENSIONER SLIPPER AND VIBRATION DAMPER Measure the chain tensioner slipper and vibration damper wears. Maximum wear: 1.0 mm (0.039 in.) If the wear is greater than maximum, replace the slipper and/or damper.
Wear
A11259
Raise
3. (a) (b) (c)
Move
Lock
INSPECT CHAIN TENSIONER Check that the plunger moves smoothly when the ratchet pawl is raised with your finger. Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger.
A11223
2002 ECHO (RM884U)
Author :
Date :
632
EM-20
EM177-01
ATDC20
Mark Link
INSTALLATION
1. (a) INSTALL TIMING CHAIN After setting the crankshaft at ATDC40-140 , set cams of intake and exhaust timing sprockets at ATDC 20 and then the reset the crankshaft at ATDC 20 . Install the chain vibration damper with the 2 bolts. Torque: 9.0 Nm (92 kgfcm, 80 in.lbf) Align the match marks of timing chain mark plate (Yellow), camshaft timing sprocket, camshaft timing gear and crankshaft timing sprocket to install the timing chain as shown in the illustration.
(b)
Timing Mark
(c)
Mark Link
HINT: To prevent the exhaust camshaft from spring back turn it using a wrench and set it at the mark on a chain. (d) Install the chain tensioner slipper.
30 Timing Mark
A11224
2. (a)
(b)
(c)
A11225
(d) (e)
INSTALL CHAIN TENSIONER While rotating the lock plate of the tensioner up-ward, push in the plunger of the tensioner as shown in the illustration. While rotating the lock plate of the tensioner down-ward, insert a bar of 2.5 mm (0.098 in.) into the holes in the lock plate. Install the chain tensioner with the 2 bolts. Torque: 9.0 Nm (92 kgfcm, 80 in.lbf) Remove the bar from the chain tensioner. Check that the tension between the intake and exhaust camshaft timing sprocket.
2002 ECHO (RM884U)
Author :
Date :
634
EM-21
3. (a)
FIPG
FIPG
(b)
Seal Width: 4 - 5 mm
A11260
INSTALL TIMING CHAIN COVER AND WATER PUMP Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block. S Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. S Thoroughly clean all components to remove all the loose material. S Using a non-residue solvent, clean both sealing surfaces. Apply seal packing to the timing chain cover as shown in the illustration. Seal packing: Part No. 08826 - 00100 or equivalent S Install a nozzle that has been cut to a 4 - 5 mm (0.16 - 0.20 in.) opening. S FIPG shall be accumulated in the groove for FIPG to a depth of 2.5 mm (0.10 in.) or more.
HINT: Avoid applying an excessive amount to the surface. S Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. S Immediately remove nozzle from the tube and reinstall cap.
(c)
Seal Packing
Seal Packing Seal Width 4 - 5 mm
Apply seal packing to 4 locations as shown in the illustration. Seal packing: Part No. 08826 - 00080 or equivalent S Install a nozzle that has been cut to a 4 - 5 mm (0.16 - 0.20 in.) opening.
A11261
HINT: Avoid applying an excessive amount to the surface. S Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. S Immediately remove nozzle from the tube and reinstall cap. (d) Install 2 new O-rings to the cylinder block and oil pan No. 1.
2002 ECHO (RM884U)
Author :
Date :
635
EM-22
(e)
D F
B A A A
E G
A C
A11274
Install the timing chain cover, new O-ring and water pump with the 16 bolts and 3 nuts. Uniformly tighten the bolts and nut in several passes. Torque: Bolt A 11 Nm (113 kgfcm, 8 ftlbf) Bolt B 24 Nm (245 kgfcm, 18 ftlbf) Bolt C 11 Nm (113 kgfcm, 8 ftlbf) Bolt D 24 Nm (245 kgfcm, 18 ftlbf) Bolt E 11 Nm (113 kgfcm, 8 ftlbf) Nut F 24 Nm (245 kgfcm, 18 ftlbf) Nut G 11 Nm (113 kgfcm, 8 ftlbf) NOTICE: S Pay attention not to wrap the chain and slipper over the chain cover seal line. S After installing the chain cover, must install the mounting bracket and water pump within 15 minutes. HINT: Each bolt length in indicated in the illustration. A 20 mm (0.787 in.) B 30 mm (1.181 in.) C 35 mm (1.378 in.) D 20 - 14 mm (0.787 - 0.551 in.) E 35 mm (1.378 in.)
