engine mechanical echo 2002

7/28/2019 Engine Mechanical ECHO 2002

1/85

EM167-01

A11216

-ENGINE MECHANICAL CO/HC

EM-1

615Author: Date:

2002 ECHO (RM884U)

CO/HCINSPECTIONHINT:

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 hand2. 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 mea-

surement order prescribed by the applicable local regulations.


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EM-2-ENGINE MECHANICAL CO/HC

616Author: Date:

2002 ECHO (RM884U)

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 HC Problems Causes

Normal High Rough idle 1. Faulty ignitions:

S Incorrect timing

SFouled, shorted or improperly gapped plugs

SOpen or crossed high-tension cords

2. Incorrect valve clearance

3. Leaky intake and exhaust valves

4. Leaky cylinders

Low High Rough idle

(Fluctuating HC reading)

1. Vacuum leaks:

SPCV hoses

S Intake manifoldSThrottle body

S IAC valve

SBrake booster line

2. Lean mixture causing misfire

High High Rough idle

(Black smoke from exhaust)

1. Restricted air filter

2. Plugged PCV valve

3. Faulty SFI systems:

SFaulty pressure regulator

SDefective ECT sensor

SDefective IAT sensor

SFaulty ECM

S

Faulty injectorsSFaulty throttle position sensor
http://../di/eg/cip0130.pdfhttp://../di/eg/cip0130.pdf


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EM168-01

A11217

-ENGINE MECHANICAL COMPRESSION

EM-3

617Author: Date:

2002 ECHO (RM884U)

COMPRESSIONINSPECTIONHINT:

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. INSPECT CYLINDER COMPRESSION PRESSURE

(a) Insert a compression gauge into the spark plug hole.

(b) Fully open the throttle.

(c) While cranking the engine, measure the compression

pressure.

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 pos-

sible.

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 pastthe gasket.
http://../ig/igncoi/remo.pdfhttp://../ig/igncoi/remo.pdf


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EM-4-ENGINE MECHANICAL COMPRESSION

618Author: Date:

2002 ECHO (RM884U)

6. REINSTALL SPARK PLUGS

7. REINSTALL IGNITION COIL (See page IG-7 )

8. REINSTALL NO. 2 CYLINDER HEAD COVER
http://../ig/igncoi/inst.pdfhttp://../ig/igncoi/inst.pdf


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EM17B-01

A11250

Water Bypass Pipe

Knock Sensor

Thermostat

Water Inlet

Engine CoolantDrain Union

z

Nm(kgfcm, ftlbf) : Specified torque

zNon-reusable partL

Precoated part

Gasket

L

z Gasket Oil Pressure

Switch

9.0 (90, 80 in.lbf)

9.0 (90, 80 in.lbf)

9.0 (90. 80 in.lbf)

9.0 (90, 80 in.lbf)

-ENGINE MECHANICAL CYLINDER BLOCK

EM-61

675Author: Date:

2002 ECHO (RM884U)

CYLINDER BLOCK

COMPONENTS


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A11251

No.1 Compression Ring

No.2 Compression Ring

Oil Ring(Expander)

Piston

Oil Ring(Side Rail)

Connecting Rod Bushing

Connecting Rod

Connecting Rod Bearing

z Crankshaft Rear Oil Seal

Lower Main Bearing

Connecting Rod Cap

Cylinder Block

Upper Main Bearing

Crankshaft Thrust Washer

Crankshaft

Crankshaft Bearing Cap

Gasket

Crankshaft Thrust Washer

Oil Filter Union

Oil Filter

Oil Pan No.2

Oil strainer

11 (112, 8)38 (387, 28)

Piston Pin

30 (306, 22)

24 (245, 18)

Nm(kgfcm, ftlbf) : Specified torque

zNon-reusable part

See page EM-78

x10

x10

O-ringz

z

z

Gasketz

O-ringz

See page EM-78

1st 22 (220,16)2nd Turn 90

1st 15 (150,11)2nd Turn 90

O-ringz

Oil Pan No.1

9.0 (92, 80 in.lbf)

EM-62-ENGINE MECHANICAL CYLINDER BLOCK

676Author: Date:

2002 ECHO (RM884U)
http://reas.pdf/http://reas.pdf/http://reas.pdf/http://reas.pdf/


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EM17C-01

A10451

A11268

A11269


EM-63

677Author: Date:

2002 ECHO (RM884U)

DISASSEMBLY1. M/T:

REMOVE FLYWHEEL

2. A/T:

REMOVE DRIVE PLATE

3. INSTALL ENGINE TO ENGINE STAND FOR

DISASSEMBLY

4. REMOVE TIMING CHAIN (See page EM-15 )

5. REMOVE CYLINDER HEAD

(See page EM-28 )

6. REMOVE ENGINE WIRE

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.

14. REMOVE OIL PAN NO. 2

(a) Remove the 9 bolts and 2 nuts.

(b) 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 sur-

face of the oil pan No. 1.

S Be careful not to damage the oil pan No. 2 flange.
http://../timcha/remo.pdfhttp://../cylhea/remo.pdfhttp://../co/ther/remo.pdfhttp://../sf/knosen/comp.pdfhttp://../lu/oaf/insp.pdfhttp://../lu/oaf/repl.pdfhttp://../lu/oaf/repl.pdfhttp://../lu/oaf/insp.pdfhttp://../sf/knosen/comp.pdfhttp://../co/ther/remo.pdfhttp://../cylhea/remo.pdfhttp://../timcha/remo.pdf


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A11270

A11271

A11272

A10452

A10453


678Author: Date:

2002 ECHO (RM884U)

15. REMOVE OIL STRAINER

Remove the 2 nuts, oil strainer and gasket.

16. REMOVE OIL PAN NO. 1

(a) Uniformly loosen and remove the 13 bolts, in several

passes, in the sequence shown.

(b) Using screwdriver remove the oil pan No. 1 by prying the

portions between the cylinder block and oil pan No. 1.

(c) Remove the 2 O-rings from cylinder block.

17. CHECK CONNECTING ROD THRUST CLEARANCE

Using a dial indicator, measure the thrust clearance while mov-

ing 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 crank-

shaft.

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.


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A10454

A10455

Plastigage

A10456

A10457


EM-65

679Author: Date:

2002 ECHO (RM884U)

(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.

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.

(g) 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.

(h) Remove the 2 bolts, connecting rod cap and lower bear-

ing. (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 bear-

ings. If necessary, grind or replace the crankshaft.
http://reas.pdf/http://reas.pdf/


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A01198

Mark1, 2 or 3

Mark1, 2 or 3

A01166

A10458


680Author: Date:

2002 ECHO (RM884U)

HINT:

If replacing a bearing, replace it with one having the same num-

ber as marked on the connecting rod. There are 3 sizes of stan-

dard bearings, marked 1, 2 and 3 accordingly.

Reference

Standard bearing center wall thickness

Mark mm (in.)

1 1.488 - 1.492 (0.0586 - 0.0587)

2 1.492 - 1.496 (0.0587 - 0.0589)

3 1.496 - 1.500 (0.0589 - 0.0591)

(j) Completely remove the plastigage.

