Engine Mechanical: Other Toyota Echo I

VALVE CLEARANCE

Note. Adjust valve clearance with engine cold.

Scheme 16

1. Remove upper cylinder head cover. Disconnect 2 PCV hoses and necessary electrical connections to access valve cover. Remove ignition coils and spark plugs.
2. Remove valve cover nuts, seal washers, valve cover and gasket. Rotate crankshaft clockwise (viewed from timing chain end of engine) so that cylinder No. 1 is at TDC on compression stroke and timing mark (groove) on crankshaft pulley aligns with "0" mark on timing chain cover. Cylinder No. 1 is front cylinder at timing chain end of engine. Align camshaft timing sprockets with marks pointing up.
3. Ensure valve lifters on cylinder No. 1 are loose and valve lifters on cylinder No. 4 are tight. If conditions are not as described, rotate crankshaft clockwise one complete revolution (360 degrees).
4. Using feeler gauge, measure and record valve clearance between valve lifter and camshaft on intake valves of cylinders No. 1 and 2, and exhaust valves of cylinders No. 1 and 3. Record valve clearance. Rotate crankshaft clockwise one complete revolution (360 degrees) with timing mark (groove) on crankshaft pulley aligned with "0" mark on timing chain cover.
5. Measure and record valve clearance on intake valves of cylinders No. 3 and 4, and exhaust valves of cylinders No. 2 and 4. Ensure valve clearance is within specification. See «VALVE CLEARANCE SPECIFICATIONS»(ref-159209-S06658673022003111800000) table. VALVE CLEARANCE SPECIFICATIONS Application (1) In. (mm) Intake Valve.006-.010 (.15-.25) Exhaust Valve.010-.014 (.25-.35) (1) Adjust valve clearance with engine cold.
6. If valve clearance requires adjustment, ensure No. 1 cylinder is at TDC. Place matchmarks on timing chain and camshaft timing sprockets. (Scheme 16) Rotate crankshaft counterclockwise 40 degrees from TDC. Remove plug from timing chain cover. While rotating stopper plate of tensioner downward, turn exhaust camshaft clockwise and push in plunger of chain tensioner. With plunger pushed into tensioner body, insert suitable pin into hole of stopper plate and tensioner body. (Scheme 16) CAUTION: DO NOT rotate crankshaft with timing chain removed.
7. Remove valve timing controller assembly. Remove timing chain from camshaft timing sprockets. Secure timing chain aside. Do not allow timing chain to drop below timing chain cover. Use proper procedure to remove intake and exhaust camshaft assembly. See «CAMSHAFT»(ref-159209-S40041780812003111800000) under REMOVAL & INSTALLATION.
8. Using small screwdriver and magnet, remove adjusting shim. Measure and record thickness of adjusting shim removed. Using measured clearance and adjusting shim thickness, select proper replacement adjustment shim. (Scheme 17)and (Scheme 18). Select a new adjustment shim with thickness as close as possible to calculated values. Install replacement adjusting shim.
9. Ensure crankshaft is at TDC. Install exhaust camshaft. Temporarily install valve timing controller. Ensure timing marks on camshaft sprockets face upward. (Scheme 16) Reinstall camshaft bearing cap assembly. See «CAMSHAFT»(ref-159209-S40041780812003111800000) under REMOVAL & INSTALLATION. Remove valve timing controller. Align matchmarks on timing chain with exhaust camshaft sprocket. Align matchmarks on timing chain with valve timing controller. Install controller to intake camshaft. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-159209-S36718258952003111800000).
10. Remove stopper pin from chain tensioner body. Install NEW plug in front cover. See «TORQUE SPECIFICATIONS»(ref-159209-S36718258952003111800000). Rotate crankshaft one revolution and ensure timing marks on crankshaft and camshafts align. Recheck valve clearance.
11. Apply sealant to top of area where front cover meets cylinder head. Using NEW gasket, install valve cover and sealing washers. Install and tighten valve cover nuts to specification. See «TORQUE SPECIFICATIONS»(ref-159209-S36718258952003111800000). To install remaining components, reverse removal procedure.