4. (a)
INSTALL RH ENGINE MOUNTING BRACKET Apply seal packing to threads of the mounting bolt. Seal packing: Part No. 08826 - 00080 or equivalent
A11258
HINT: Do not apply seal packing to 2 or 3 threads of the bolt end. (b) Install the mounting bracket with the 4 bolts. Torque: 55 Nm (561 kgfcm, 41 ftlbf) 5. INSTALL CRANKSHAFT POSITION SENSOR Torque: Bolt A 7.5 Nm (76 kgfcm, 66 in.lbf) Bolt B 11 Nm (113 kgfcm, 8 ftlbf) 6. INSTALL OIL CONTROL VALVE (See page EM-44 ) Torque: 8.0 Nm (82 kgfcm, 71 in.lbf)
2002 ECHO (RM884U)
Author :
Date :
636
EM-23
SST
SST
7. (a) (b) (c) (d)
INSTALL CRANKSHAFT PULLEY Clean the crankshaft pulley inside. Install the pin to the crankshaft. Align the hole in the crank pulley with the pin position and install the crank pulley. Using SST, install the pulley bolt. SST 09213-70010, 09330-00021 Torque: 128 Nm (1,300 kgfcm, 94 ftlbf)
A11262
Seal Packing
8. (a) (b)
B00301
9 7
4 10
1 11
3 8
5
A11222
(c) HINT: Part must be assembled within 3 minutes of application. Otherwise the material must be remove and reapplied. (d) Install the cylinder head cover and cable bracket with the 7 bolts, 2 seal washers and 2 nuts. Uniformly tighten the bolts and nuts, in the several passes, in the sequence shown. Torque: 10 Nm (100 kgfcm, 7 ftlbf) (e) Connect the 2 PCV hoses to the cylinder head cover. (f) Install the ignition coil (See page IG-7 ).
INSTALL CYLINDER HEAD COVER Remove any old packing (FIPG) material. Apply seal packing to 2 locations as shown in the illustration. Seal packing: Part No. 08826 - 00080 or equivalent Install the gasket to the cylinder head cover.
A A B A
9. (a)
(b)
B
A11221
10. 11. 12. 13. 14. 15.
INSTALL RH ENGINE MOUNTING INSULATOR Install the RH engine mounting insulator with the 5 bolts and nut. Torque: Bolt A 45 Nm (459 kgfcm, 33 ftlbf) Bolt B and nut 52 Nm (530 kgfcm, 38 ftlbf) w/ A/C: Install the liquid tube with the bolt. INSTALL PS PUMP (See page SR-32 ) INSTALL GENERATOR AND DRIVE BELT (See page CH-17 ) INSTALL RH ENGINE UNDER COVER INSTALL RH FRONT WHEEL FILL WITH ENGINE COOLANT START ENGINE AND CHECK FOR COOLANT LEAKS
2002 ECHO (RM884U)
Author :
Date :
637
EM-15
EM174-03
REMOVAL
1. 2. 3. 4. 5. DRAIN ENGINE COOLANT REMOVE RH FRONT WHEEL REMOVE RH ENGINE UNDER COVER REMOVE DRIVE BELT AND GENERATOR (See page CH-7 ) DISCONNECT PS PUMP FROM ENGINE (See page SR-24 )
6. REMOVE RH ENGINE MOUNTING INSULATOR (a) Set the jack to the engine. HINT: Place a wooden block between the jack and engine.
A01045
(b)
(c) 7. (a) (b) (c) (d)
A11221
w/ A/C: Remove the bolt holding the liquid tube to the RH engine mounting insulator. Remove the 5 bolts, nut and RH engine mounting insulator. REMOVE CYLINDER HEAD COVER Remove the 4 nuts and No.2 cylinder head cover. Remove the ignition coils (See page IG-6 ). Remove the 2 PCV hoses from the cylinder head cover. Remove the 7 bolts, 2 seal washers, 2 nuts, cylinder head cover and gasket.
A11222
8. (a)
SET NO.1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley, and align its groove with timing mark 0 of the timing chain cover.
A11244
2002 ECHO (RM884U)
Author :
Date :
629
EM-16
Timing Marks
(b)
Check that both timing marks on the camshaft timing sprocket and valve timing controller assembly are facing right up as shown in the illustration. If not, turn the crankshaft 1 revolution (360) and align the marks as above.
A11245
SST
9. (a) (b)
SST
REMOVE CRANKSHAFT PULLEY Using SST, remove the pulley bolt. SST 09213-70010, 09330-00021 Remove the crankshaft pulley and pin.
A11253
SST
HINT: If necessary, remove the pulley with SST. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
