Engine Mechanical: Removal & Installation Toyota Echo I

REMOVAL & INSTALLATION

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal.

Removal

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-159209-S04477984222003111800000) . Disconnect negative battery cable. Drain cooling system and engine oil. Remove hood, battery and battery tray. Remove air cleaner assembly with air intake hose. Remove outer front cowl top panel.
2. Disconnect necessary coolant hoses and cooling fan electrical connectors. Remove radiator. Disconnect control cables at throttle body. Label and disconnect necessary electrical connectors, coolant hoses, fuel lines and vacuum hoses for engine removal. Disconnect engine wire harness from ECM, located behind glove box. Pull out wire harness through firewall.
3. Raise and support vehicle. Remove lower engine covers. Disconnect necessary electrical connectors, control cables and speedometer cable from transaxle. Drain transaxle fluid.
4. On A/T models, disconnect oil cooler lines at transaxle. On M/T models, remove clutch release cylinder with hose attached and secure aside. On all models, remove power steering pump and A/C compressor with hoses attached, and secure aside.
5. Disconnect front and rear heated oxygen sensor connectors. Remove exhaust pipe center section. Remove front wheels. Remove bolts and ABS speed sensor from top of steering knuckle (if equipped). Remove left and right front drive axles. See under appropriate REMOVAL & INSTALLATION in FWD AXLE SHAFTS article in DRIVE AXLES.
6. Support engine with hoist. Remove suspension member. Remove rear (firewall side) engine mount through-bolt. Remove through-bolt and right (timing belt side) engine mount. Remove left (transaxle side) engine mount insulator and bracket. Lift engine and transaxle from vehicle.

Installation

1. Install engine and transaxle. Install right (timing belt side) engine mount and through-bolt. Install left (transaxle side) bracket and engine mount insulator. Install rear (firewall side) engine mount through-bolt. Tighten all bolts to specification. See «TORQUE SPECIFICATIONS»(ref-159209-S36718258952003111800000) .
2. Install suspension member. Use NEW snap ring on end of axle shaft. Install axle shaft in transaxle. Ensure axle shaft moves in and out and cannot be pulled from transaxle.
3. To install remaining components, reverse removal procedure. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-159209-S36718258952003111800000) . Fill cooling system. Adjust control cables. Fill transaxle with ATF Type T-IV on A/T models or SAE 75W-90 GL-5 gear oil on M/T models.

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-159209-S04477984222003111800000). Disconnect negative battery cable. Drain cooling system. Remove water filler pipe. Remove outer front cowl top panel. Remove air cleaner assembly with air intake hose.
2. Remove alternator and drive belt. Disconnect PCV hoses. Remove bolts, ignition coils and spark plugs. Label and disconnect control cables, vacuum hoses, coolant hoses and electrical connectors at throttle body. Remove throttle body.
3. Remove bolts and separate center exhaust pipe from exhaust manifold. Remove bolts/nuts, exhaust manifold heat insulator, exhaust manifold and gasket. Disconnect engine wire harness, connectors and brackets from intake manifold. Remove intake manifold and gasket. CAUTION: DO NOT allow fuel injectors to fall from delivery pipe when removing. NOTE: Spacers are installed between delivery pipe and cylinder head. Note direction of spacers and fuel injector electrical connectors for installation reference.
4. Remove valve cover and gasket. Remove fuel delivery pipe, injectors and spacers. Remove bolt, camshaft position sensor and "O" ring from cylinder head. Camshaft position sensor is located on flywheel/drive plate end of cylinder head, just below valve cover.
5. Remove timing chain cover. See «TIMING CHAIN»(ref-159209-S01678303202003111800000). Remove timing chain from camshaft timing sprockets. Remove, but do not disassemble valve timing controller assembly. Using proper procedure, remove camshafts. See «CAMSHAFT»(ref-159209-S40041780812003111800000). CAUTION: Cylinder head bolts must be loosened in proper sequence to prevent cylinder head warpage.
6. Remove cylinder head bolts in sequence. (Scheme 10) Remove cylinder head.