Scheme 17

Scheme 18

FUEL PRESSURE RELEASE

Note. Manufacturer recommends disconnecting electrical connector at electric fuel pump and operating engine until engine stalls before loosening fuel line connection.

1. Remove rear seat cushion and floor panel cover for access to electrical connector for electric fuel pump. Electric fuel pump is located in fuel tank. Disconnect fuel pump electrical connector.
2. Start engine and allow engine to idle until engine stalls. Turn ignition off. Reconnect electrical connector. Reinstall floor panel cover and rear seat cushion.
3. Disconnect negative battery cable. Place approved gasoline container under fuel line. Cover fuel line connection with shop towel.
4. Slowly loosen fuel line connection to release fuel pressure. Once fuel pressure is released, fuel system components may be serviced.

Note. Remove engine and transaxle as an assembly.

OIL PAN

Note. Manufacturer recommends removing engine from vehicle before servicing oil pan. See ENGINE .

Cylinder Head

1. Inspect cylinder head warpage at cylinder block and manifold surfaces. Replace cylinder head if warpage exceeds specification. See «CYLINDER HEAD»(ref-159209-S02776641392003111800000) table under ENGINE SPECIFICATIONS. Inspect combustion chambers, head gasket surface, intake and exhaust ports for damage and cracks. Replace head if any cracks are found.
2. Install camshafts in cylinder head. Measure camshaft oil clearance and end play. See «CAMSHAFT»(ref-159209-S40041780812003111800000) under REMOVAL & INSTALLATION.
3. Ensure valve lifter diameter, bore diameter and oil clearance are within specification. See «VALVE LIFTERS»(ref-159209-S34461808042003111800000) table under ENGINE SPECIFICATIONS. Replace components if not as specified.

Valve Springs

Ensure valve spring free length, pressure and out-of-square are within specification. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS. If valve springs are not within specifications, replace valve springs.

Valve Stem Oil Seals

Remove valve stem seals with needle-nose pliers. Intake valve stem oil seal is Light Brown and exhaust valve stem oil seal is Gray. Lubricate valve stem oil seal with engine oil. Install valve stem oil seal using the appropriate diameter socket.

Valve Guides

1. Ensure valve guide inside diameter is within specification. See «CYLINDER HEAD»(ref-159209-S02776641392003111800000) table under ENGINE SPECIFICATIONS. Replace valve guide if inside diameter exceeds specification.
2. To replace valve guide, gradually heat cylinder head to 176-212°F (80-100°C ). Use Valve Guide Remover/Installer (SST 09201-01055, 09950-70010) and hammer, drive out valve guide from camshaft side of cylinder head.
3. Measure cylinder head valve guide bore inside diameter. If bore inside diameter is.3813-.3821" (9.685-9.706 mm), use standard valve guide. If bore inside diameter is.3833-.3849" (9.735-9.756 mm), use oversize valve guide. If bushing bore diameter of cylinder head is greater than.3849" (9.756 mm), replace cylinder head.
4. To install valve guide, gradually heat cylinder head to 176-212°F (80-100°C ). Use Valve Guide Remover/Installer (SST 09201-01055, 09950-70010) and hammer, drive in valve guide from camshaft side of cylinder head. Ensure protrusion height is 354-.370" (9.0-9.4 mm). (Scheme 19)
5. Using.197" (5.00 mm) reamer, ream valve guide to obtain specified valve stem-to-guide oil clearance. See «CYLINDER HEAD»(ref-159209-S02776641392003111800000) table under ENGINE SPECIFICATIONS.

Scheme 19

Valve Seat

Ensure valve seat angle and seat width are within specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Valve seat replacement information is not available from manufacturer.

Valves

Ensure minimum refinish length, stem diameter and valve margin are within specification. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.

Valve Seat Correction Angles

Use degree and 45-degree stones to lower valve seat contact area. Use 75-degree and 45-degree stones to raise valve seat contact area.

Valve Lifters

Ensure valve lifter diameter, lifter bore diameter and oil clearance are within specification. See VALVE LIFTERS table under ENGINE SPECIFICATIONS.

