engine TOYOTA ECHO 2004 1.G Repair Manual

2192004 ECHO from Aug. ’03 Prod. (OM52526U)
Z72109
Toyota recommends “Toyota Super Long
Life Coolant” which has been tested to
ensure that it will not cause corrosion nor
result in malfunction of your engine
coolant system with proper usage. “Toyota
Super Long Life Coolant” is formulated
with long−life hybrid organic acid
technology and has been specifically
designed to avoid engine cooling system
malfunction on Toyota vehicles.
Please contact your Toyota dealer for
further details.
Checking the radiator and
condenser
If any of the above parts are extremely
dirty or you are not sure of their condi-
tion, take your vehicle to a Toyota dealer.
CAUTION
To prevent burning yourself, be care-
ful not to touch the radiator or con-
denser when the engine is hot.
NOTICE
To prevent damage to the radiator
and condenser, do not perform the
work by yourself.
Checking brake fluid
SU72002
To check the fluid level, simply look at
the seethrough reservoir. The level
should be between the “MAX” and
“MIN” lines on the reservoir.
It is normal for the brake fluid level to go
down slightly as the brake pads wear. So
be sure to keep the reservoir filled.
If the reservoir needs frequent refilling, it
may indicate a serious mechanical prob-
lem.
If the level is low, add SAE J1703 or
FMVSS No.116 DOT 3 brake fluid to the
brake reservoir.

2202004 ECHO from Aug. ’03 Prod. (OM52526U)
Remove and replace the reservoir cap by
hand. Fill the brake fluid to the dotted
line. This brings the fluid to the correct
level when you put the cap back on.
Use only newly opened brake fluid. Once
opened, brake fluid absorbs moisture from
the air, and excess moisture can cause a
dangerous loss of braking.
CAUTION
Take care when filling the reservoir
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
If you spill some of the fluid, be sure
to wash it off with water to prevent
it from damaging the parts or paint.
Checking power steering fluid
SU72009Open
Close
Check the fluid level through the reser-
voir. If necessary, add automatic trans-
mission fluid DEXRONII or III.
If the vehicle has been driven around 80
km/h (50 mph) for 20 minutes (a little
more in frigid temperatures), the fluid is
hot (60C—80C or 140F—175F). You
may also check the level when the fluid
is cold (about room temperature,
10C—30C or 50F—85F) if the engine
has not been run for about five hours.

2332004 ECHO from Aug. ’03 Prod. (OM52526U)
NOTICE
Be sure the engine and all accesso-
ries are off before performing main-
tenance.
When checking the battery, remove
the ground cable from the negative
terminal (“” mark) first and rein-
stall it last.
Be careful not to cause a short cir-
cuit with tools.
Take care no solution gets into the
battery when washing it.
—Checking battery condition
SU73002
Ty p e A
GreenDarkClear or
light yellow
Bluewhite
Red Ty p e B
CHECKING BY THE INDICATOR
Check the battery condition by the indi-
cator color.
Indicator color
ConditionTy p e ATy p e B
GREENBLUEGood
DARKWHITE
Charging necessary.
Have battery
checked by your
Toyota dealer.
CLEAR
or
LIGHT
YELLOW
RED
Have battery
checked by your
Toyota dealer.
Battery recharging precautions
During recharging, the battery is pro-
ducing hydrogen gas.
Therefore, before recharging:
1. If recharging with the battery installed
on the vehicle, be sure to disconnect
the ground cable.
2. Be sure the power switch on the re-
charger is off when connecting the
charger cables to the battery and when
disconnecting them.
CAUTION
Always charge the battery in an un-
confined area. Do not charge the
battery in a garage or closed room
where there is not sufficient ventila-
tion.
Only do a slow charge (5A or less).
Charging at a quicker rate is dan-
gerous. The battery may explode,
causing personal injuries.
NOTICE
Never recharge the battery while the
engine is running. Also, be sure all
accessories are turned off.

