Engine Mechanical: Diagnosis Toyota Echo I

TROUBLE SHOOTING

To trouble shoot mechanical engine components, see BASIC TROUBLE SHOOTING article in GENERAL INFORMATION.

Inspection

1. Inspect cylinder head for damage, cracks or warpage. Replace cylinder head if warpage exceeds specification. See «CYLINDER HEAD»(ref-159209-S02776641392003111800000) table under ENGINE SPECIFICATIONS.
2. Inspect intake manifold and exhaust manifold-to-cylinder head surfaces for warpage. Replace manifold if warpage exceeds specification. See «MANIFOLD WARPAGE SPECIFICATIONS»(ref-159209-S11248570632003111800000) table. MANIFOLD WARPAGE SPECIFICATIONS Application In. (mm) Exhaust Manifold .0276 (.70) Intake Manifold .0039 (.10)
3. Inspect cylinder block deck surface for warpage. Replace cylinder block if deck surface warpage exceeds specification. See «CYLINDER BLOCK»(ref-159209-S03989035572003111800000) table under ENGINE SPECIFICATIONS.
4. Inspect camshaft and components. See «CAMSHAFT»(ref-159209-S40041780812003111800000) . Measure valve lifter diameter and bore diameter. Ensure oil clearance is within specification. Replace components if oil clearance is not within specification. See «VALVE LIFTERS»(ref-159209-S34461808042003111800000) table under ENGINE SPECIFICATIONS.

1. Using caliper, measure length of 16 links with chain fully stretched. Measure chain at 3 different places. If measurement exceeds specification, replace chain. See «TIMING CHAIN»(ref-159209-S19282302502003111800000) table under ENGINE SPECIFICATIONS. Wrap chain around timing sprockets. Using caliper, measure timing sprocket diameters with chain. Caliper must contact chain rollers for measuring. If measurement exceeds specification, replace chain. See «TIMING CHAIN»(ref-159209-S19282302502003111800000) table under ENGINE SPECIFICATIONS.
2. Measure chain tensioner slipper and vibration damper for wear. If wear exceeds .039" (1.0 mm), replace slipper and/or damper. Ensure chain tensioner plunger moves smoothly when ratchet pawl is raised with finger. Release ratchet pawl and ensure plunger is locked in place and does not move when pushed with finger.

Inspect components for damage. Measure valve lifter diameter and lifter bore diameter. Ensure oil clearance is within specification. Replace components if not within specification. See VALVE LIFTERS table under ENGINE SPECIFICATIONS.

1. Inspect components for damage. Check camshaft journal diameter, lobe height and journal runout. Replace camshaft if not within specification. See «CAMSHAFT»(ref-159209-S03081208462003111800000) table under ENGINE SPECIFICATIONS.
2. Install camshaft in cylinder head. Using Plastigage, check camshaft oil clearance with camshaft bearing cap bolts tightened to specification in sequence. see scheme 10 See «TORQUE SPECIFICATIONS»(ref-159209-S36718258952003111800000).
3. Replace camshaft and/or cylinder head if oil clearance is not within specification. See «CAMSHAFT»(ref-159209-S03081208462003111800000) table under ENGINE SPECIFICATIONS.
4. Check camshaft end play with camshaft bearing cap bolts tightened to specification in sequence. see scheme 10 See «TORQUE SPECIFICATIONS»(ref-159209-S36718258952003111800000). Replace camshaft and/or cylinder head if camshaft end play is not within specification. See «CAMSHAFT»(ref-159209-S03081208462003111800000) table under ENGINE SPECIFICATIONS.

1. Inspect components for damage. Coat relief valve with engine oil and ensure relief valve slides freely in pressure relief valve bore. If valve fails to slide freely, replace pressure relief valve.
2. Install drive and driven rotors in oil pump body. Using feeler gauge, measure driven rotor-to-oil pump body clearance between outer edge of driven rotor and oil pump body. (Scheme 9) Replace rotor assembly and/or oil pump body if clearance exceeds specification. See «OIL PUMP SPECIFICATIONS»(ref-159209-S15554703982003111800000) table.
3. Using feeler gauge, measure rotor tip clearance between outside edge of tip on drive rotor and inside edge of tip on driven rotor. (Scheme 9) Replace rotor assembly if rotor tip clearance exceeds specification. See «OIL PUMP SPECIFICATIONS»(ref-159209-S15554703982003111800000) table.
4. With both rotors installed in oil pump body, place straightedge across oil pump body. Using feeler gauge, measure clearance between straightedge and rotors. Replace rotor assembly and/or oil pump body if clearance is greater than maximum wear limit. See «OIL PUMP SPECIFICATIONS»(ref-159209-S15554703982003111800000) table.

OIL PUMP SPECIFICATIONS

Scheme 9