A11254
REMOVE CRANKSHAFT POSITION SENSOR (See page IG-12 ) 11. REMOVE RH ENGINE MOUNTING BRACKET Remove the 4 bolts and mounting bracket. 12. REMOVE WATER PUMP (See page CO-4 ) 13. REMOVE OIL CONTROL VALVE (See page EM-28 )
10.
A11258
14. (a) (b) (c)
A11255
REMOVE TIMING CHAIN COVER Remove the 13 bolts and nut. Using a torx wrench socket (E8), remove the stud bolt. Remove the timing chain cover by prying the portions between the cylinder head and cylinder block with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder head and cylinder block.
2002 ECHO (RM884U)
Author :
Date :
630
EM-17
(d)
Remove the 2 O-rings from the cylinder block and oil pan No.1. 15. REMOVE CHAIN TENSIONER Remove the 2 bolts and chain tensioner. 16. REMOVE CHAIN TENSIONER SLIPPER 17. REMOVE CHAIN VIBRATION DAMPER Remove the 2 bolts and damper. 18. REMOVE TIMING CHAIN
2002 ECHO (RM884U)
Author :
Date :
631
EM-19
EM176-01
REPLACEMENT
REPLACE CRANKSHAFT FRONT OIL SEAL (a) Using a knife, cut off the oil seal lip. (b) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip.
A11256
(c)
Using SST and a hammer, tap in the oil seal until its surface is flush with the timing chain cover edge. SST 09612-2201 1
SST
A11257
2002 ECHO (RM884U)
Author :
Date :
633
EM-5
ENGINE MECHANICAL VALVE CLEARANCE
VALVE CLEARANCE
EM169-01
ADJUSTMENT
HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE CYLINDER HEAD COVER (See page EM-15 )
2. (a)
SET NO.1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley, and align its groove with the timing mark 0 of the timing chain cover.
A11244
Timing Marks
(b)
Check that both timing marks on the camshaft timing sprocket and valve timing controller assembly are facing right upas shown in the illustration. If not, turn the crankshaft 1 revolution (360) and align the marks as above.
A11245
2 2
1 1
3. (a)
3 3
1 1
A11218
(b)
4 4 3 3
(c)
INSPECT VALVE CLEARANCE Check only the valves indicated. S Using a feeler gauge, measure the clearance between the valve lifter and camshaft. S Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): Intake 0.15 - 0.25 mm (0.006 - 0.010 in.) Exhaust 0.25 - 0.35 mm (0.010 - 0.014 in.) Turn the crankshaft 1 revolution (360) and align the mark as above. (See procedure in step 2) Check only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a))
4 4
2 2
A11219
2002 ECHO (RM884U)
Author :
Date :
619
EM-6
4. (a) (b) (c)
ADJUST VALVE CLEARANCE Set the No.1 cylinder to the TDC/compression (See procedure in step 2). Place matchmarks on the timing chain and camshaft timing sprockets. Rotate the crankshaft countercleckwise 40 from the TDC.
Matchmarks
A11252
(d) (e)
B12689
Remove the plug from the timing chain cover. Using driver to hold the stopper plate of tensioner above the chain tentioner service hole. (f) Turn the exhaust camshaft a little clockwise. (g) Remove the driver from the chain tensioner service hole to lower the stopper plate, then insert the bar of 2 - 3 mm (0.08 - 0.12 in.). NOTICE: S When the bar does not get inserted, turn the exhaust camshaft a little counterclockwise, then clockwise to insert it. S Fix the bar with tape or others so that it does not be dropped off. (h) Hold the hexagonal portion of camshaft with a wrench, and loosen the bolt for camshaft timing sprocket. (i) Remove the 19 bolts, No. 1 and No. 2 camshaft bearing caps. (j) Remove the bolt and valve timing sprocket with the chain. (k) Hold the hexagonal portion of the camshaft with a wrench, and remove the bolt and valve timing controller assembly with the chain. NOTICE: Do not disassembled the valve timing controller assembly. (l) Remove the intake and exhaust camshaft assembly. HINT: When disconnect the timing chain from the camshaft timing sprocket, holding the timing chain.