Piston & Rod

1. Ensure connecting rod and connecting rod cap are marked with matching cylinder number for installation reference. Piston and connecting rod must be installed in cylinder block with front mark facing timing chain end of engine. (Scheme 20)
2. Before disassembling piston and connecting rod, try to move piston back and forth on piston pin. Replace piston and piston pin as an assembly if any movement is felt. When removing piston from connecting rod, press piston pin from piston.
3. Ensure connecting rod bend and twist are within specification. Measure crankpin and piston pin bore diameters. Piston pin should push fit in small end of rod. Repair or replace if not within specification. See «CONNECTING RODS»(ref-159209-S17058595312003111800000) table under ENGINE SPECIFICATIONS.
4. To reassemble, install piston on connecting rod so front mark on top of piston aligns with front mark on connecting rod. (Scheme 20) Coat piston pin and piston pin holes with engine oil. Press piston pin into piston.

Scheme 20

Fitting Pistons

1. To determine piston-to-cylinder clearance, measure piston skirt diameter at 1.06" (27.0 mm) from top of piston at 90-degree angle to piston pin. Measure cylinder bore diameter in thrust and axial direction. See «CYLINDER BLOCK»(ref-159209-S41332611302003111800000) .
2. Subtract piston diameter measurement from cylinder bore diameter measurement. If oil clearance is greater than maximum, replace all pistons. If necessary, replace cylinder block. See «PISTONS, PINS & RINGS»(ref-159209-S07903971352003111800000) and «CYLINDER BLOCK»(ref-159209-S03989035572003111800000) table under ENGINE SPECIFICATIONS.

Piston Rings

1. Insert piston ring into cylinder bore. Position piston ring 4.33" (110 mm) from top of deck. Ensure piston ring end gaps are within specification. See «PISTONS, PINS & RINGS»(ref-159209-S07903971352003111800000) table under ENGINE SPECIFICATIONS.
2. Using a feeler gauge, measure clearance between piston ring and wall of ring groove. If clearance is not as specified, replace piston. See «PISTONS, PINS & RINGS»(ref-159209-S07903971352003111800000) table under ENGINE SPECIFICATIONS.
3. Install oil ring expander and 2 side rails. Install second compression ring in proper location. (Scheme 21) Position piston rings with ring end gaps in proper areas. (Scheme 22)

Scheme 21

Scheme 22

Rod Bearings

1. Ensure connecting rod and connecting rod cap are match marked for reassembly. Piston, connecting rod and connecting rod cap must be installed so front mark is toward timing chain end of engine. (Scheme 20)
2. Connecting rod cap and rod bearing are stamped with size mark ("1", "2" or "3"). (Scheme 23) Ensure size marks on connecting rod cap and rod bearing are same. NOTE: If replacing rod bearing, ensure size mark on replacement rod bearing is same as size mark on original rod bearing.
3. Rod bearing thickness is determined by size mark. See «ROD BEARING SPECIFICATIONS»(ref-159209-S27927351422003111800000) table. Install connecting rod and connecting rod cap with front mark (protrusion) toward timing chain end of engine. (Scheme 20)
4. Measure rod cap bolt tension area thickness. If measurement exceeds minimum, replace bolt. See «CONNECTING ROD»(ref-159209-S17058595312003111800000) table under ENGINE SPECIFICATIONS. Coat threads of connecting rod bolt and connecting rod nut-to-connecting rod cap surface with engine oil before tightening nuts to specification. See «TORQUE SPECIFICATIONS»(ref-159209-S36718258952003111800000).
5. Ensure bearing oil clearance and connecting rod side play are within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-159209-S37038679772003111800000) and «CONNECTING RODS»(ref-159209-S17058595312003111800000) tables under ENGINE SPECIFICATIONS.

