engine TOYOTA ECHO 2004 1.G Workshop Manual

2042004 ECHO from Aug. ’03 Prod. (OM52526U)
Exhaust system
If you notice any change in the sound of
the exhaust or smell exhaust fumes, have
the cause located and corrected immedi-
ately. (See “Engine exhaust cautions” in
Section 2.)
INSIDE THE VEHICLE
Items listed below should be checked
regularly, e.g. while performing periodic
services, cleaning the vehicle, etc.
Lights
Make sure the headlights, stop lights, tail
lights, turn signal lights, and other lights
are all working. Check headlight aim.
Service reminder indicators and warning
buzzers
Check that all service reminder indicators
and warning buzzers function properly.
Steering wheel
Be alert for changes in steering condition,
such as hard steering or strange noise.Seats
Check that all front seat controls such as
seat adjusters, seatback recliner, etc. op-
erate smoothly and that all latches lock
securely in any position. Check that the
head restraints move up and down
smoothly and that the locks hold securely
in any latched position. For folding−down
rear seatbacks, check that the latches
lock securely.
Seat belts
Check that the seat belt system such as
buckles, retractors and anchors operate
properly and smoothly. Make sure that the
belt webbings are not cut, frayed, worn or
damaged.
Accelerator pedal
Check the pedal for smooth operation and
uneven pedal effort or catching.
Clutch pedal
Check the pedal for smooth operation.
Brake pedal
Check the pedal for smooth operation and
that the pedal has the proper clearance.
Check the brake booster function.
Brakes
At a safe place, check that the brakes do
not pull to one side when applied.Parking brake
Check that the lever has the proper travel
and that, on a safe incline, your vehicle
is held securely with only the parking
brake applied.
Automatic transmission “Park” mecha-
nism
Check the lock release button of the se-
lector lever for proper and smooth opera-
tion. On a safe incline, check that your
vehicle is held securely with the selector
lever in “P” position and all brakes re-
leased.
OUTSIDE THE VEHICLE
Items listed below should be performed
from time to time, unless otherwise
specified.
Fluid leaks
Check underneath for leaking fuel, oil, wa-
ter or other fluid after the vehicle has
been parked for a while. If you smell fuel
fumes or notice any leak, have the cause
found and corrected immediately.
Doors and engine hood
Check that all doors including trunk lid
operate smoothly and all latches lock se-
curely. Make sure the engine hood sec-
ondary latch secures the hood from open-
ing when the primary latch is released.

2052004 ECHO from Aug. ’03 Prod. (OM52526U)
Tire pressure
Check the pressure with a gauge ev-
ery two weeks, or at least once a
month. See Section 7−2 for additional
information.
Tire surface and wheel nuts
Check the tires carefully for cuts,
damage or excessive wear. See Sec-
tion 7−2 for additional information.
When checking the tires, make sure
no nuts are missing, and check the
nuts for looseness. Tighten them if
necessary.
Tire rotation
Rotate the tries according to the
maintenance schedule. (For sched-
uled maintenance information, please
refer to the “Scheduled Maintenance
Guide” or “Owner ’s Manual Supple-
ment”.)Be on the alert for changes in perfor-
mance, sounds, and visual tip−offs that
indicate service is needed. Some impor-
tant clues are as follows:
Engine missing, stumbling, or pinging
Appreciable loss of power
Strange engine noises
A leak under the vehicle (however, wa-
ter dripping from the air conditioning
after use is normal.)
Change in exhaust sound (This may
indicate a dangerous carbon monoxide
leak. Drive with the windows open and
have the exhaust system checked im-
mediately.)
Flat−looking tire; excessive tire squeal
when cornering; uneven tire wear
Vehicle pulls to one side when driving
straight on a level road
Strange noises related to suspension
movement
Loss of brake effectiveness; spongy
feeling brake or clutch pedal; pedal al-
most touches floor; vehicle pulls to one
side when braking
Engine coolant temperature continually
higher than normalIf you notice any of these clues, take your
vehicle to your Toyota dealer as soon as
possible. It probably needs adjustment or
repair.
CAUTION
Do not continue driving with the ve-
hicle unchecked. It could result in se-
rious vehicle damage and possibly
personal injury.
Does your vehicle need
repairing?

2072004 ECHO from Aug. ’03 Prod. (OM52526U)
DOITYOURSELF MAINTENANCE
Introduction
Engine compartment overview208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse locations209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Do−it−yourself service precautions209 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts and tools211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Positioning the jack212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 1

2082004 ECHO from Aug. ’03 Prod. (OM52526U)
Engine compartment overview
1. Windshield washer fluid tank
2. Engine oil filler cap
3. Power steering fluid reservoir
4. Brake fluid reservoir
5. Battery
6. Fuse blocks
7. Engine coolant reservoir
8. Radiator
9. Condenser
10. Electric cooling fan
11. Engine oil level dipstick
SU71011