Scheme 10

1. Install NEW cylinder head gasket on cylinder block. Ensure all holes in cylinder head gasket align with holes in cylinder block. Install cylinder head.
2. Apply engine oil on threads and cylinder head bolt-to-cylinder head contact surfaces on cylinder head bolts. Install and tighten cylinder head bolts to specification in sequence. (Scheme 10) See «TORQUE SPECIFICATIONS»(ref-159209-S36718258952003111800000). CAUTION: Crankshaft must always be rotated clockwise. DO NOT rotate crankshaft counterclockwise. DO NOT force valve timing controller assembly to camshaft when installing.
3. Connect upper radiator hose and heater hoses to water hose unions. Install camshafts using proper procedure. See «CAMSHAFT»(ref-159209-S40041780812003111800000). Install exhaust camshaft sprocket and valve timing controller assembly. Ensure timing marks are facing upward.
4. Install timing chain. See «TIMING CHAIN»(ref-159209-S01678303202003111800000). If camshaft or cylinder head components are serviced, adjust valve clearance. See «VALVE CLEARANCE»(ref-159209-S32722745322003111800000) under ADJUSTMENTS.
5. If fuel injectors were removed from delivery pipe, install NEW grommets on fuel injectors. Coat NEW "O" rings with gasoline and install on fuel injectors. Ensure 2 spacers are installed between delivery pipe and cylinder head in original direction. With delivery pipe-to-cylinder head bolts loosely installed, ensure all fuel injectors rotate smoothly. Ensure electrical connector on fuel injector is facing valve cover before tightening delivery pipe-to-cylinder head bolts to specification. See «TORQUE SPECIFICATIONS»(ref-159209-S36718258952003111800000).
6. Install remaining components. Use NEW gaskets and "O" rings. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-159209-S36718258952003111800000). Fill cooling system and adjust control cables.

1. Remove accessory drive belts and crankshaft pulley. Using a knife, cut seal lip from seal. Pry seal from timing chain cover. DO NOT damage sealing surfaces.
2. To install, apply grease to lip of seal. Using hammer and Seal Installer (SST 09612-22011), install seal until seal surface is even with timing chain cover. To install remaining components, reverse removal procedure.

1. Disconnect negative battery cable. Drain engine coolant. Raise and support vehicle. Remove passenger's side lower engine cover. Remove accessory drive belts. Disconnect generator and power steering pump from engine.
2. Slightly raise engine to remove weight from right (timing belt side) engine mount. Remove through-bolt and right (timing belt side) engine mount and bracket. Remove upper cylinder head cover, valve cover and gasket.
3. Rotate crankshaft and align groove with timing mark "O" of timing chain cover. Ensure camshaft sprocket timing marks are facing up. Remove crankshaft pulley bolt. Using puller, remove crankshaft pulley. Remove crankshaft position sensor.
4. Remove water pump. Remove oil control valve. Remove bolts, stud bolt, nuts and timing chain cover.
5. Remove timing chain tensioner, tensioner slipper, vibration damper and timing chain.

Scheme 11

Scheme 12

Scheme 13

1. Set crankshaft at 40-140 degrees ATDC. Set intake and exhaust timing sprockets at 20 degrees ATDC. Align timing chain mark plate (Yellow) to timing marks on exhaust camshaft sprocket, intake valve timing sprocket and crankshaft sprocket. (Scheme 11) Install chain vibration damper. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-159209-S36718258952003111800000).
2. Install chain tensioner slipper. Lock plunger into tensioner body with suitable pin. Install chain tensioner. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-159209-S36718258952003111800000). Remove pin from tensioner body. Ensure that chain tension exists between camshaft sprockets. Rotate crankshaft 360 degrees clockwise, ensure timing marks on sprockets and chain align. (Scheme 11)
3. Ensure timing chain cover is clean. Apply sealant to timing chain cover. (Scheme 12) Install NEW "O" rings to cylinder block and oil pan No. 1. Install timing chain cover, new "O"ring and water pump. Ensure bolts are properly located. (Scheme 13) Tighten bolts and nuts uniformly in several passes. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-159209-S36718258952003111800000).
4. To install remaining components, reverse removal procedure. To ensure proper engine mount alignment, install all right (timing belt side) engine mount bolts/nuts before tightening to specification. See «TORQUE SPECIFICATIONS»(ref-159209-S36718258952003111800000).

Remove camshafts. See CAMSHAFT . Note location of valve lifters for installation reference. Remove valve lifters from cylinder head.

To install, reverse removal procedure. Ensure components are installed in original location and valve lifter rotates smoothly in cylinder head. If camshaft or valve lifters are replaced, check valve clearance. See VALVE CLEARANCE under ADJUSTMENTS.

1. Remove upper cylinder head cover. Remove bolts, ignition coils and spark plugs. Disconnect 2 PCV hoses and necessary electrical connections to access valve cover. Remove valve cover. Remove retaining bolt, camshaft position sensor and "O" ring from cylinder head. Camshaft position sensor is located on flywheel/drive plate end of cylinder head, just below valve cover.
2. Rotate crankshaft clockwise (viewed from timing chain end of engine) so 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. With cylinder No. 1 at TDC on compression stroke, ensure camshaft timing marks point upward.
3. Remove accessory drive belts. Remove plug from timing chain cover to access chain tensioner. Raise lock plate and turn crankshaft clockwise to push plunger into tensioner body. Install suitable pin to hole of lock plate to hold plunger in tensioner body.
4. Hold camshaft with wrench on hexagonal area of camshaft and remove camshaft sprocket bolts. Remove camshaft sprocket from exhaust camshaft. Remove valve timing controller assembly from intake camshaft. NOTE: Note location of camshaft bearing caps. Camshaft bearing caps are stamped with numbers on top. Camshaft bearing caps are also stamped with either an "I" for intake camshaft or an "E" for exhaust camshaft. (Scheme 14) Arrow on top of camshaft bearing cap must point toward timing chain end of engine. CAUTION: Ensure camshaft is lifted upward evenly from cylinder head when loosening camshaft bearing cap bolts. Camshafts must be properly positioned to lift camshaft straight from cylinder head to prevent damage to cylinder head and camshaft. DO NOT pry or force camshafts from cylinder head, or component damage will result.
5. Remove camshaft bearing cap bolts in sequence. (Scheme 15) If exhaust camshaft is not lifted upward evenly after removing all bearing cap bolts and bearing caps, reinstall only No. 3 camshaft bearing cap on exhaust camshaft and slightly tighten bolts. Alternately loosen bolts on No. 3 camshaft bearing cap while pulling upward on front of exhaust camshaft. Remove exhaust camshaft from cylinder head. Follow this procedure for intake camshaft.