ROD BEARING SPECIFICATIONS

Scheme 23

Crankshaft & Main Bearings

1. Main bearing caps contain a location number and a front mark. No. 1 main bearing cap is located at timing chain end of engine and No. 5 is at flywheel/drive plate end of engine.
2. Remove main bearing cap bolts in sequence. (Scheme 24) Remove main bearing caps, crankshaft, thrust washers and main bearings.
3. Cylinder block main bearing bore inside diameter is identified by size mark ("1", "2", "3", "4", "5" or "6") stamped on cylinder block. (Scheme 25) Front size mark indicates No. 1 main bearing bore and rear size mark indicates No. 5 main bearing bore.
4. Crankshaft main bearing journal diameter is identified by size mark ("0", "1", "2", "3", "4" or "5") on crankshaft counterweight. (Scheme 25) Front lower size mark indicates No. 1 main bearing journal. Rear lower size mark indicates No. 5 main bearing journal.
5. Measure crankshaft. Ensure journal diameter, taper and out-of-round are within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-159209-S37038679772003111800000) table under ENGINE SPECIFICATIONS.
6. Main bearing size mark ("1", "2", "3" or "4") is located on side of main bearing. (Scheme 25) If replacing main bearing, ensure size mark on replacement main bearing is same as size mark on original main bearing.
7. If main bearing size mark cannot be obtained, add size marks on cylinder block and crankshaft together to determine size mark of main bearing to be used. For example, if size mark on cylinder block is "2" and size mark on crankshaft is "1", use main bearing with size mark "3".
8. Main bearing thickness is determined by size mark. See «MAIN BEARING SPECIFICATIONS»(ref-159209-S35375769332003111800000) table. Install main bearings, thrust bearings, crankshaft and main bearing caps. Ensure main bearing caps are properly installed in numerical sequence with No. 1 at timing chain end of engine and No. 5 at flywheel/drive plate end of engine. Ensure front mark on each main bearing cap is pointing toward timing chain end of engine.
9. Inspect main bearing cap bolts. Measure tension portion of bolt. If measurement does not meet, or is less than minimum thickness, replace bolt. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-159209-S37038679772003111800000) table under ENGINE SPECIFICATIONS. Coat threads and bolt-to-main bearing cap surfaces with engine oil. Install and tighten main bearing cap bolts to specification in sequence using several steps. (Scheme 24) See «TORQUE SPECIFICATIONS»(ref-159209-S36718258952003111800000).
10. Ensure crankshaft main bearing oil clearance and crankshaft end play are within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-159209-S37038679772003111800000) table under ENGINE SPECIFICATIONS.

MAIN BEARING SPECIFICATIONS

Scheme 24

Scheme 25

Thrust Bearing

Using a dial indicator, measure thrust clearance while moving crankshaft back and forth. If thrust clearance is greater than maximum, replace thrust washer as a set. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.

Cylinder Block

1. Inspect cylinder block deck surface warpage. Replace cylinder block if deck surface warpage exceeds specification. See «CYLINDER BLOCK»(ref-159209-S03989035572003111800000) table under ENGINE SPECIFICATIONS. Visually check cylinder for scratches, wear and discoloration. If deep scratches are present, replace cylinder block.
2. Measure cylinder bore diameter at 3 different places, 90 degrees apart at .39" (10.0 mm) from top and bottom of cylinder bore and at center of cylinder bore. Ensure cylinder bore diameter is within specification. See «CYLINDER BLOCK»(ref-159209-S03989035572003111800000) table under ENGINE SPECIFICATIONS. Replace cylinder block if cylinder bore exceeds specification. If wear is less than .008" (.2 mm), use a ridge reamer and remove ridge from top of cylinder.

Oil Pressure

With engine at normal operating temperature, oil pressure should be at least 4.3 psi (0.3 kg/cm 2 ) at idle and 22-80 psi (1.5-5.6 kg/cm 2 ) at 3000 RPM.

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

CONNECTING RODS

CONNECTING RODS

ENGINE PISTONS, ENGINE PISTON PINS & ENGINE PISTON RINGS

ENGINE PISTONS, ENGINE PISTON PINS & ENGINE PISTON RINGS

CYLINDER BLOCK

TIMING CHAIN

TIMING CHAIN

VALVES & VALVE SPRINGS

VALVES & VALVE SPRINGS

CYLINDER HEAD

CAMSHAFT

CAMSHAFT

VALVE LIFTERS