19. REMOVE PISTON AND CONNECTING ROD

ASSEMBLIES

(a) Using a ridge reamer, remove all the carbon from the top

of the cylinder.

(b) Push the piston, connecting rod assembly and upper

bearing through the top of the cylinder block.

HINT:

S Keep the bearings, connecting rod and cap together.

S 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 mov-

ing the crankshaft back and forth.


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.)


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A10459

A10460

A10461

A10462


EM-67

681Author: Date:

2002 ECHO (RM884U)

21. REMOVE BEARING CAPS AND CHECK OIL CLEAR-

ANCE

(a) Uniformly loosen and remove the 10 bearing cap bolts in

several passes in the sequence shown.

(b) Using the 2 removed bearing cap bolts, remove the bear-

ing cap and lower bearing by wiggling the bearing cap

right and left.

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.

(g) Lay a strip of plastigage acrose each journal.

(h) Install the bearing caps (See page EM-44 ).

Torque:


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.


0.010 - 0.023 mm (0.0004 - 0.0009 in.)


0.07 mm (0.0028 in.)

If the oil clearance is greater then maximum, replace the bear-

ings. If necessary, replace the crankshaft.
http://../cylhea/inst.pdfhttp://../cylhea/inst.pdf


12/85

A10463

No. 1 No. 2

No. 3No. 4

No. 5

No. 1

No. 2

No. 3

No. 4

No. 5

NumberMark

Total number : Number mark

Cylinder block (A)+

Crankshaft (B)

Use bearing

0 - 2 3 - 5 6 - 8 9 -11

1

EXAMPLE: Cylinder block 4 (A)+ Crankshaft 3 (B)

= Total number 7 (Use bearing 3)

2 3 4


682Author: Date:

2002 ECHO (RM884U)

HINT:

If using a standard bearing, replace it with one having the same

number. If the number of the bearing cannot be determined, se-

lect the correct bearing by adding together the numbers im-

printed on the cylinder block and crankshaft, then selecting the

bearing with the same number as the total. There are 4 sizesof standard bearings, marked 1, 2, 3 and 4 accordingly.

Reference

Item Mark mm (in.)

Cylinder block main journal bore diameter (A) 0

1

2

3

4

5

6

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)

Crankshaft main journal diameter (B) 0

1

2

3

4

5

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)

Standard bearing center wall thickness 1

2

3

4

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)

(k) Completely remove the Plastigage.

22. REMOVE CRANKSHAFT

(a) Lift out the crankshaft.

(b) 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 or-

der.


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A12947

A12948

A12963

SST SST

SST


EM-69

683Author: Date:

2002 ECHO (RM884U)

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.

24. REMOVE PISTON RINGS

(a) Using a piston ring expander, remove the 2 compression

rings.

(b) Remove the 2 side rails and oil ring by hand.

HINT:

Arrange the piston rings in the correct order only.

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.


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A01165

EM17D-01

A01169

A01167


684Author: Date:

2002 ECHO (RM884U)

INSPECTION1. 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.

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.

4. INSPECT CYLINDER BORE DIAMETER

Visually check the cylinder for vertical scratches.

If deep scratches are present, replace the cylinder block.


15/85

A01168

EM2548 A01467

Front

ThrustDirection

AxialDirection

A10 mm(0.39 in.)

B

C 10 mm(0.39 in.)

1

2

1

2

A01166

A01194

A12949


EM-71

685Author: Date:

2002 ECHO (RM884U)

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.

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.

7. INSPECT 12 POINTED HEAD BEARING CAP SUB-

ASSEMBLY 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.

8. CLEAN PISTON

(a) Using a gasket scraper, remove the carbon from the pis-

ton top.


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A12950

A12951

A1295227 mm

A12953


686Author: Date:

2002 ECHO (RM884U)

(b) Using a groove cleaning tool or broken ring, clean the pis-

ton ring grooves.

(c) Using solvent and a brush, thoroughly clean the piston.

NOTICE:

Do not use a wire brush.

9. INSPECT PISTON OIL CLEARANCE

(a) 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 direc-

tions. (See procedure in step 5)

(c) Subtract the piston diameter measurement from the cylin-

der bore diameter measurement.


0.045 - 0.068 mm (0.00177 - 0.00268 in.)


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 pis-

ton 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.


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A12954

110mm

EM7639

Z00064

Z00065

A01185


EM-73

687Author: Date:

2002 ECHO (RM884U)

11. INSPECT PISTON RING END GAP

(a) Insert the piston ring into the cylinder bore.

(b) Using a piston, push the piston ring a little beyond the bot-

tom 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 pistonring, replace the cylinder block.

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 con-

necting rod assembly.

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 as-

sembly.

13. INSPECT PISTON PIN OIL CLEARANCE

(a) 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.)


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EM0227

A01470

A11241


688Author: Date:

2002 ECHO (RM884U)

(b) 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.)


0.05 mm (0.0020 in.)

If the oil clearance is greater than maximum, replace the bush-

ing. 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.

15. INSPECT CRANKSHAFT FOR CIRCLE RUNOUT

(a) Place the crankshaft on V-blocks.

(b) 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 crank-

shaft.


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A11242


EM-75

689Author: Date:

2002 ECHO (RM884U)

16. INSPECT MAIN JOURNALS AND CRANK PINS

(a) 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 out-

of-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.
http://disa.pdf/http://disa.pdf/


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EM17F-01

A12957

(Cavity)

(Protrusion)

Front Mark

SST

SST

SST

A12958

No.2

A12959Upper Side Rail No. 2 Compression

Lower Side Railand ExpanderNo.1 Compression

Front


692Author: Date:

2002 ECHO (RM884U)

REASSEMBLYHINT:

S Thoroughly clean all parts to be assembled.

S Before installing the parts, apply fresh engine oil to all slid-

ing and rotating surfaces.

S Replace all gaskets, O-rings and oil seals with new parts.

1. ASSEMBLE PISTON AND CONNECTING ROD

(a) Gradually heat the piston side of connecting rod to 80 -

90C (176 - 194F).

(b) Coat the piston pin and pin holes of the piston with engine

oil.

(c) Align the cavity on the piston with the protrusion on the

connecting rod.

(d) Using SST, press in the piston pin.

SST 09221- 25026 (09221- 00021, 09221- 00030,09221-00190, 09221-00141, 09221-00150)

2. INSTALL PISTON RINGS

(a) Install the oil ring expander and 2 side rails by hand.

(b) Using a piston ring expander, install the 2 compression

rings.

(c) Position the piston rings so that the ring ends are as

shown.

NOTICE:

Do not align the ring ends.


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A01190

A10470

BlockSide:

CapSide:

A B C D

A10459

1

2 4

35

6

7

8

9

10


EM-79

693Author: Date:

2002 ECHO (RM884U)

3. Supply parts:

INSTALL MAIN BEARINGS

HINT:

Upper bearings have an oil groove and oil holes; Lower bear-

ings do not.

(a) Align the bearing claw with the claw groove of the cylinderblock, 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.

