brake TOYOTA ECHO 2005 1.G Service Manual

2162005 ECHO from Aug. ’04 Prod. (OM52636U)
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 leave anything that may
burn easily, such as paper or rags,
in the engine compartment.
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.

2182005 ECHO from Aug. ’04 Prod. (OM52636U)
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 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
. . . . . .

2192005 ECHO from Aug. ’04 Prod. (OM52636U)
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.
Do not raise the vehicle with some-
one in the vehicle.
When raising the vehicle, do not
place any objects on top of or un-
derneath the jack.
NOTICE
Make sure to place the jack correctly,
or your vehicle may be damaged.

2212005 ECHO from Aug. ’04 Prod. (OM52636U)
DOITYOURSELF MAINTENANCE
Engine and Chassis
Checking the engine oil level222
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the engine coolant level 224
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the radiator and condenser 225
. . . . . . . . . . . . . . . . . . . . . . . . .
Checking brake fluid 225
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. . . .
Checking power steering fluid 226
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking tire inflation pressure 227
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking and replacing tires 230
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotating tires 232
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . . . . . . .
Installing snow tires and chains 232
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing wheels 234
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . . .
Aluminum wheel precautions 235
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 2

2252005 ECHO from Aug. ’04 Prod. (OM52636U)
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. 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 refi
lling, 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.
Checking the radiator and
condenser

2262005 ECHO from Aug. ’04 Prod. (OM52636U)
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 DEXRON II 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 (60 C—80 C or 140 F—175 F). You
may also check the level when the fluid
is cold (about room temperature,
10 C—30 C or 50 F—85 F) if the engine
has not been run for about five hours.

2342005 ECHO from Aug. ’04 Prod. (OM52636U)
CAUTION
Do not exceed 50 km/h (30 mph) or
the chain manufacturer ’s recom-
mended speed limit, whichever is
lower.
Drive carefully avoiding bumps,
holes, and sharp turns, which may
cause the vehicle to bounce.
Avoid sharp turns or lockedwheel
braking, as use of chains may ad-
versely affect vehicle handling.
When driving with chains installed,
be sure to drive carefully. Slow
down before entering curves to
avoid losing control of the vehicle.
Otherwise an accident may occurs.
NOTICE
Do not attempt to use a tire chain on
the compact spare tire, as it may re-
sult in damage to the vehicle as well
as the tire.
Replacing wheels
WHEN TO REPLACE YOUR WHEELS
If you have wheel damage such as
bending, cracks or heavy corrosion, the
wheel should be replaced.
If you fail to replace a damaged wheel,
the tire may slip off the wheel or they
may cause loss of handling control.
WHEEL SELECTION
When replacing wheels, care should be
taken to ensure that the wheels are re-
placed by ones with the same load ca-
pacity, diameter, rim width, and offset.
This must be observed on compact spare
tires, too.
Correct replacement wheels are available
at your Toyota dealer.
A wheel of a different size or type may
adversely affect handling, wheel and bear-
ing life, brake cooling, speedometer/odom-
eter calibration, stopping ability, headlight
aim, bumper height, vehicle ground clear-
ance, and tire or snow chain clearance to
the body and chassis.Replacement with used wheels is not rec-
ommended as they may have been sub-
jected to rough treatment or high mileage
and could fail without warning. Also, bent
wheels which have been straightened may
have structural damage and therefore
should not be used. Never use an inner
tube in a leaking wheel which is designed
for a tubeless tire.
CAUTION
Observe the following instructions.
Otherwise, an accident may occur re-
sulting in death or serious injuries.
Do not use wheels other than the
manufacturer ’s recommended size, as
this may cause dangerous handling
characteristics resulting in loss of
control.

2502005 ECHO from Aug. ’04 Prod. (OM52636U)
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 DEXRON II
or III

2522005 ECHO from Aug. ’04 Prod. (OM52636U)
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, audio, interior
light, gauges of meters, wireless re-
mote control system
9. SPARE 15 A: Spare
10. SPARE 30 A: Spare
11. GAUGE 10 A: Back−up lights, charging
system, air c onditioning system, power
window system, gauges of meters
12. ACC 15 A: Clock, audio, cigarette
lighter
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, audio, illuminations
20. FOG 15 A: Front fog lights

2532005 ECHO from Aug. ’04 Prod. (OM52636U)
21. HAZ 10 A: Turn signal lights, emergen-
cy flashers
22. STOP 10 A: Stop lights, high mounted
stop light, anti −lock brake system, shift
lock system, multiport fuel injection
system/s equential multiport fuel injec-
tion system
Fuses (type B)
23. HTR SUB1 50 A: Air conditioning sys-
tem (PTC 1)
24. RDI 30 A: Electric cooling fan
25. AM1 40 A: “ACC”, “GAUGE”, “WIPER”,
and “ECU −IG” fuses
26. POWER 30 A: Power windows
27. HTR 40 A: Air conditioning system
28. DEF 30 A: Rear window defogger sys-
tem.
Fuses (type C)
29. MAIN 60 A: “EFI”, “DOME”, “HORN”,
“ST”, “AM2”, “H −LP LH”, and “H −LP
RH” fuse
30. ALT 100 or 120 A: “ECU−B”, “TAIL”,
“D/L”, “OBD”, “A.C”, “HTR”, “POWER”,
“STOP” and “FL DEF” fuses
31. ABS 60 A: Anti−lock brake system