2102004 ECHO from Aug. ’03 Prod. (OM52526U)
CAUTION
When the engine is running, keep
hands, clothing, and tools away
from the moving fan and engine
drive belts. (Removing rings,
watches, and ties is advisable.)
Right after driving, the engine
compartment—the engine, radiator,
exhaust manifold and spark plug
boots, etc.—will be hot. So be care-
ful not to touch them. Oil, fluids
and spark plugs may also be hot.
If the engine is hot, do not remove
the radiator cap or loosen the drain
plugs to prevent burning yourself.
Do not smoke, cause sparks or al-
low open flames around fuel or the
battery. Their fumes are flammable.
Be extremely cautious when work-
ing on the battery. It contains poi-
sonous and corrosive sulfuric acid.
Do not get under your vehicle with
just the body jack supporting it. Al-
ways use automotive jack stands or
other solid supports.
Be sure that the ignition is off if
you work near the electric cooling
fans or radiator grille. With the
ignition on, the electric cooling fans
will automatically start to run if the
engine coolant temperature is high
and/or the air conditioning is on.
Use eye protection whenever you
work on or under your vehicle
where you may be exposed to flying
or falling material, fluid spray, etc.
Used engine oil contains potentially
harmful contaminants which may
cause skin disorders such as in-
flammation or skin cancer, so care
should be taken to avoid prolonged
and repeated contact with it. To re-
move used engine oil from your
skin, wash thoroughly with soap
and water.
Do not leave used oil within the
reach of children.
Dispose of used oil and filter only
in a safe and acceptable manner.
Do not dispose of used oil and fil-
ter in household trash, in sewers or
onto the ground. Call your dealer or
a service station for information
concerning recycling or disposal.
Take care when filling the brake and
clutch fluid reservoirs because
brake fluid can harm your eyes and
damage painted surfaces. If fluid
gets in your eyes, flush your eyes
with clean water immediately. If you
still feel uncomfortable with your
eyes, go to the doctor.
NOTICE
Remember that battery and ignition
cables carry high currents or volt-
ages. Be careful of accidentally
causing a short circuit.
Add only “Toyota Super Long Life
Coolant” or similar high quality eth-
ylene glycol based nonsilicate,
nonamine, nonnitrite, and nonbo-
rate coolant with longlife hybrid
organic acid technology to fill the
radiator. “Toyota Super Long Life
Coolant” is premixed with 50%
coolant and 50% deionized water.
If you spill some of the coolant, be
sure to wash it off with water to
prevent it from damaging the parts
or paint.

2112004 ECHO from Aug. ’03 Prod. (OM52526U)
Do not allow dirt or anything else
to fall through the spark plugholes.
Use only spark plugs of the speci-
fied type. Using other types will
cause engine damage, loss of per-
formance or radio noise.
Do not overfill automatic transmis-
sion fluid, or the transmission
could be damaged.
Do not drive with the air cleaner
filter removed, or excessive engine
wear could result. Also backfiring
could cause a fire in the engine
compartment.
Be careful not to scratch the glass
surface with the wiper frame.
When closing the engine hood,
check to see that you have not for-
gotten any tools, rags, etc.
Parts and tools
Here is a list of parts and tools you will
need to perform do−it−yourself mainte-
nance. Remember all Toyota parts are de-
signed in metric sizes, so your tools must
be metric.
CHECKING THE ENGINE OIL LEVEL
Parts (if level is low):
Engine oil API grade SL
“Energy−Conserving” or ILSAC
multigrade having viscosity proper for
your climate
Tools:
Rag or paper towel
Funnel (only for adding oil)
CHECKING THE ENGINE COOLANT
LEVEL
Parts (if level is low):
“Toyota Super Long Life Coolant” or
similar high quality ethylene glycol
based non−silicate, non−amine, non−ni-
trite, and non−borate coolant with long−
life hybrid organic acid technology.
“Toyota Super Long Life Coolant” is
pre−mixed with 50% coolant and 50%
deionized water.
Tools:
Funnel (only for adding coolant)CHECKING BRAKE FLUID
Parts (if level is low):
SAE J1703 or FMVSS No.116 DOT 3
brake fluid
Tools:
Rag or paper towel
Funnel (only for adding fluid)
CHECKING POWER STEERING FLUID
Parts (if level is low):
Automatic transmission fluid
DEXRON®II or III
Tools:
Rag or paper towel
Funnel (only for adding fluid)
CHECKING BATTERY CONDITION
Tools:
Warm water
Baking soda
Grease
Conventional wrench (for terminal
clamp bolts)
CHECKING AND REPLACING FUSES
Parts (if replacement is necessary):
Genuine Toyota fuse or equivalent with
same amperage rating as original

2122004 ECHO from Aug. ’03 Prod. (OM52526U)
ADDING WASHER FLUID
Parts:
Water
Washer fluid containing antifreeze (for
winter use)
Tools:
Funnel
REPLACING LIGHT BULBS
Parts:
Bulb with same number and wattage
rating as original (See charts in
“Replacing light bulbs” in Section 7−3.)
Positioning the jack
SU41101a
Do not jack up Do not jack up
Lower back
outer panel
(protrusion)
Attachment
When jacking up your vehicle with the
jack, position the jack correctly as
shown in the illustration.
Jack position
. . . . . . . . . .
Front—Front suspension member
Rear—Lower back outer panel
Support position for
Pantograph jack
. . . . . .
CAUTION
When jacking, be sure to observe the
following to reduce the possibility of
personal injury:
Follow jacking instructions.
Do not put any part of your body
under the vehicle supported by a
jack. Personal injury may occur.
Do not start or run the engine while
your vehicle is supported by the
jack.
Stop the vehicle on a level firm
ground, firmly set the parking brake
and put the transmission in “P”
(automatic) or reverse (manual).
Make sure to set the jack properly
in the jack point. Raising the ve-
hicle with jack improperly posi-
tioned will damage the vehicle or
may allow the vehicle to fall off the
jack and cause personal injury.
Never get under the vehicle when
the vehicle is supported by the jack
alone; use vehicle support stands.

2152004 ECHO from Aug. ’03 Prod. (OM52526U)
DOITYOURSELF MAINTENANCE
Engine and Chassis
Checking the engine oil level216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the engine coolant level218 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the radiator and condenser219 . . . . . . . . . . . . . . . . . . . . . . . . .
Checking brake fluid219 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking power steering fluid220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking tire inflation pressure221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking and replacing tires224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotating tires226 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing snow tires and chains226 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing wheels228 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aluminum wheel precautions229 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 2

2162004 ECHO from Aug. ’03 Prod. (OM52526U)
Checking the engine oil level
SU72001
Low levelFull level
Add
oilO.K.To o
full
With the engine at operating tempera-
ture and turned off, check the oil level
on the dipstick.
1. To get a true reading, the vehicle
should be on a level ground. After turn-
ing off the engine, wait a few minutes
for the oil to drain back into the bottom
of the engine.
2. Pull the dipstick out, hold a rag under
the end and wipe it clean.
3. Reinsert the dipstick—Push it in as far
as it will go, or the reading will not be
correct.
4. Pull the dipstick out and look at the oil
level while holding a rag under the
end.
CAUTION
Be careful not to touch the hot ex-
haust manifold.
NOTICE
Be careful not to drop the engine oil
on the vehicle components.
If the oil level is below or only slightly
above the low level, add engine oil of
the same type as already in the engine.
Remove the oil filler cap and add engine
oil in small quantities at a time, checking
the dipstick. We recommend that you use
a funnel when adding oil.
The approximate quantity of oil needed to
fill between the low level and the full level
on the dipstick is indicated below for ref-
erence.
When the level reaches within the correct
range, install the filler cap hand−tight.
Oil quantity, L (qt., lmp. qt.):
1.5 (1.6, 1.3)
NOTICE
Be careful not to spill the engine
oil on the vehicle components.
Avoid overfilling, or the engine
could be damaged.
Check the oil level on the dipstick
once again after adding the oil.
Engine oil selection
“Toyota Genuine Motor Oil” is filled in
your Toyota vehicle. Use Toyota approved
“Toyota Genuine Motor Oil” or equivalent
to satisfy the following grade and viscos-
ity.
Oil grade:
API grade SL “Energy−Conserving” or
ILSAC multigrade engine oil.

2182004 ECHO from Aug. ’03 Prod. (OM52526U)
Z72109
To ensure excellent lubrication perfor-
mance for your engine, “Toyota Genuine
Motor Oil” is available, which has been
specifically tested and approved for all
Toyota engines.
Please contact your Toyota dealer for fur-
ther details about “Toyota Genuine Motor
Oil”.Look at the seethrough coolant reser-
voir when the engine is cold. The cool-
ant level is satisfactory if it is between
the “FULL” and “LOW” lines on the
reservoir. If the level is low, add the
coolant. (For the coolant type, see
“Coolant type selection” described be-
low.)
The coolant level in the reservoir will vary
with engine temperature. However, if the
level is on or below the “LOW” line, add
coolant. Bring the level up to the “FULL”
line.
If the coolant level drops within a short
time after replenishing, there may be a
leak in the system. Visually check the
radiator, hoses, engine coolant filler cap,
radiator cap and drain cock and water
pump.
If you can find no leak, have your Toyota
dealer test the cap pressure and check
for leaks in the cooling system.
CAUTION
To prevent burning yourself, do not
remove the radiator cap when the en-
gine is hot.
Coolant type selection
Use of improper coolants may damage
your engine cooling system.
Only use “Toyota Super Long Life Coolant”
or similar high quality ethylene glycol
based non−silicate, non−amine, non−nitrite,
and non−borate coolant with long−life hy-
brid organic acid technology. (Coolant with
long−life hybrid organic acid technology
consists of the combination of low phos-
phates and organic acids.)
“Toyota Super Long Life Coolant” is pre-
mixed with 50% coolant and 50% deion-
ized water. This coolant provides protec-
tion down to about −35°C (−31°F).
NOTICE
Do not use plain water alone.
Checking the engine coolant
level