4. Manufacture parts:

INSTALL MAIN BEARINGS

HINT:

Upper bearings have an oil groove and oil holes; Lower bear-

ings 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.


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A01205

A10456


694Author: Date:

2002 ECHO (RM884U)

(c) Install and uniformly tighten the 10 bolts of the bearing

cap is several passes, in the sequence shown.

Torque:


2ND Turn 90

(d) Check that the crankshaft turns smoothly.7. CHECK CRANKSHAFT THRUST CLEARANCE (See

page EM-63 )

8. INSTALL PISTON AND CONNECTING ROD AS-

SEMBLES

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 CONNECTINGROD

(a) Match the numbered connecting rod cap with the con-

necting 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 fac-

ing in the correct direction.

10. INSTALL CONNECTING ROD CAP BOLTS

HINT:

S The connecting rod cap bolts are tightened in 2 progres-

sive steps (steps (b) and (d)).

S If any of the connecting rod cap bolts is broken or de-

formed, replace it.

(a) Apply a light coat of engine oil on the threads and under

the heads of the connecting rod cap bolts.

(b) Install and alternately tighten the 2 connecting rod cap

bolts in several passes.

Torque:


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 )
http://disa.pdf/http://disa.pdf/http://disa.pdf/http://disa.pdf/


23/85

A10464

Seal Width 2 - 3 mm

A11271

1

25

6

34

7 8 9 1011

1215

1314

B CAB


EM-81

695Author: Date:

2002 ECHO (RM884U)

12. INSTALL OIL PAN NO. 1

(a) 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 sur-faces and sealing grooves.

S Thoroughly clean all components to remove all the

loose material.

S Using a non-residue solvent, clean both sealing

surfaces.

(b) 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.

HINT:

Avoid applying an excessive amount to the surface.

S Parts must be assembled within 3 minutes of ap-

plication. Otherwise the material must be remove d

and reapplied.

S Immediately remove nozzle from the tube and rein-

stall 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.

(e) Install and uniformly tighten the 13 bolts, in several

passes, in the sequence shown.

Torque: 24 Nm (245 kgfcm, 18 ftlbf)

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.
http://repl.pdf/http://repl.pdf/


24/85

A11270

A10465Seal Width 2.5 - 3.5 mm

A11269


696Author: Date:

2002 ECHO (RM884U)

14. INSTALL OIL STRAINER

Install a new gasket, and oil strainer with the 2 nuts.


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 bear-ing cap and oil pan.

S Using a razor blade and gasket scraper, remove all

the old packing (FIPG) material from the gasket sur-

faces 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 illustra-

tion.

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.

HINT:

Avoid applying an excessive amount to the surface.

S Parts must be assembled within 3 minutes of ap-

plication. Otherwise the material must be remove d

and reapplied.

S Immediately remove nozzle from the tube and rein-

stall cap.

(c) 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)

16. INSTALL OIL FILTER UNION


17. INSTALL OIL FILTER (See page LU-2 )
http://../lu/oaf/repl.pdfhttp://../lu/oaf/repl.pdf


25/85

P12477

Adhesive

A10451

A09012

M/T

1

2

34

5

6


EM-83

697Author: Date:

2002 ECHO (RM884U)

18. INSTALL ENGINE COOLANT DRAIN UNION

(a) Apply adhesive to 2 or 3 threads.

Adhesive:

Part No. 08833-00080, THREE BOND 1344,

LOCTITE 242 or equivalent

(b) Install the drain union.Torque: 35 Nm (350 kgfcm, 25 ftlbf)

HINT:

After applying the specified torque, rotate the drain union clock-

wise until its drain port is facing downward.

19. INSTALL KNOCK SENSOR


20. INSTALL OIL PRESSURE SWITCH

(See page LU-1 )

21. INSTALL THERMOSTAT (See page CO-10 )

22. INSTALL WATER BYPASS PIPE


23. INSTALL ENGINE WIRE

24. INSTALL CYLINDER HEAD (See page EM-44 )

25. INSTALL TIMING SPROCKETS AND TIMING CHAIN

(See page EM-20 )

26. REMOVE ENGINE STAND

27. M/T:

INSTALL FLYWHEEL

HINT:

The flywheel bolts are tightened in 2 progressive steps, (a) and

(c).

(a) Install and uniformly tighten the 6 mounting bolts, in sev-

eral 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).
http://../lu/oaf/insp.pdfhttp://../co/ther/inst.pdfhttp://../cylhea/inst.pdfhttp://../timcha/inst.pdfhttp://../timcha/inst.pdfhttp://../cylhea/inst.pdfhttp://../co/ther/inst.pdfhttp://../lu/oaf/insp.pdf


26/85

P08755

A/T

Adhesive

A09018

A/T

1

4

6

2

3

5


698Author: Date:

2002 ECHO (RM884U)

28. A/T:

INSTALL DRIVE PLATE

(a) Install the front spacer, drive plate and rear plate on the

crankshaft.

(b) Apply adhesive to 2 or 3 threads of the mounting bolt end,

Adhesive:Part No. 08833-00070, THREE BOND or equivalent

(c) Install and uniformly tighten the 6 mounting bolts, in sev-

eral passes, in the sequence shown.



27/85

EM17E-01

A01182

SST

A01184

Oil Hole

EM6535

A01443

A12955

Cut Position


690Author: Date:

2002 ECHO (RM884U)

REPLACEMENT1. REPLACE CONNECTING ROD BUSHINGS

(a) Using SST and a press, press out the bushing.

SST 09222-30010

(b) Align the oil hoses of a new bushing and the connecting

rod.

(c) Using SST and a press, press in the bushing.

SST 09222-30010

(d) Using a pin hole grinder, hone the bushing to obtain the

standard specified clearance (See page EM-70 ) be-

tween the bushing and piston pin.

(e) Check the piston pin fit at normal room temperature. Coat

the piston pin with engine oil, and push it into the connect-

ing rod with your thumb.

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 screw-

driver tip.
http://insp.pdf/http://insp.pdf/


28/85

A12956

SST


EM-77

691Author: Date:

2002 ECHO (RM884U)

(c) Apply MP grease to a new oil seal lip.

(d) Using SST and a hammer, tap in the oil seal until its sur-

face is flush with the rear oil seal retainer edge.