2352004 ECHO from Aug. ’03 Prod. (OM52526U)
If the new fuse immediately blows out,
there is a problem with the electrical sys-
tem. Have your Toyota dealer correct it as
soon as possible.
CAUTION
Never use a fuse with a higher am-
perage rating, or any other object, in
place of a fuse. This may cause ex-
tensive damage and possibly a fire.
Adding washer fluid
If any washer does not work or low
windshield washer fluid level warning
light comes on, the washer tank may be
empty. Add washer fluid.
You may use plain water as washer fluid.
However, in cold areas where tempera-
tures range below freezing point, use
washer fluid containing antifreeze. This
product is available at your Toyota dealer
and most auto parts stores. Follow the
manufacturer’s directions for how much to
mix with water.
NOTICE
Do not use engine antifreeze or any
other substitute because it may dam-
age your vehicle’s paint.
Replacing light bulbs—
The following illustrations show how to
gain access to the bulbs. When replacing
a bulb, make sure the ignition switch and
light switch are off. Use bulbs with the
wattage ratings given in the table.
CAUTION
To prevent burning yourself, do not
replace the light bulbs while they
are hot.
Halogen bulbs have pressurized gas
inside and require special handling.
They can burst or shatter if
scratched or dropped. Hold a bulb
only by its plastic or metal case.
Do not touch the glass part of a
bulb with bare hands.
NOTICE
Only use a bulb of the listed type.

2412004 ECHO from Aug. ’03 Prod. (OM52526U)
SPECIFICATIONS
Specifications
Dimensions and weight242 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine242 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel242 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service specifications243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tires245 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuses246 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8

2422004 ECHO from Aug. ’03 Prod. (OM52526U)
Dimensions and weight
Overall length
mm (in.): 4180 (164.6)
Overall width
mm (in.): 1660 (65.4)
1690 (66.5)
∗
1
Overall height
mm (in.): 1510 (59.4)∗
2
1520 (59.8)∗
3
Wheelbase
mm (in.): 2370 (93.3)
Front tread
mm (in.): 1440 (56.7)
Rear tread
mm (in.): 1420 (55.9)
Vehicle capacity weight
(occupants+luggage)
kg(lb.): 351 (775)
∗
1:With Sports Fender And Rocker Panel
Extensions
∗
2:With P175/65R14 81S tires
∗
3:With P185/60R15 84T tires
Engine
Model:
1NZ−FE
Type:
4 cylinder in line, 4 cycle, gasoline
Bore and stroke, mm (in.):
75.0  84.7 (2.95  3.33)
Displacement, cm
3 (cu. in.):
1497 (91.3)
Fuel
Fuel type:
Unleaded gasoline, Octane Rating 87 (Re-
search Octane Number 91) or higher
Fuel tank capacity, L (gal., Imp. gal.):
45 (11.9, 9.9)

2432004 ECHO from Aug. ’03 Prod. (OM52526U)
Service specifications
ENGINE
Valve clearance (engine cold), mm (in.):
Intake 0.15—0.25 (0.006—0.010)
Exhaust 0.25—0.35 (0.010—0.014)
Spark plug type:
DENSO K16R−U
NGK BKR5EYA
Spark plug gap, mm(in.):
0.8 (0.031)
Drive belt tension measured with Boroughs
drive belt tension gauge No. BT−33−73F
(used belt), lbf:
Generator belt 10020
Power steering pump belt 6510
ENGINE LUBRICATION
Oil capacity (drain and refill), L (qt., Imp.
qt.):
With filter 3.7 (3.9, 3.3)
Without filter 3.4 (3.6, 3.0)
“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
Please contact your Toyota dealer for fur-
ther details.
Recommended oil viscosity:
SAE 5W−30
OIL008
Outside temperature
COOLING SYSTEM
Total capacity, L (qt., Imp. qt.):
Manual transmission 4.4 (4.7, 3.9)
Automatic transmission 4.3 (4.5, 3.8)
Coolant type:
“Toyota Super Long Life Coolant” is
filled in your Toyota vehicle at factory
fill. In order to avoid technical problems,
only use “Toyota Super Long Life Cool-
ant” or similar high quality ethylene gly-
col based non−silicate, non−amine, non−
nitrite, and non−borate coolant with
long−life hybrid organic acid technology.
Do not use plain water alone.
Please contact your Toyota dealer for
further details.
BATTERY
Open voltage
∗ at 20C (68F):
12.6—12.8 V Fully charged
12.2—12.4 V Half charged
11.8—12.0 V Discharged
∗: Voltage that is checked 20 minutes af-
ter the key is removed with all the lights
turned off
Charging rates: 5 A max.

