Download - 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.
-
7/28/2019 Engine Mechanical ECHO 2002
2/85
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 -
7/28/2019 Engine Mechanical ECHO 2002
3/85
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 -
7/28/2019 Engine Mechanical ECHO 2002
4/85
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 -
7/28/2019 Engine Mechanical ECHO 2002
5/85
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
-
7/28/2019 Engine Mechanical ECHO 2002
6/85
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/ -
7/28/2019 Engine Mechanical ECHO 2002
7/85
EM17C-01
A10451
A11268
A11269
-ENGINE MECHANICAL CYLINDER BLOCK
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 -
7/28/2019 Engine Mechanical ECHO 2002
8/85
A11270
A11271
A11272
A10452
A10453
EM-64-ENGINE MECHANICAL CYLINDER BLOCK
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.
-
7/28/2019 Engine Mechanical ECHO 2002
9/85
A10454
A10455
Plastigage
A10456
A10457
-ENGINE MECHANICAL CYLINDER BLOCK
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/ -
7/28/2019 Engine Mechanical ECHO 2002
10/85
A01198
Mark1, 2 or 3
Mark1, 2 or 3
A01166
A10458
EM-66-ENGINE MECHANICAL CYLINDER BLOCK
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.
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.)
-
7/28/2019 Engine Mechanical ECHO 2002
11/85
A10459
A10460
A10461
A10462
-ENGINE MECHANICAL CYLINDER BLOCK
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:
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 bear-
ings. If necessary, replace the crankshaft.
http://../cylhea/inst.pdfhttp://../cylhea/inst.pdf -
7/28/2019 Engine Mechanical ECHO 2002
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
EM-68-ENGINE MECHANICAL CYLINDER BLOCK
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.
-
7/28/2019 Engine Mechanical ECHO 2002
13/85
A12947
A12948
A12963
SST SST
SST
-ENGINE MECHANICAL CYLINDER BLOCK
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.
-
7/28/2019 Engine Mechanical ECHO 2002
14/85
A01165
EM17D-01
A01169
A01167
EM-70-ENGINE MECHANICAL CYLINDER BLOCK
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.
-
7/28/2019 Engine Mechanical ECHO 2002
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
-ENGINE MECHANICAL CYLINDER BLOCK
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.
-
7/28/2019 Engine Mechanical ECHO 2002
16/85
A12950
A12951
A1295227 mm
A12953
EM-72-ENGINE MECHANICAL CYLINDER BLOCK
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.
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 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.
-
7/28/2019 Engine Mechanical ECHO 2002
17/85
A12954
110mm
EM7639
Z00064
Z00065
A01185
-ENGINE MECHANICAL CYLINDER BLOCK
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.)
-
7/28/2019 Engine Mechanical ECHO 2002
18/85
EM0227
A01470
A11241
EM-74-ENGINE MECHANICAL CYLINDER BLOCK
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.)
Maximum oil clearance:
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.
-
7/28/2019 Engine Mechanical ECHO 2002
19/85
A11242
-ENGINE MECHANICAL CYLINDER BLOCK
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/ -
7/28/2019 Engine Mechanical ECHO 2002
20/85
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
EM-78-ENGINE MECHANICAL CYLINDER BLOCK
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.
-
7/28/2019 Engine Mechanical ECHO 2002
21/85
A01190
A10470
BlockSide:
CapSide:
A B C D
A10459
1
2 4
35
6
7
8
9
10
-ENGINE MECHANICAL CYLINDER BLOCK
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.