SST 09223-15030, 09950-70010 (09951-07100)


29/85

EM16H-01

A11277

Nm (kgfcm, ftlbf)

zNon-reusable part

: Specified torque

PS Oil PressureSwitch Connector

Liquid Tube

Generator

Generator Connector

RH Engine MountingInsulator

Generator Wire

RH Engine Under Cover

PS Pump

Air Cleaner Cap

Air Filter

Air Cleaner Case

VSV for EVAP ConnectorMAF Sensor Connector

Accelerator Cable

Front Exhaust Pipe

z Gasket

7.5 (76, 66 in.lbf)

7.5 (76, 66 in.lbf)A/C Compressor

45 (459, 33)

52 (530, 38)

52 (530, 38)

62 (630, 46)

EM-24-ENGINE MECHANICAL CYLINDER HEAD

638Author: Date:

2002 ECHO (RM884U)

CYLINDER HEAD

COMPONENTS


30/85

A11283

Wiper ArmWiper Arm Head Cap

Cowl Top VentilatorLower RH

Wiper Motor and WiperLink Assembly

Cowl Top VentilatorLower LH

Hood to Cowl Top Seal

Outer Front Cowl TOp Panel

7.8 (80, 69 in.lbf)

5.4 (55, 48 in.lbf)

20 (205, 15)

Nm (kgfcm, ftlbf) : Specified torque

-ENGINE MECHANICAL CYLINDER HEAD

EM-25

639Author: Date:

2002 ECHO (RM884U)


31/85

A11248

Nm (kgfcm, ftlbf)

z Non-reusable part

: Specified torque

Heat Insulator

Exhaust Manifold Stay

Exhaust Manifold

Ignition Coil(w/ Igniter)

No. 2 Cylinder Head Cover

PCV Valve

ECT Sensor

Camshaft Position Sensor

Camshaft Position Sensor Connector

Intake Manifold

Engine Wire

Oil Dipstickand Oil Guide

Throttle Body

O-Ringz

GasketzGasketz

Engine Wire

Gasketz

Gasketz37 (377, 27)

8.0 (82, 71 in.lbf)

27 (280, 20)

Oil Filter

Oil ControlValve

30 (300, 22)


640Author: Date:

2002 ECHO (RM884U)


32/85

A11275

Nm (kgfcm, ftlbf)

z Non-reusable part

: Specified torque

RH Engine Mounting Bracket

Timing Chain Cover

Cylinder Head Cover

PCV Hose

Front CrankshaftOil Seal

Gasket

Water Pump Pulley

Water Pump

O-Ring

Chain TensionerSlipper

Chain Vibration Damper

Tinming Chain

Timing ChainTensioner

Pin

z

z

Crankshaft Pulley

Gasket

Valve Lifter

Keeper

Spring Retainer

Valve Spring

Oil SealSpring Seat

Valve GuideBushing

No. 1 CamshaftBearing Cap

Valve TimingController Assembly Valve

Cylinder Head

Camshaft TimingSprocket

No. 2 CamshaftBearing Cap z

z Gasket

O-Ringz

55 (561, 41)

128 (1,300, 94)

15 (150, 11)

11 (110, 8)

Injector

1st:2nd: 903rd: 90(See page EM-44 )

29.4 (300, 22)


EM-27

641Author: Date:

2002 ECHO (RM884U)
http://inst.pdf/http://inst.pdf/


33/85

EM16J-01

A01061

SST

A01062

A01064


EM-31

645Author: Date:

2002 ECHO (RM884U)

DISASSEMBLY1. REMOVE VALVE LIFTERS

HINT:

Arrange the valve lifters in the correct order.

2. REMOVE VALVES

(a) Using SST, compress the valve spring and remove the 2

keepers.

SST 09202-70020 (09202-00010)

(b) Remove the spring retainer.

(c) Remove the valve spring.(d) Remove the valve.

(e) Using needle-nose pliers, remove the oil seal.

(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 re-

tainers in the correct order.


34/85

A01076

EM16K-01

A01077

A01068

A01069

A01070


646Author: Date:

2002 ECHO (RM884U)

INSPECTION1. CLEAN TOP SURFACES OF PISTONS AND CYL-

INDER BLOCK

(a) Turn the crankshaft, and bring each piston to top dead

center (TDC). Using a gasket scraper, remove all the car-

bon from the piston surface.

(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 compressedair.

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 sur-

face.

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 sur-

face.

4. CLEAN CYLINDER HEAD

Using a soft brush and solvent, thoroughly clean the cylinder

head.


35/85

A01479

A01075

Cylinder Block Side

Intake Manifold Side

Exhaust Manifold Side

A01071

EM0580


EM-33

647Author: Date:

2002 ECHO (RM884U)

5. CLEAN VALVE GUIDE BUSHINGS

Using a valve guide bushing brush and solvent, clean all the

guide bushings.

6. INSPECT FOR FLATNESS


surface contacting the cylinder block and the manifolds for war-

page.


If warpage is greater than maximum, replace the cylinder head.

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.

8. CLEAN VALVES

(a) Using a gasket scraper, chip off any carbon from the valve

head.

(b) Using a wire brush, thoroughly clean the valve.


36/85

A01478

Z00052

EM0180

44.5

EM0181

Margin Thickness


648Author: Date:

2002 ECHO (RM884U)

9. INSPECT VALVE STEMS AND GUIDE BUSHINGS

(a) 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.)

(b) 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 theguide bushing inside diameter measurement.


Intake 0.025 - 0.060 mm (0.00098 - 0.00236 in.)

Exhaust 0.030 - 0.065 mm (0.00118 - 0.00256 in.)


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. INSPECT VALVES

(a) 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.

(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.


37/85

EM2534

Overall Length

A01073

45 CarbideCutter

ResiduaryWidth

Resurface

A01074

Width

EM0185

45

20

1.0 - 1.4 mm

EM0186

75

1.0 - 1.4 mm

45


EM-35

649Author: Date:

2002 ECHO (RM884U)

(d) 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.

(b) 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.

(2) If the seating is too low on the valve face, use 75

and 45 cutters to correct the seat.


38/85

A01072

EM0988

Deviation

EM0801

EM0281

EM1628


650Author: Date:

2002 ECHO (RM884U)

(d) Hand-lap the valve and valve seat with an abrasive com-

pound.

(e) After hand-lapping, clean the valve and valve seat.

12. INSPECT VALVE SPRINGS

(a) 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 valvespring.

(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.

(c) 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 lbfat 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 cam-

shaft.


39/85

EM2011

EM2538

A01452

Plastigage

A12943

A01453


EM-37

651Author: Date:

2002 ECHO (RM884U)

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 cam-

shaft.

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 clear-

ance.

16. INSPECT CAMSHAFT JOURNAL CLEARANCE

(a) Clean the bearing caps and camshaft journals.

(b) Place the camshafts on the cylinder head.

(c) Lay a strip of Plastigage across each of the camshaft jour-

nal.

(d) 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.

(f) Measure the plastigage at its widest point.


0.040 - 0.095 mm (0.00157 - 0.00374 in.)


0.115 mm (0.00453 in.)

If the oil clearance is greater than maximum, replace the cam-

shaft. If necessary, replace the bearing caps and cylinder headas a set.

(g) Completely remove the Plastigage.

(h) Remove the camshafts.


40/85

A01455

A01080

P16860


652Author: Date:

2002 ECHO (RM884U)

17. INSPECT CAMSHAFT THRUST CLEARANCE

(a) Install the camshafts (See page EM-44 ).

(b) Using a dial indicator, measure the thrust clearance while

moving the camshaft back and forth.


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. INSPECT VALVE LIFTERS AND LIFTER BORES

(a) 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.)

(b) 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.


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.


41/85

A01078

A01079


EM-39

653Author: Date:

2002 ECHO (RM884U)

19. INSPECT INTAKE MANIFOLD


surface contacting the cylinder head for warpage.


If warpage is greater than maximum, replace the manifold.

20. INSPECT EXHAUST MANIFOLD


surface contacting the cylinder head for warpage.


If warpage is greater than maximum, replace the manifold.


42/85

EM16N-01

A11249

Lod No.

A11228

1

2

3

4 5

6 7

8 9

10

A12126

Front

9090


658Author: Date:

2002 ECHO (RM884U)

INSTALLATIONHINT:




S Replace all gaskets and oil seals with new ones.

1. PLACE CYLINDER HEAD ON CYLINDER BLOCK

(a) 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 thegasket with the bottom part of the head.

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.

(c) Mark the front of the cylinder head bolt with paint.

(d) Retighten the cylinder head bolts by 90 and 90 in the

numerical order shown.

(e) Check that the paint mark is now at a 180 angle to the

front.

(f) Install the bolt holding the water bypass pipe to the cylin-

der head.Torque: 9.0 Nm (92 kgfcm, 80 in.lbf)


43/85

A12945

No.1 Cam Lobe

A12946

A12943

9

9

96

5

2

1

4

3

8

7


EM-45

659Author: Date:

2002 ECHO (RM884U)

(g) Connect the upper radiator hose to the water hose

unions.

(h) Connect the heater hose to the water hose unions.

3. INSTALL CAMSHAFTS

(a) Place the 2 camshafts on the cylinder head with the No.1

cam lobes facing as shown the illustration.

(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.

(d) 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 ASSEMBLYAND CAMSHAFT TIMING SPROCKET

(a) Apply engine oil in the rage from the tip of the intake cam-

shaft to 16 mm from that tip.

(b) Align the timing mark on the value timing controller as-

sembly with the knock pin, and install the value timing

controller assembly to the camshaft.

NOTICE:

Do not push valve timing controller assembly to the cam-

shaft forcibly when installing it.

(c) Align the knock pin hole in the camshaft timing sprocketwith the knock pin of the camshaft, and install the sprock-

et to the camshaft.

(d) Temporarily install the timing sprocket bolt.


44/85

A11264

A11265


660Author: Date:

2002 ECHO (RM884U)

(e) Hold the hexagon head portion of the camshaft with a

wrench, and install the bolt.


5. CHECK AND ADJUST VALVE CLEARANCE

(See page EM-5 )

6. INSTALL CYLINDER HEAD COVER(See page EM-20 )

7. INSTALL CAMSHAFT TIMING SPROCKETS

(See page EM-20 )

8. INSTALL OIL FILTER CAP

9. INSTALL PCV VALVE

10. INSTALL ECT SENSOR

(See page SF-54 )

11. INSTALL CAMSHAFT POSITION SENSOR

(See page IG-10 )

12. INSTALL TIMING CHAIN COVER(See page EM-20 )

13. INSTALL INTAKE MANIFOLD

(a) 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.


(b) Connect the EVAP hose for ORVR.

(c) Connect the brake booster vacuum hose.

14. CONNECT ENGINE WIRE TO CYLINDER HEAD

(a) Install the engine wire protector to the 2 brackets on the

intake manifold with the 2 bolts.

(b) Connect the ECT sensor connector.

(c) Connect the camshaft position sensor connector.

(d) Connect the oil control valve connector.

(e) Connect the 4 injector connectors.(f) Connect the 2 ground wire.

15. INSTALL THROTTLE BODY

(See page SF-36 )

16. INSTALL PCV HOSES

17. INSTALL SPARK PLUGS

(See page IG-1 )

18. INSTALL IGNITION COILS (See page IG-7 )
http://../valcle/adju.pdfhttp://../timcha/inst.pdfhttp://../timcha/inst.pdfhttp://../sf/ects/insp.pdfhttp://../ig/cps/inst.pdfhttp://../timcha/inst.pdfhttp://../sf/thrbod/inst.pdfhttp://../ig/ignsy/ovi.pdfhttp://../ig/igncoi/inst.pdfhttp://../ig/igncoi/inst.pdfhttp://../ig/ignsy/ovi.pdfhttp://../sf/thrbod/inst.pdfhttp://../timcha/inst.pdfhttp://../ig/cps/inst.pdfhttp://../sf/ects/insp.pdfhttp://../timcha/inst.pdfhttp://../timcha/inst.pdfhttp://../valcle/adju.pdf


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A11227

A11226

A11263


EM-47

661Author: Date:

2002 ECHO (RM884U)

19. INSTALL EXHAUST MANIFOLD

(a) Install a new gasket and the exhaust manifold with the 3

bolts 2 nuts. Uniformly tighten the nuts in several passes.


(b) Install the upper heat insulator with the 4 bolts.


20. INSTALL EXHAUST MANIFOLD STAY

Install the manifold stay with the 3 bolts. Alternately tighten the

bolts.


21. 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.


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.


26. FILL WITH ENGINE COOLANT

27. START ENGINE AND CHECK FOR LEAKS

28. RECHECK ENGINE COOLANT LEVEL AND OIL

LEVEL
http://../ch/gene/inst.pdfhttp://../ch/gene/inst.pdf


46/85

EM16M-01

A11230

For Radiator Hose For Water Bypass Hose

15 mm 18 mm

A11231

Adhesive

A11232

A

B

A01063

SST


656Author: Date:

2002 ECHO (RM884U)

REASSEMBLYHINT:




S Replace oil seals with new ones.

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.

(b) Apply adhesive to the water hose union hole of the cylin-

der head.

Adhesive:

Part No.08833-00070, THREE BOND 1324 or

equivalent

(c) 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 mea-suring the amount of protrusion while pressing.

2. INSTALL VALVES

(a) Using SST, push in a new oil seal.

SST 09201-41020


47/85

S05923

Intake ExhaustMarkNOK

Gray SurfaceLight Brown Surface

A01065

(1)

(2)

(3)(4)

A01061

SST

A07307


EM-43

657Author: Date:

2002 ECHO (RM884U)

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.

(b) Install the valve (1), spring (2), valve spring (3), and spring

retainer (4).

(c) Using SST, compress the valve spring and place the 2

keepers around the valve stem.

SST 09202-70020 (09202-00010)

(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.


48/85

EM16I-01

A11263

A11226

A11227


642Author: Date:

2002 ECHO (RM884U)

REMOVAL1. DRAIN ENGINE COOLANT

2. REMOVE WATER FILLER

(a) Disconnect the No. 3 radiator hose.

(b) Remove the 2 bolts and water filler.

3. REMOVE OUTER FRONT COWL TOP PANEL

(See page BO-31 )

4. REMOVE DRIVE BELT AND ALTERNATOR

(See page CH-7 )

5. REMOVE AIR CLEANER ASSEMBLY

6. DISCONNECT ACCELERATOR CABLE

7. DISCONNECT CENTER EXHAUST PIPE FROM

EXHAUST MANIFOLD

(a) Remove the 2 bolts and 2 springs holding the front ex-

haust pipe to the exhaust manifold.

(b) Remove the gasket.

8. REMOVE EXHAUST MANIFOLD STAY

Remove the 3 bolts and exhaust manifold stay.