Valve Lifter
(m)
Tie the timing chain with a string as shown in the illustration. NOTICE: S Be careful not to drop anything inside the timing chain cover. S Do not allow the chain to come into contact with water or dust. (n) Remove the valve lifters.
A11247
2002 ECHO (RM884U)
Author :
Date :
620
EM-7
(o)
A01082
Determine the replacement valve lifter size according to these Formula or Charts: S Using a micrometer, measure the thickness of the removed lifter. S Calculate the thickness of a new lifter so the valve clearance comes within the specified value. T.......... Thickness of used lifter A......... Measured valve clearance N......... Thickness of new lifter Intake N = T + (A - 0.20 mm (0.008 in.)) Exhaust N = T + (A - 0.30 mm (0.012 in.)) S Select a new lifter with a thickness as close as possible to the calculated values.
HINT: Lifter are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.).
2002 ECHO (RM884U)
Author :
Date :
621
EM-8
2002 ECHO (RM884U)
Valve Lifter Selection Chart (Intake)
New lifter thickness Lifter No. 06 08 10 12 14 16 18 20 Thickness 5.060 (0.1992) 5.080 (0.2000) 5.100 (0.2008) 5.120 (0.2016) 5.140 (0.2024) 5.160 (0.2031) 5.180 (0.2039) 5.200 (0.2047) 5.220 (0.2055) 5.240 (0.2063) 5.260 (0.2071) 5.280 (0.2079) Lifter No. 30 32 34 36 38 40 42 44 46 48 50 52 Thickness 5.300 (0.2087) 5.320 (0.2094) 5.340 (0.2102) 5.360 (0.2110) 5.380 (0.2118) 5.400 (0.2126) 5.420 (0.2134) 5.440 (0.2142) 5.460 (0.2150) 5.480 (0.2157) 5.500 (0.2165) 5.520 (0.2173) Lifter No. 54 56 58 60 62 64 66 68 70 72 74
mm (in.) Thickness
Author : Date : Intake valve clearance (Cold): 0.15 - 0.25 mm (0.006 - 0.010 in.) EXAMPLE: The 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0157 in.). Replace the 5.250 mm (0.2067 in.) lifter with a new No. 48 lifter.
A01234
5.540 (0.2181) 5.560 (0.2189) 5.580 (0.2197) 5.600 (0.2205) 5.620 (0.2213) 5.640 (0.2220) 5.660 (0.2228) 5.680 (0.2236) 5.700 (0.2244) 5.720 (0.2252) 5.740 (0.2260)
22 24 26 28
622
2002 ECHO (RM884U)
Valve Lifter Selection Chart (Exhaust)
New lifter thickness Lifter No. 06 08 10 12 14 Thickness 5.060 (0.1992) 5.080 (0.2000) 5.100 (0.2008) 5.120 (0.2016) 5.140 (0.2024) 5.160 (0.2031) 5.180 (0.2039) 5.200 (0.2047) 5.220 (0.2055) 5.240 (0.2063) 5.260 (0.2071) 5.280 (0.2079) Lifter No. 30 32 34 36 38 40 42 44 46 48 50 52 Thickness 5.300 (0.2087) 5.320 (0.2094) 5.340 (0.2102) 5.360 (0.2110) 5.380 (0.2118) 5.400 (0.2126) 5.420 (0.2134) 5.440 (0.2142) 5.460 (0.2150) 5.480 (0.2157) 5.500 (0.2165) 5.520 (0.2173) Lifter No. 54 56 58 60 62 64 66 68 70 72 74
mm (in.) Thickness
Author : Date : Exhaust valve clearance (Cold): 0.25 - 0.35 mm (0.010 - 0.014 in.) EXAMPLE: The 5.340 mm (0.2102 in.) lifter is installed, and the measured clearance is 0.440 mm (0.0173 in.). Replace the 5.340 mm (0.2102 in.) lifter with a new No. 48 lifter. 623
A01235
5.540 (0.2181) 5.560 (0.2189) 5.580 (0.2197) 5.600 (0.2205) 5.620 (0.2213) 5.640 (0.2220) 5.660 (0.2228) 5.680 (0.2236) 5.700 (0.2244) 5.720 (0.2252) 5.740 (0.2260)
16 18 20 22 24 26 28
EM-9
EM-10
(p) (q) (r) (s)
Reinstall the valve lifters (See page EM-42 ). Align the crankshaft pulley groove with the timing mark 0 of the timing chain cover. Hold the timing chain, and place the exhaust camshaft and timing sprocket assembly. Align the matchmarks on the timing chain and camshaft timing sprocket.
(t) (u)
Reinstall the intake camshaft, valve timing controller assembly and camshaft bearing caps (See page EM-44 ). Remove the bar from the timing chain tensioner.
A11246
Timing Marks
(v)
Check that both timing marks on the camshaft timing sprocket and valve timing controller assembly are facing right upas shown in the illustration.
A11245
(w) (x) (y) (z) 5.

A11252
Matchmarks
Check that the matchmarks on the timing chain and camshaft timing sprockets. Install a new plug to the timing chain cover. Torque: 15 Nm (150 kgfcm, 11 ftlbf) Recheck the valve clearance (See procedure in step 3). Check the valve timing (See page EM-18 ). REINSTALL CYLINDER HEAD COVER (See page EM-20 )
2002 ECHO (RM884U)
Author :
Date :
624

Engine Mechanical ECHO 2002

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EM-1

ENGINE MECHANICAL CO/HC

2002 ECHO (RM884U)

Rough idle (Fluctuating HC reading)

Rough idle (Black smoke from exhaust)

2002 ECHO (RM884U)

5. (a) (b) (c)

2002 ECHO (RM884U)

2002 ECHO (RM884U)

9.0 (90, 80 in.lbf)

9.0 (90, 80 in.lbf)

L Engine Coolant Drain Union

Oil Pressure Switch

2002 ECHO (RM884U)

Piston Piston Pin

Connecting Rod Bearing Connecting Rod Cap

Oil Pan No.1 z Gasket z O-ring x10

Oil Filter Union

Oil Filter Oil Pan No.2

z Gasket Nm(kgfcm, ftlbf) : Specified torque zNon-reusable part

14. (a) (b)

2002 ECHO (RM884U)

2002 ECHO (RM884U)

2002 ECHO (RM884U)

Completely remove the plastigage.

19. (a) (b) HINT:

2002 ECHO (RM884U)

2002 ECHO (RM884U)

No. 1 No. 3 No. 5

No. 1 No. 3 No. 5

Cylinder block 4 (A) + Crankshaft 3 (B) = Total number 7 (Use bearing 3)

Crankshaft main journal diameter (B)

Standard bearing center wall thickness

(k) 22. (a) (b)

2002 ECHO (RM884U)

2002 ECHO (RM884U)

2002 ECHO (RM884U)

2002 ECHO (RM884U)

2002 ECHO (RM884U)

11. (a) (b)

2002 ECHO (RM884U)

15. (a) (b)

2002 ECHO (RM884U)

2002 ECHO (RM884U)

No.1 Compression and Expander Front

Lower Side Rail

Upper Side Rail No. 2 Compression A12959

Supply parts: INSTALL MAIN BEARINGS

Manufacture parts: INSTALL MAIN BEARINGS

2002 ECHO (RM884U)

2002 ECHO (RM884U)

2002 ECHO (RM884U)

Seal Width 2.5 - 3.5 mm

2002 ECHO (RM884U)

22. 23. 24. 25. 26.

M/T: INSTALL FLYWHEEL

2002 ECHO (RM884U)

28. (a) (b)

2002 ECHO (RM884U)

2002 ECHO (RM884U)

2002 ECHO (RM884U)

Air Cleaner Cap

Air Filter Generator Wire

Generator Connector Air Cleaner Case A/C Compressor