-
7/28/2019 Engine Mechanical ECHO 2002
22/85
A01205
A10456
EM-80-ENGINE MECHANICAL CYLINDER BLOCK
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:
1ST 22 Nm (220 kgfcm, 16 ftlbf)
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:
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 )
http://disa.pdf/http://disa.pdf/http://disa.pdf/http://disa.pdf/ -
7/28/2019 Engine Mechanical ECHO 2002
23/85
A10464
Seal Width 2 - 3 mm
A11271
1
25
6
34
7 8 9 1011
1215
1314
B CAB
-ENGINE MECHANICAL CYLINDER BLOCK
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/ -
7/28/2019 Engine Mechanical ECHO 2002
24/85
A11270
A10465Seal Width 2.5 - 3.5 mm
A11269
EM-82-ENGINE MECHANICAL CYLINDER BLOCK
696Author: Date:
2002 ECHO (RM884U)
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 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
Torque: 30 Nm (306 kgfcm, 21 ftlbf)
17. INSTALL OIL FILTER (See page LU-2 )
http://../lu/oaf/repl.pdfhttp://../lu/oaf/repl.pdf -
7/28/2019 Engine Mechanical ECHO 2002
25/85
P12477
Adhesive
A10451
A09012
M/T
1
2
34
5
6
-ENGINE MECHANICAL CYLINDER BLOCK
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
Torque: 39 Nm (400 kgfcm, 29 ftlbf)
20. INSTALL OIL PRESSURE SWITCH
(See page LU-1 )
21. INSTALL THERMOSTAT (See page CO-10 )
22. INSTALL WATER BYPASS PIPE
Torque: 9.0 Nm (92 kgfcm, 80 in.lbf)
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 -
7/28/2019 Engine Mechanical ECHO 2002
26/85
P08755
A/T
Adhesive
A09018
A/T
1
4
6
2
3
5
EM-84-ENGINE MECHANICAL CYLINDER BLOCK
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.
Torque: 88 Nm (890 kgfcm, 65 ftlbf)
-
7/28/2019 Engine Mechanical ECHO 2002
27/85
EM17E-01
A01182
SST
A01184
Oil Hole
EM6535
A01443
A12955
Cut Position
EM-76-ENGINE MECHANICAL CYLINDER BLOCK
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/ -
7/28/2019 Engine Mechanical ECHO 2002
28/85
A12956
SST
-ENGINE MECHANICAL CYLINDER BLOCK
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)
-
7/28/2019 Engine Mechanical ECHO 2002
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
-
7/28/2019 Engine Mechanical ECHO 2002
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)
-
7/28/2019 Engine Mechanical ECHO 2002
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)
EM-26-ENGINE MECHANICAL CYLINDER HEAD
640Author: Date:
2002 ECHO (RM884U)
-
7/28/2019 Engine Mechanical ECHO 2002
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)
-ENGINE MECHANICAL CYLINDER HEAD
EM-27
641Author: Date:
2002 ECHO (RM884U)
http://inst.pdf/http://inst.pdf/ -
7/28/2019 Engine Mechanical ECHO 2002
33/85
EM16J-01
A01061
SST
A01062
A01064
-ENGINE MECHANICAL CYLINDER HEAD
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.
-
7/28/2019 Engine Mechanical ECHO 2002
34/85
A01076
EM16K-01
A01077
A01068
A01069
A01070
EM-32-ENGINE MECHANICAL CYLINDER HEAD
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.
-
7/28/2019 Engine Mechanical ECHO 2002
35/85
A01479
A01075
Cylinder Block Side
Intake Manifold Side
Exhaust Manifold Side
A01071
EM0580
-ENGINE MECHANICAL CYLINDER HEAD
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
Using a precision straight edge and feeler gauge, measure the
surface contacting the cylinder block and the manifolds for war-
page.
Maximum warpage: 0.05 mm (0.0020 in.)
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.
-
7/28/2019 Engine Mechanical ECHO 2002
36/85
A01478
Z00052
EM0180
44.5
EM0181
Margin Thickness
EM-34-ENGINE MECHANICAL CYLINDER HEAD
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.
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. 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.
-
7/28/2019 Engine Mechanical ECHO 2002
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
-ENGINE MECHANICAL CYLINDER HEAD
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.
-
7/28/2019 Engine Mechanical ECHO 2002
38/85
A01072
EM0988
Deviation
EM0801
EM0281
EM1628
EM-36-ENGINE MECHANICAL CYLINDER HEAD
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.
-
7/28/2019 Engine Mechanical ECHO 2002
39/85
EM2011
EM2538
A01452
Plastigage
A12943
A01453
-ENGINE MECHANICAL CYLINDER HEAD
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.
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 cam-
shaft. If necessary, replace the bearing caps and cylinder headas a set.
(g) Completely remove the Plastigage.
(h) Remove the camshafts.
http://inst.pdf/http://inst.pdf/ -
7/28/2019 Engine Mechanical ECHO 2002
40/85
A01455
A01080
P16860
EM-38-ENGINE MECHANICAL CYLINDER HEAD
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.
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. 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.
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.
http://inst.pdf/http://inst.pdf/ -
7/28/2019 Engine Mechanical ECHO 2002
41/85
A01078
A01079
-ENGINE MECHANICAL CYLINDER HEAD
EM-39
653Author: Date:
2002 ECHO (RM884U)
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.