9. REMOVE EXHAUST MANIFOLD

(a) Remove the 4 bolts and upper heat insulator.

(b) Remove the 3 bolts 2 nuts, exhaust manifold and gasket.

10. REMOVE IGNITION COIL (See page IG-5 )

11. REMOVE SPARK PLUGS

(See page IG-1 )

12. REMOVE PCV HOSES13. REMOVE THROTTLE BODY

(See page SF-34 )
http://../bo/fwaw/comp.pdfhttp://../ch/gene/remo.pdfhttp://../ig/igncoi/comp.pdfhttp://../ig/ignsy/ovi.pdfhttp://../sf/thrbod/remo.pdfhttp://../sf/thrbod/remo.pdfhttp://../ig/ignsy/ovi.pdfhttp://../ig/igncoi/comp.pdfhttp://../ch/gene/remo.pdfhttp://../bo/fwaw/comp.pdf


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A11265

A11264

A12943

1

2 9 7 3

4

3

368

5


EM-29

643Author: Date:

2002 ECHO (RM884U)

14. DISCONNECT ENGINE WIRE FROM CYLINDER HEAD

(a) Disconnect the ECT sensor connector

(b) Disconnect the camshaft position sensor connector

(c) Disconnect the oil control valve connector.

(d) Disconnect the 4 injector connectors.

(e) Disconnect the 2 ground wires(f) Remove the 2 nuts, and disconnect the engine wire pro-

tector from the 2 brackets on the intake manifold.

15. REMOVE INTAKE MANIFOLD

(a) Disconnect the EVAP hose for ORVR

(b) Disconnect the brake booster vacuum hose

(c) Remove the 3 bolts, 2 nuts, intake manifold and gasket.

16. REMOVE CAMSHAFT POSITION SENSOR

17. REMOVE ECT SENSOR18. REMOVE OIL CONTROL VALVE

19. REMOVE PCV VALVE

20. REMOVE OIL FILLER CAP

21. REMOVE HEAD COVER (See page EM-15 )

22. REMOVE INJECTOR (See page SF-20 )

23. REMOVE TIMING CHAIN COVER (See page EM-15 )

24. 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 as-

sembly.

25. REMOVE CAMSHAFTS

Uniformly loosen and remove the 19 bearing cap bolts, in sever-

al 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
http://../timcha/remo.pdfhttp://../sf/inje/remo.pdfhttp://../timcha/remo.pdfhttp://../timcha/remo.pdfhttp://../sf/inje/remo.pdfhttp://../timcha/remo.pdf


50/85

A11228

1

23

45

67

8

9

10

A12944


644Author: Date:

2002 ECHO (RM884U)

(c) 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 removingbolts in an incorrect order.

(d) Remove the bolt holding the water bypass pipe to the cyl-

inder head.

(e) Lift the cylinder head from the dowels on the cylinder

block and replace the cylinder head on wooden blocks on

a bench.

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 cylin-

der head and cylinder block.


51/85

A01067

80 - 100C

EM16L-01

A01066

SST

A01445

Both intake and exhaust

Bushing bore diametermm (in.)

Bushing size

9.685 - 9.706(0.38130 - 0.38213) Use STD

9.735 - 9.756(0.38327 - 0.38493) Use O/S 0.05

A01446

SST


654Author: Date:

2002 ECHO (RM884U)

REPLACEMENTREPLACE VALVE GUIDE BUSHINGS

(a) Gradually heat the cylinder head to 80 - 100C (176 -

212F).

(b) Using SST and a hammer, tap out the guide bushing.

SST 09201-01055, 09950-70010 (09951-07100)

(c) Using a caliper gauge, measure the bushing bore diame-

ter of the cylinder head.

(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 fol-

lowing 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 -

212F).

(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.)


52/85

A01447


EM-41

655Author: Date:

2002 ECHO (RM884U)

(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.
http://insp.pdf/http://insp.pdf/


53/85

EM178-01

A11278

Hood


LH Engine Under Cover

Battery Tray

Battery Clamp

Air Cleaner Case

Air Filter

Air Cleaner Cap

VSV for EVAP Connector

Battery

Washer Hose

MAF Sensor Connector

7.5 (76, 66 in.lbf)

Accelerator Cable


7.5 (76, 66 in.lbf)

EM-48-ENGINE MECHANICAL ENGINE UNIT

662Author: Date:

2002 ECHO (RM884U)

ENGINE UNIT

COMPONENTS


54/85

A11279

PS Oil PressureSwitch Connector

Liquid Tube

Generator

Generator Connector


Generator Wire

PS Pump

A/C Compressor

Upper Radiator Support

LowerRadiator Hose

Radiator Assembly

Radiator ReservoirHose

Oil Cooler Hose for A/T

Horn Connector

Radiator Cover

Radiator SupportCushion

Grommet

Heater Hose

Brake Booster Vacuum Hose

Fuel Tube

Fusible Link

J/B Cover

Fuel Tube Clamp


25 (250, 18)

45 (459, 32)

52 (530, 38)

52 (530, 38)

-ENGINE MECHANICAL ENGINE UNIT

EM-49

663Author: Date:

2002 ECHO (RM884U)


55/85

B07685

Glove Compartment Door

ECM

Cover


664Author: Date:

2002 ECHO (RM884U)


56/85

A11283

Wiper ArmWiper Arm Head Cap

Cowl Top VentilatorLower RH

Wiper Motor and WiperLink Assembly

Cowl Top VentilatorLower LH

Hood to Cowl Top Seal

Outer Front Cowl TOp Panel

7.8 (80, 69 in.lbf)

5.4 (55, 48 in.lbf)

20 (205, 15)



EM-51

665Author: Date:

2002 ECHO (RM884U)


57/85

A11280

A/T:Transmission Control Cable

RH Drive Shaft LH Drive Shaft

Clutch Release Cylinder

M/T:Transmission Control Cable


LH Engine Under Cover

Front Exhaust Pipe

Suspension Member

Rear EngineMounting Bracket

Rear EngineMounting Insulator


z Non-reusable part

Gasket

Center Brace

z

z

Gasketz

32 (330, 24)

62 (630, 46)

49 (500, 36)


666Author: Date:

2002 ECHO (RM884U)


58/85

EM17A-01

A11267

A11221

A

B

B

A

A

A11243

A11518


EM-57

671Author: Date:

2002 ECHO (RM884U)

INSTALLATION1. ASSEMBLY ENGINE AND TRANSAXLE

(M/T: See page MX-8 )

(A/T: See page AX-33 )

2. INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN

VEHICLE

(a) Attach the engine sling device to the engine hangers.

(b) Slowly lower the vehicle, and raise the engine into the en-

gine compartment.

(c) Keep the engine level, and align RH and LH mountings

with the body bracket.

(d) 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)

(e) Install the liquid tube with the bolt.

(f) Connect the LH engine mounting, and install the 2 bolts.


3. INSTALL REAR ENGINE MOUNTING

(a) Install the rear engine mounting bracket with the 3 bolts.


(b) Temporarily install the rear engine mounting insulator with

the through bolt and lock nut.

4. INSTALL SUSPENSION MEMBER

(Manual steering: See page SR-43 )

(Power steering: See page SR-61 )

5. INSTALL DRIVE SHAFT (See page SA-24 )
http://../mx/mxu/inst.pdfhttp://../ax/axu/inst.pdfhttp://../sr/msg/inst.pdfhttp://../sr/psg/inst.pdfhttp://../sa/fds/inst.pdfhttp://../sa/fds/inst.pdfhttp://../sr/psg/inst.pdfhttp://../sr/msg/inst.pdfhttp://../ax/axu/inst.pdfhttp://../mx/mxu/inst.pdf


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A11266

A11281

A11239

A11237


672Author: Date:

2002 ECHO (RM884U)

6. INSTALL CENTER EXHAUST PIPE

(a) 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)(b) Install the floor brace with the 2 bolts.

(c) Connect the connector for front heated oxygen sensor.

(d) Install the rear heated oxygen sensor.

7. CONNECT PS PUMP TO ENGINE (See page SR-32 )

8. CONNECT ENGINE WIRE TO CABIN

(a) Push in the engine wire to the cabin.

(b) Connect the 2 cowl wire connectors to the connectors on

the bracket.

(c) Connect the 4 ECM connectors.

(d) Install the lower panel (See page BO-84 ).

9. CONNECT ENGINE WIRE TO ENGINE COMPART-

MENT

(a) Connect the positive cable to the positive terminal.

(b) Connect the connector to the fusible link.

(c) Connect the cable clamp to the relay box.

(d) Connect the connector to the relay box.

10. CONNECT TRANSAXLE CONTROL CABLE(S) TO

TRANSAXLE
http://../sr/psvp/inst.pdfhttp://../bo/inspan/inst.pdfhttp://../bo/inspan/inst.pdfhttp://../sr/psvp/inst.pdf


60/85

D08225

A11236

A11235

A11234

A11233


EM-59

673Author: Date:

2002 ECHO (RM884U)

11. M/T:

CONNECT CLUTCH RELEASE CYLINDER TO TRANS-

AXLE

(a) Connect the clutch release cylinder with the 2 bolts.


(b) Connect the bracket to the transaxle with the bolt.Torque: 4.9 Nm (50 kgfcm, 43 in.lbf)

12. w/ A/C:

CONNECT A/C COMPRESSOR TO ENGINE

(a) Connect the A/C compressor to the engine with the 4

bolts.


(b) Connect the A/C compressor connector.13. INSTALL RADIATOR ASSEMBLY (See page CO-23 )

14. INSTALL GENERATOR AND DRIVE BELT

(See page CH-7 )

15. CONNECT TUBE, HOSE AND CONNECTOR

(a) Connect the heater hose to the water hose union on the

cylinder head.

(b) Connect the brake booster vacuum hose.

(c) Connect the heater hose to the water bypass pipe.

(d) Connect the fuel tube to the fuel pipe on vehicle side.

(e) Install the fuel pipe clamp.

16. INSTALL AIR CLEANER CASE

(a) Install the air cleaner case and air cleaner inlet assembly

with the 4 bolts.


(b) Install the air filter.

17. INSTALL AIR CLEANER CAP

(a) Connect the air cleaner hose to the throttle body with the

hose clamp.

(b) Install the air cleaner cap to the air cleaner case.

(c) Connect the 2 clamps.

(d) Connect the 2 hose to the VSV for EVAP.

(e) Connect the PCV hose to the cylinder head.(f) Connect the MAF sensor connector.

18. CONNECT ACCELERATOR CABLE
http://../co/radi/inst.pdfhttp://../ch/gene/remo.pdfhttp://../ch/gene/remo.pdfhttp://../co/radi/inst.pdf


61/85


674Author: Date:

2002 ECHO (RM884U)

19. INSTALL OUTER FRONT COWL TOP PANEL (See

page BO-35 )

20. INSTALL ENGINE UNDER COVERS

21. INSTALL HOOD

22. INSTALL BATTERY AND TRAY

23. FILL WITH ENGINE COOLANT24. FILL WITH ENGINE OIL

25. FILL WITH TRANSAXLE OIL

26. START ENGINE AND CHECK FOR LEAKS

27. RECHECK ENGINE COOLANT AND OIL LEVELS
http://../bo/fwaw/inst.pdfhttp://../bo/fwaw/inst.pdf


62/85

EM179-01

A11233

A11234

A11235


EM-53

667Author: Date:

2002 ECHO (RM884U)

REMOVAL1. REMOVE BATTERY AND TRAY

2. REMOVE HOOD

3. REMOVE OUTER FRONT COWL TOP PANEL (See

page BO-32 )

4. REMOVE ENGINE UNDER COVERS

5. DRAIN ENGINE COOLANT

6. DRAIN ENGINE OIL

7. DRAIN TRANSAXLE OIL

8. DISCONNECT ACCELERATOR CABLE

9. REMOVE AIR CLEANER CAP

(a) Disconnect the MAF sensor connector.

(b) Disconnect the PCV hose from the cylinder head.

(c) Disconnect the 2 hose from the VSV for EVAP.

(d) Disconnect the 2 clamps, and disconnect the air cleaner

cap from the air cleaner case.

(e) Loosen the hose clamp, and disconnect the air cleaner

hose from the throttle body.

(f) Remove the air cleaner cap and air cleaner hose assem-

bly.

10. REMOVE AIR CLEANER CASE

(a) Remove the air filter.

(b) Remove the 4 bolts and air cleaner case and air cleaner

inlet assembly.

11. DISCONNECT TUBE, HOSES AND CONNECTORS

(a) Remove the fuel pipe clamp.

(b) Disconnect the fuel tube from fuel pipe on vehicle side.

(c) Disconnect the heater hose from water bypass pipe.

(d) Disconnect the brake booster vacuum hose from pipe.

(e) Disconnect the heater hose from water hose union on cyl-

inder head.12. REMOVE DRIVE BELT AND GENERATOR (See page

CH-7 )
http://../bo/fwaw/remo.pdfhttp://../ch/gene/remo.pdfhttp://../ch/gene/remo.pdfhttp://../bo/fwaw/remo.pdf


63/85

A11236

w/ A/C

D08225

M/T

A11237

A11239


668Author: Date:

2002 ECHO (RM884U)

13. REMOVE RADIATOR ASSEMBLY (See page CO-16 )

14. w/ A/C:

DISCONNECT A/C COMPRESSOR FROM ENGINE

(a) Disconnect the A/C compressor connector.

(b) Remove the 4 bolts, and disconnect the A/C compressor

from the engine.

HINT:Suspend the A/C compressor securely.

15. M/T:

DISCONNECT CLUTCH RELEASE CYLINDER FROM

TRANSAXLE

(a) Remove the bolt, and disconnect the bracket from the

transaxle.

(b) Remove the 2 bolts, and disconnect the release cylinder

from the transaxle.

16. DISCONNECT TRANSAXLE CONTROL CABLE(S)

FROM TRANSAXLE

17. DISCONNECT ENGINE WIRE FROM ENGINE

COMPARTMENT

(a) Disconnect the connector from the relay box.