2442004 ECHO from Aug. ’03 Prod. (OM52526U)
CLUTCH
Pedal free play, mm (in.):
5—15 (0.2—0.6)
Fluid type:
SAE J1703 or FMVSS No. 116 DOT 3
MANUAL TRANSAXLE
Oil capacity, L (qt., Imp. qt.):
1.9 (2.0, 1.7)
Oil type:
Gear oil API GL−4 or GL−5
Recommended oil viscosity:
SAE 75W−90
AUTOMATIC TRANSAXLE
Fluid capacity (drain and refill),
L (qt., Imp. qt.):
2.9 (3.1, 2.6)
Fluid type:
Toyota Genuine ATF Type T−IV
Change automatic transmission fluid only
as necessary.Generally, it is necessary to change
automatic transmission fluid only if your
vehicle is driven under one of the Special
Operating Conditions listed in your
“Scheduled Maintenance Guide” or
“Owner ’s Manual Supplement”. When
changing the automatic transmission fluid,
use only “Toyota Genuine ATF Type T−IV”
(ATF JWS3309 or NWS6500) to aid in
assuring optimum transaxle performance.
Notice: Using automatic transmission
fluid other than “Toyota Genuine ATF
Type TIV” may cause deterioration in
shift quality, locking up of your trans-
mission accompanied by vibration, and
ultimately damage the automatic trans-
mission of your vehicle.BRAKES
Minimum pedal clearance when depressed
with the pressure of 490 N (50 kgf, 110
lbf) with the engine running, mm (in.):
55 (2.2)
Pedal free play, mm (in.):
1—6 (0.04—0.24)
Pad wear limit, mm (in.):
1.0 (0.04)
Lining wear limit, mm (in.):
1.0 (0.04)
Parking brake adjustment when pulled with
the force of 196 N (20 kgf, 44 lbf):
6—9 clicks
Fluid type:
SAE J1703 or FMVSS No. 116 DOT 3
STEERING
Wheel free play:
Less than 30 mm (1.2 in.)
Power steering fluid type:
Automatic transmission fluid DEXRONII
or III

2462004 ECHO from Aug. ’03 Prod. (OM52526U)
Fuses
SU81001a
Engine compartment
Fuses (type A)
1. P/POINT 15 A: No circuit
2. HLP RH/HLP LO RH 10 A: Right−
hand headlight
3. HLP LH/HLP LO LH 10 A: Left−
hand headlight
4. ST 30 A: Starter system
5. AM2 15 A: Starter system, SRS airbag
system, multiport fuel injection sys-
tem/sequential multiport fuel injection
system, discharge warning system
6. HORN 15 A: Horn
SU81002a
Instrument panel
7. EFI 15 A: Multiport fuel injection sys-
tem/sequential multiport fuel injection
system
8. DOME 15 A: Clock, radio, interior light,
gauges of meters, wireless remote con-
trol system
9. SPARE 15 A: Spare
10. SPARE 30 A: Spare
11. GAUGE 10 A: Back−up lights, charging
system, air conditioning system, power
window system, gauges of meters
12. ACC 15 A: Clock, radio, cigarette light-
er
13. A.C 7.5 A: Air conditioning system
SU81003a
Engine compartment
14. WIPER 20 A: Windshield wipers and
washer
15. ECUIG 7.5 A: Anti−lock brake system,
electric cooling fan
16. D/L 25 A: Power door lock system
17. ECUB 7.5 A: SRS airbag system
18. OBD 7.5 A: On−board diagnosis sys-
tem
19. TAIL 10 A: Tail lights, parking lights,
license plate lights, radio, illuminations
20. FOG 15 A: Front fog lights

2002MY ECHO U L/O0109
2004 ECHO from Aug. ’03 Prod. (OM52526U)
Publication No. OM52526U
Part No. 01999-52526
Printed in Japan 01−0308−00
(
Quick index
If a service reminder indicator or warning buzzer comes on 90. . . .
If your vehicle will not start 174. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
If your engine stalls while driving 177. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
If your vehicle overheats 177. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
If you have a flat tire 178. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
If your vehicle needs to be towed 189. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tips for driving during break-in period 142. . . . . . . . . . . . . . . . . . . . . . . . .
How to start the engine 166. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General maintenance 203. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Complete index NO TAG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas station information
Fuel type:
UNLEADED gasoline, Octane Rating 87 (Research Octane Number 91)
or higher
See page 142 for detailed information.
Fuel tank capacity:
45 L (11.9 gal., 9.9 lmp.gal.)
Engine oil:
API grade SL “Energy−Conserving” or ILSAC
multigrade engine oil is recommended.
See page 216 for detailed information.
Automatic transmission fluid:
Toyota Genuine ATF Type T−IV
See page 244 for detailed information.
Tire information: See pages 221 through 229.
Tire pressure: See page 245.
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