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.
-
7/28/2019 Engine Mechanical ECHO 2002
42/85
EM16N-01
A11249
Lod No.
A11228
1
2
3
4 5
6 7
8 9
10
A12126
Front
9090
EM-44-ENGINE MECHANICAL CYLINDER HEAD
658Author: Date:
2002 ECHO (RM884U)
INSTALLATIONHINT:
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 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)
-
7/28/2019 Engine Mechanical ECHO 2002
43/85
A12945
No.1 Cam Lobe
A12946
A12943
9
9
96
5
2
1
4
3
8
7
-ENGINE MECHANICAL CYLINDER HEAD
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.
-
7/28/2019 Engine Mechanical ECHO 2002
44/85
A11264
A11265
EM-46-ENGINE MECHANICAL CYLINDER HEAD
660Author: Date:
2002 ECHO (RM884U)
(e) Hold the hexagon head portion of the camshaft with a
wrench, and install the bolt.
Torque: 64 Nm (650 kgfcm, 47 ftlbf)
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.
Torque: 30 Nm (300 kgfcm, 22 ftlbf)
(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 -
7/28/2019 Engine Mechanical ECHO 2002
45/85
A11227
A11226
A11263
-ENGINE MECHANICAL CYLINDER HEAD
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.
Torque: 27 Nm (275 kgfcm, 20 ftlbf)
(b) Install the upper heat insulator with the 4 bolts.
Torque: 8.0 Nm (82 kgfcm, 71 in.lbf)
20. INSTALL EXHAUST MANIFOLD STAY
Install the manifold stay with the 3 bolts. Alternately tighten the
bolts.
Torque: 37 Nm (377 kgfcm, 27 ftlbf)
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.
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
http://../ch/gene/inst.pdfhttp://../ch/gene/inst.pdf -
7/28/2019 Engine Mechanical ECHO 2002
46/85
EM16M-01
A11230
For Radiator Hose For Water Bypass Hose
15 mm 18 mm
A11231
Adhesive
A11232
A
B
A01063
SST
EM-42-ENGINE MECHANICAL CYLINDER HEAD
656Author: 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 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
-
7/28/2019 Engine Mechanical ECHO 2002
47/85
S05923
Intake ExhaustMarkNOK
Gray SurfaceLight Brown Surface
A01065
(1)
(2)
(3)(4)
A01061
SST
A07307
-ENGINE MECHANICAL CYLINDER HEAD
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.
-
7/28/2019 Engine Mechanical ECHO 2002
48/85
EM16I-01
A11263
A11226
A11227
EM-28-ENGINE MECHANICAL CYLINDER HEAD
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 -
7/28/2019 Engine Mechanical ECHO 2002
49/85
A11265
A11264
A12943
1
2 9 7 3
4
3
368
5
-ENGINE MECHANICAL CYLINDER HEAD
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 -
7/28/2019 Engine Mechanical ECHO 2002
50/85
A11228
1
23
45
67
8
9
10
A12944
EM-30-ENGINE MECHANICAL CYLINDER HEAD
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.
-
7/28/2019 Engine Mechanical ECHO 2002
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
EM-40-ENGINE MECHANICAL CYLINDER HEAD
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.)