(b) Disconnect the cable clamp from the relay box.

(c) Disconnect the connector from the fusible link.

(d) Disconnect the positive cable from the positive terminal.
http://../co/radi/remo.pdfhttp://../co/radi/remo.pdf


64/85

A11281

A11240

A11266

D05696


EM-55

669Author: Date:

2002 ECHO (RM884U)

18. DISCONNECT ENGINE WIRE FROM CABIN

(a) Remove the lower panel (See page BO-76 ).

(b) Disconnect the 4 ECM connectors.

(c) Disconnect the 2 cowl wire connectors from connectors

on bracket.

(d) Pull out the engine wire from the cabin.

19. DISCONNECT PS PUMP FROM ENGINE

(See page SR-24 )

20. REMOVE CENTER EXHAUST PIPE

(a) Disconnect the rear heated oxygen sensor.

(b) Disconnect the connector for front heated oxygen sensor.

(c) Remove the 2 bolts and floor brace.

(d) Remove the 3 bolts, 2 springs and pipe clamp.

(e) Disconnect the 2 O-ring, and remove the center exhaust

pipe and 2 gaskets.

21. REMOVE DRIVE SHAFTS (See page SA-18 )

22. REMOVE SUSPENSION MEMBER

(Manual steering: See page SR-35 )

(Power steering: See page SR-48 )

23. REMOVE REAR ENGINE MOUNTING

(a) Remove the through bolt, lock nut and rear engine mount-

ing insulator.

(b) Remove the 2 bolts, nut and rear engine mounting brack-

et.

24. ATTACH ENGINE SLING DEVICE TO ENGINE HANG-ERS

(a) Remove the bolt, and disconnect the condenser.

(b) Install the 2 engine hangers in the correct direction.

Engine hanger part No.: 12281-21010

Bolt part No.:

91512-B1016 2 pieces


(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.
http://../bo/inspan/remo.pdfhttp://../sr/psvp/remo.pdfhttp://../sa/fds/remo.pdfhttp://../sr/msg/remo.pdfhttp://../sr/psg/remo.pdfhttp://../sr/psg/remo.pdfhttp://../sr/msg/remo.pdfhttp://../sa/fds/remo.pdfhttp://../sr/psvp/remo.pdfhttp://../bo/inspan/remo.pdf


65/85

A11243

A11221

A11267


670Author: Date:

2002 ECHO (RM884U)

25. REMOVE ENGINE AND TRANSAXLE ASSEMBLY

FROM VEHICLE

(a) Remove the 2 bolts, and disconnect the LH engine

mounting.

(b) Remove the 2 bolts and nut, and disconnect the RH en-

gine mounting.

(c) Remove the bolt holding the liquid tube to the RH engine

mounting insulator.

(d) Remove the 3 bolts and RH engine mounting insulator.

(e) Lift the engine out of the vehicle slowly and carefully.

HINT:

Make sure the engine is clear of steering gear assembly all wir-

ing, 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 )
http://../mx/mxu/remo.pdfhttp://../ax/axu/remo.pdfhttp://../ax/axu/remo.pdfhttp://../mx/mxu/remo.pdf


66/85

EM17G-01

A11282


z Non-reusable part

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.

Heated Oxygen Sensor(Bank1 Sensor1)

Heated Oxygen Sensor(Bank1 Sensor2)

Front Exhaust Pipe

Tailpipe

z Gasket

Heat Insulator

O-Ring

O-Ring

O-Ring

62 (630, 46)

32 (330, 24)

Heat Insulator

Heat Insulator

z Gasket

Center Brace

-ENGINE MECHANICAL EXHAUST SYSTEM

EM-85

699Author: Date:

2002 ECHO (RM884U)

EXHAUST SYSTEM

COMPONENTS


67/85

EM16B-01

D08002

TOYOTA Hand-Held Tester

DLC3

EM-12-ENGINE MECHANICAL IDLE SPEED

626Author: Date:

2002 ECHO (RM884U)

IDLE SPEEDINSPECTION1. INSTALL CONDITIONS

(a) Engine at normal operating temperature

(b) Air cleaner installed(c) All pipes and hoses of air induction system connected

(d) All vacuum lines properly connected

(e) SFI system wiring connectors fully plugged

(f) All operating accessories switched OFF

(g) Ignition timing check correctly

(h) Transmission in neutral position

(i) Air conditioning switched OFF

2. 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


68/85

EM16A-01

D08002

TOYOTA Hand-Held Tester

DLC3

A11220

-ENGINE MECHANICAL IGNITION TIMING

EM-11

625Author: Date:

2002 ECHO (RM884U)

IGNITION TIMINGINSPECTION1. WARM UP ENGINE

Allow the engine to warm up to normal operating temperature.

2. 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 for further details.3. CONNECT TIMING LIGHT TO ENGINE

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


69/85

EM173-01

A11276

PS Oil Pressure

Switch Connector

Liquid Tube

Generator

Generator Connector


Generator Wire



PS Pump

A/C Compressure

Drive Belt

45 (459, 33)

52 (530, 38)

52 (530, 38)

25 (250, 18)

-ENGINE MECHANICAL TIMING CHAIN

EM-13

627Author: Date:

2002 ECHO (RM884U)

TIMING CHAIN

COMPONENTS


70/85

A11273

Nm (kgfcm, ftlbf)

z Non-reusable part: Specified torque

RH Engine Mounting Bracket

Timing Chain Cover

No. 2 Cylinder Head Cover

Cylinder Head Cover

Ignition Ciol(w/ Igniter)

PCV Hose

Front CrankshaftOil Seal

Crankshaft Pulley

Gasket

Water Pump Pulley

Water Pump

Gasket

Chain TensionerSlipper

Chain Vibration Damper

Tinming Chain

Timing ChainTensioner

Pin

z

z

O-Ringz

O-Ringz

11 (110, 8)

15 (150, 11)

128 (1,300, 94)

EM-14-ENGINE MECHANICAL TIMING CHAIN

628Author: Date:

2002 ECHO (RM884U)


71/85

EM175-01

P04776

123.2 mm

16 Links

EM2378

A11259Wear

A11223

Raise

Move Lock


632Author: Date:

2002 ECHO (RM884U)

INSPECTION1. INSPECT TIMING CHAIN AND TIMING SPROCKETS

(a) 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 se-

lected at random.

(b) Wrap the chain around the timing sprocket.

(c) Using a vernier calipers, measure the timing sprocket di-

ameter with the chain.

NOTICE:

Vernier calipers must contact the chain rollers for measur-

ing.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.

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.

3. INSPECT CHAIN TENSIONER

(a) Check that the plunger moves smoothly when the ratchet

pawl is raised with your finger.

(b) Release the ratchet pawl and check that the plunger is

(c) locked in place by the ratchet pawl and does not move

when pushed with your finger.


72/85

EM177-01

A11224

ATDC20 Mark Link

Timing Mark

30

Timing Mark

Mark Link

A11225


634Author: Date:

engine mechanical echo 2002

Documents