Scheme 14

Scheme 15

1. Apply lubricant to camshaft journals. Install camshafts to cylinder head. Install bearing caps in proper location. (Scheme 14) Apply light coat of oil to bolt threads and under bolt heads. Tighten bolts in sequence and to specification. (Scheme 15) See «TORQUE SPECIFICATIONS»(ref-159209-S36718258952003111800000).
2. Install camshaft timing sprocket and valve timing controller. Align timing marks. Install timing chain. See «TIMING CHAIN»(ref-159209-S40551612732003111800000).
3. If camshafts were serviced or replaced, check and adjust valve clearance. See «VALVE CLEARANCE»(ref-159209-S32722745322003111800000) under ADJUSTMENTS. To install remaining components, reverse removal procedure. Using NEW gasket, install valve cover and sealing washers. Install and tighten valve cover nuts to specification. See «TORQUE SPECIFICATIONS»(ref-159209-S36718258952003111800000).

Remove transaxle and flywheel/drive plate. For M/T, see REMOVAL & INSTALLATION under CLUTCHES article in TRANSAXLE/TRANSMISSION. For A/T, see REMOVAL & INSTALLATION - A/T article in in TRANSAXLE/TRANSMISSION. Using a knife, cut off oil seal lip. Pry oil seal from cylinder block. DO NOT damage sealing surfaces.

1. Ensure all sealing surfaces are clean. Apply grease to lip of oil seal. Using Oil Seal Installer (SST 09223-15030), install oil seal until flush with cylinder block.
2. Apply Loctite to flywheel/drive plate bolts. Install and tighten flywheel/drive plate bolts to specification in a crisscross pattern. See «TORQUE SPECIFICATIONS»(ref-159209-S36718258952003111800000) . To install remaining components, reverse removal procedure.

1. Drain cooling system. Remove drive belt. Remove bolts from water pump pulley. Remove 3 bolts, 2 nuts, water pump and gasket.
2. Apply bead of sealant on water pump-to-cylinder block surface. Install water pump. Install and tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-159209-S36718258952003111800000) . To install remaining components, reverse removal procedure.

1. Remove bolts/nuts from No. 2 oil pan. Remove No. 2 oil pan. Be careful not to damage oil pan sealing surface. Remove 2 nuts, and oil strainer. Loosen No. 1 oil pan bolts in several passes. Remove No. 1 oil pan. Remove 2 "O"rings from cylinder block.
2. To install, ensure sealing surfaces are clean. Apply bead of sealant on inside of bolt holes and at center of No. 1 oil pan sealing surface, between bolt holes. Install No. 1 oil pan. Install and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-159209-S36718258952003111800000) . Install oil strainer. Apply bead of sealant on inside of bolt holes and at center of No. 2 oil pan sealing surface, between bolt holes. Install oil pan. Install and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-159209-S36718258952003111800000) .
3. To install remaining components, reverse removal procedure using NEW gaskets. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-159209-S36718258952003111800000) . Fill crankcase with oil. See «CRANKCASE CAPACITIES»(ref-159209-S14463733782003111800000) table. CRANKCASE CAPACITIES Application Qts. (L) With Oil Filter Change 3.9 (3.7) W/O Oil Filter Change 3.6 (3.4) Dry Fill 4.3 (4.1)

Removal & Disassembly

1. Remove timing chain cover. See «TIMING CHAIN»(ref-159209-S01678303202003111800000) under REMOVAL & INSTALLATION.
2. Remove 2 bolts, 3 screws and oil pump cover from timing chain cover. Remove plug, spring and relief valve.

Reassembly & Installation

1. Install relief valve, spring and plug to oil pump body. Tighten to specifications. See «TORQUE SPECIFICATIONS»(ref-159209-S36718258952003111800000) .
2. Install rotors to timing chain cover, ensuring reference marks on rotors face toward oil pump cover. Install oil pump cover to timing chain cover with 2 bolts and 3 screws. Tighten to specifications. See «TORQUE SPECIFICATIONS»(ref-159209-S36718258952003111800000) . To install remaining components, reverse removal procedure.