-
7/28/2019 Engine Mechanical ECHO 2002
52/85
A01447
-ENGINE MECHANICAL CYLINDER HEAD
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/ -
7/28/2019 Engine Mechanical ECHO 2002
53/85
EM178-01
A11278
Hood
RH Engine Under Cover
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
Nm (kgfcm, ftlbf) : Specified torque
7.5 (76, 66 in.lbf)
EM-48-ENGINE MECHANICAL ENGINE UNIT
662Author: Date:
2002 ECHO (RM884U)
ENGINE UNIT
COMPONENTS
-
7/28/2019 Engine Mechanical ECHO 2002
54/85
A11279
PS Oil PressureSwitch Connector
Liquid Tube
Generator
Generator Connector
RH Engine MountingInsulator
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
Nm (kgfcm, ftlbf) : Specified torque
25 (250, 18)
45 (459, 32)
52 (530, 38)
52 (530, 38)
-ENGINE MECHANICAL ENGINE UNIT
EM-49
663Author: Date:
2002 ECHO (RM884U)
-
7/28/2019 Engine Mechanical ECHO 2002
55/85
B07685
Glove Compartment Door
ECM
Cover
EM-50-ENGINE MECHANICAL ENGINE UNIT
664Author: Date:
2002 ECHO (RM884U)
-
7/28/2019 Engine Mechanical ECHO 2002
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)
Nm (kgfcm, ftlbf) : Specified torque
-ENGINE MECHANICAL ENGINE UNIT
EM-51
665Author: Date:
2002 ECHO (RM884U)
-
7/28/2019 Engine Mechanical ECHO 2002
57/85
A11280
A/T:Transmission Control Cable
RH Drive Shaft LH Drive Shaft
Clutch Release Cylinder
M/T:Transmission Control Cable
RH Engine Under Cover
LH Engine Under Cover
Front Exhaust Pipe
Suspension Member
Rear EngineMounting Bracket
Rear EngineMounting Insulator
Nm (kgfcm, ftlbf) : Specified torque
z Non-reusable part
Gasket
Center Brace
z
z
Gasketz
32 (330, 24)
62 (630, 46)
49 (500, 36)
EM-52-ENGINE MECHANICAL ENGINE UNIT
666Author: Date:
2002 ECHO (RM884U)
-
7/28/2019 Engine Mechanical ECHO 2002
58/85
EM17A-01
A11267
A11221
A
B
B
A
A
A11243
A11518
-ENGINE MECHANICAL ENGINE UNIT
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.
Torque: 49 Nm (500 kgfcm, 36 ftlbf)
3. INSTALL REAR ENGINE MOUNTING
(a) Install the rear engine mounting bracket with the 3 bolts.
Torque: 49 Nm (500 kgfcm, 36 ftlbf)
(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 -
7/28/2019 Engine Mechanical ECHO 2002
59/85
A11266
A11281
A11239
A11237
EM-58-ENGINE MECHANICAL ENGINE UNIT
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 -
7/28/2019 Engine Mechanical ECHO 2002
60/85
D08225
A11236
A11235
A11234
A11233
-ENGINE MECHANICAL ENGINE UNIT
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.
Torque: 12 Nm (120 kgfcm, 9 ftlbf)
(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.
Torque: 25 Nm (250 kgfcm, 18 ftlbf)
(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.
Torque: 7.5 Nm (76 kgfcm, 66 in.lbf)
(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 -
7/28/2019 Engine Mechanical ECHO 2002
61/85
EM-60-ENGINE MECHANICAL ENGINE UNIT
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 -
7/28/2019 Engine Mechanical ECHO 2002
62/85
EM179-01
A11233
A11234
A11235
-ENGINE MECHANICAL ENGINE UNIT
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 -
7/28/2019 Engine Mechanical ECHO 2002
63/85
A11236
w/ A/C
D08225
M/T
A11237
A11239
EM-54-ENGINE MECHANICAL ENGINE UNIT
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 -
7/28/2019 Engine Mechanical ECHO 2002
64/85
A11281
A11240
A11266
D05696
-ENGINE MECHANICAL ENGINE UNIT
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
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.
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 -
7/28/2019 Engine Mechanical ECHO 2002
65/85
A11243
A11221
A11267
EM-56-ENGINE MECHANICAL ENGINE UNIT
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 -
7/28/2019 Engine Mechanical ECHO 2002
66/85
EM17G-01
A11282
Nm (kgfcm, ftlbf) : Specified torque
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
-
7/28/2019 Engine Mechanical ECHO 2002
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
-
7/28/2019 Engine Mechanical ECHO 2002
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
-
7/28/2019 Engine Mechanical ECHO 2002
69/85
EM173-01
A11276
PS Oil Pressure
Switch Connector
Liquid Tube
Generator
Generator Connector
RH Engine MountingInsulator
Generator Wire
RH Engine Under Cover
Nm (kgfcm, ftlbf) : Specified torque
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
-
7/28/2019 Engine Mechanical ECHO 2002
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)
-
7/28/2019 Engine Mechanical ECHO 2002
71/85
EM175-01
P04776
123.2 mm
16 Links
EM2378
A11259Wear
A11223
Raise
Move Lock
EM-18-ENGINE MECHANICAL TIMING CHAIN
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.
-
7/28/2019 Engine Mechanical ECHO 2002
72/85
EM177-01
A11224
ATDC20 Mark Link
Timing Mark
30
Timing Mark
Mark Link
A11225
EM-20-ENGINE MECHANICAL TIMING CHAIN
634Author: Date: