SS-43 SERVICE SPECIFICATIONS
-
AIR CONDITIONING
AIR CONDITIONING SS072-05
SERVICE DATA 460 ± 30 g (16.23 ± 1.06 oz.)
Refrigerant charge volume Drive belt tension
New belt
490 - 690 N (50 - 70 kgf)
Used belt
340 - 440 N (35 - 45 kgf)
Idle-up speed (M/T)
Magnetic clutch not engaged
600 ± 50 rpm
Magnetic clutch engaged (Condenser fan speed at low)
700 ± 50 rpm
Magnetic clutch engaged (Condenser fan speed at high)
875 ± 50 rpm
Idle-up speed (A/T)
Magnetic clutch clearance
Magnetic clutch not engaged
700 ± 50 rpm
Magnetic clutch engaged (Condenser fan speed at low)
750 ± 50 rpm
Magnetic clutch engaged (Condenser fan speed at high)
875 ± 50 rpm 0.5 ± 0.15 mm (0.020 ± 0.0059 in.)
2002 ECHO (RM884U)
Author:
Date:
169
SS-44 SERVICE SPECIFICATIONS
-
AIR CONDITIONING SS073-05
TORQUE SPECIFICATION Part tightened
N·m
kgf·cm
ft·lbf
Compressor x Engine
25
250
18
Compressor x Discharge hose
10
100
7
Compressor x Suction hose
10
100
7
Expansion valve x Evaporator
3.4
35
30 in.·lbf
Condenser x Liquid tube
5.4
55
48 in.·lbf
Condenser x Discharge hose
5.4
55
48 in.·lbf
Pressure switch x Liquied tube
10
100
7
Pressure plate x Compressor
13.2
135
9
Water temperature switch x Engine
34
350
25
Front passenger airbag x Reinforcement
20
205
15
2002 ECHO (RM884U)
Author:
Date:
170
SS-30 SERVICE SPECIFICATIONS
-
AUTOMATIC TRANSAXLE
AUTOMATIC TRANSAXLE SS13Y-07
SERVICE DATA Line pressure (Wheel locked) Engine idling D position R position at stall (Throttle valve fully opened) D position R position Engine stall revolution Time lag
Engine idle speed (A/C OFF) Drive plate runout Torque converter clutch runout Torque converter clutch installation distance Differential oil seal drive in depth
Shift schedule D position (Throttle valve fully opened)
(Throttle valve fully closed) 2 position (Throttle valve fully opened)
L position (Throttle valve fully opened)
Lock-up point 3rd gear O/D gear
D and R positions N → D position N → R position N position Max. Max.
372 - 407 kPa (3.8 - 4.2 kgf/cm2, 54 - 60 psi) 541 - 636 kPa (5.5 - 6.5 kgf/cm2, 78 - 92 psi) 1,107 - 1,225 kPa (11.3 - 12.5 kgf/cm2, 161 - 178 psi) 1,695 - 1,813 kPa (17.3 - 18.5 kgf/cm2, 246 - 263 psi) 2,330 ± 200 rpm Less than 1.2 seconds Less than 1.5 seconds 600 ± 50 rpm 0.20 mm (0.0079 in.) 0.30 mm (0.0118 in.) More than 9.3 mm (0.366 in.)
RH LH
2.0 ± 0.5 mm (0.079 ± 0.020 in.) 5.9 ± 0.5 mm (0.232 ± 0.020 in.)
1→2 2→3 3 → O/D O/D → 3 3→2 2→1 3 → O/D O/D → 3
52 - 58 km/h (32 - 36 mph) 97 - 108 km/h (60 - 67 mph) 169 - 182 km/h (105 - 113 mph) 149 - 162 km/h (93 - 101 mph) 91 - 101 km/h (57 - 63 mph) 43 - 48 km/h (27 - 30 mph) 41 - 47 km/h (25 - 29 mph) 31 - 36 km/h (19 - 22 mph)
1→2 3→2 2→1
52 - 58 km/h (32 - 36 mph) 91 - 101 km/h (57 - 63 mph) 43 - 48 km/h (27 - 30 mph)
3→2 2→1
91 - 101 km/h (57 - 63 mph) 45 - 51 km/h (28 - 32 mph)
Throttle valve opening 5 % Lock-up ON Lock-up OFF Lock-up ON Lock-up OFF
97 - 108 km/h (60 - 67 mph) 91 - 101 km/h (57 - 63 mph) 56 - 62 km/h (35 - 39 mph) 54 - 59 km/h (34 - 37 mph)
2002 ECHO (RM884U)
Author:
Date:
156
SS-31 SERVICE SPECIFICATIONS
-
AUTOMATIC TRANSAXLE SS13Z-08
TORQUE SPECIFICATION Part tightened
N·m
kgf·cm
ft·lbf
Vehicle speed sensor x Transaxle
7.0
71
5
Direct clutch speed sensor x Transaxle
5.4
55
48 in.·lbf
Transaxle control cable x Control shaft
15
150
11
Control shaft x Park/neutral position switch
13
130
9
Bolt Nut
5.4 6.9
55 70
48 in.·lbf 61 n.·lbf
12 mm bolt: 45 mm bolt:
11 11
110 110
8 8
Valve body x Transaxle
11
110
8
ATF temperature sensor x Valve body
11
110
8
Oil strainer x Valve body
11
110
8
Oil pan x Transaxle
7.8
80
69 in.·lbf
Drain plug x Oil pan
49
500
36
Floor shift assembly x Body
12
120
9
Floor shift assembly x Transaxle control cable
12
120
9
Air cleaner bracket x Transaxle
19
195
14
Starter x Transaxle
39
400
29
Transaxle x Engine
29.5
300
22
Engine hanger x Engine
40
400
29
Steering wheel x column shaft
34
350
25
Tie rod end x Axle carrier
49
500
36
Torque converter clutch x Drive plate
27
275
20
Lower suspension arm x Axle carrier
98
1,000
72
Drive shaft lock nut
216
2,200
159
Hood x Hood hinge
11
115
8
LH engine mounting x Transaxle
49
500
36
Drive plate x Crank shaft
88
900
65
PS pipe clamp x front suspension member
7.8
80
69 in.·lbf
Rear engine mounting bracket x Front suspension member
80
810
59
116 70
1,185 715
86 52
Wiper arm x Wiper link assembly
21
214
15
Wiper arm assembly x Body
5.5
55
49 in.·lbf
Outer front cowl top panel x Body
5.0
50
43 in.·lbf
No.3 intermediate shaft assembly x Steering gear assembly
47
480
35
37 (44)
375 (450)
27 (33)
Park/neutral position switch x Transaxle
Solenoid valve x Valve body
Front suspension member x Body (MS: See page SR-35 ) (PS: See page SR-48 )
PS only: Pressure feed and return tubes x Steering gear assembly
Bolt A: Bolt B:
( ): For use without SST
2002 ECHO (RM884U)
Author:
Date:
157
SS-41 SERVICE SPECIFICATIONS
-
BODY
BODY SS140-05
TORQUE SPECIFICATION Part tightened
N·m
kgf·cm
ft·lbf
FRONT BUMPER
-
-
-
Reinforcement x Front bumper arm
20
205
15
REAR BUMPER
-
-
-
Reinforcement x Rear bumper arm
13
130
9
HOOD
-
-
-
Hood x Hood hinge
11
115
8
Hood lock x Body
7.8
80
69 in.·lbf
FRONT DOOR
-
-
-
Door hinge x Body
43
440
32
Door hinge x Door panel
43
440
32
Door lock striker x Body
23
230
17
Door check x Body
30
310
22
Door check x Door panel
5.4
55
48 in.·lbf
Outside handle x Door panel
5.4
55
48 in.·lbf
Door lock x Door panel
4.9
50
43 in.·lbf
Window regulator x Door panel
8.3
85
74 in.·lbf
Rear view mirror x Door panel
7.8
80
69 in.·lbf
REAR DOOR
-
-
-
Door hinge x Body
25
260
19
Door hinge x Door panel
25
260
19
Door lock striker x Body
23
230
17
Door check x Body
30
310
22
Door check x Door panel
5.4
55
48 in.·lbf
Outside handle x Door panel
5.4
55
48 in.·lbf
Door lock x Door panel
4.9
50
43 in.·lbf
Window regulator x Door panel
8.3
85
74 in.·lbf
-
-
-
Door lock striker x Body
4.9
50
43 in.·lbf
Luggage compartment door x Luggage door hinge
8.3
85
74 in.·lbf
Luggage compartment door lock x Luggage compartment door
4.9
50
43 in.·lbf
-
-
-
Outer front cowl top panel x Body
7.8
80
69 in.·lbf
Wiper motor x Wiper link
5.4
55
48 in.·lbf
Wiper link x Body
5.4
55
48 in.·lbf
Wiper arm x Wiper link
20
205
15
INSTRUMENT PANEL
-
-
-
Steering wheel set nut
50
510
37
Passenger airbag assembly x Reinforcement
18
185
13
LUGGAGE COMPARTMENT DOOR AND HINGE
FRONT WIPER AND WASHER
FRONT SEAT
-
-
-
Seat adjuster x Body
37
375
27
Seat adjuster x Seatback frame
43
440
32
Seat adjuster x Seat inner belt
41
420
30
2002 ECHO (RM884U)
Author:
Date:
167
SS-42 SERVICE SPECIFICATIONS
-
BODY
REAR SEAT (Bench type)
-
-
-
7.9
81
70 in.·lbf
REAR SEAT (Split type)
-
-
-
Seat cushion center bracket x Body
41
420
30
Center hinge x Body
41
420
30
Rear seat side hinge x Body
41
420
30
Seatback assembly x Center hinge
37
380
27
SEAT BELT
-
-
-
Seatback assembly x Body
Front seat outer belt retractor x Body
Upper:
4.7
48
42 in.·lbf
Front seat outer belt retractor x Body
Lower:
41
420
30
Front seat outer belt shoulder Anchor x Body
41
420
30
Front seat outer belt floor anchor x Body
41
420
30
Rear seat outer belt floor anchor x Body
41
420
30
Rear seat outer belt retractor x Body
41
420
30
Rear seat inner belt x Body
41
420
30
Rear seat center belt x Body
41
420
30
Rear seat center belt retractor x Body
41
420
30
2002 ECHO (RM884U)
Author:
Date:
168
SS-40 SERVICE SPECIFICATIONS
-
BODY ELECTRICAL
BODY ELECTRICAL SS02V-03
SERVICE DATA SPEEDOMETER (ON-VEHICLE) USA: Standard indication (mph)
Allowable range (mph)
20
18 - 24
40
38 - 44
60
56 - 66
80
78 - 88
100
98 - 110
Standard indication (km/h)
Allowable range (km/h)
20
17 - 24
40
38 - 46
60
57.5 - 67
CANADA:
80
77 - 88
100
96 - 109
120
115 - 130
140
134 - 151.5
160
153 - 173
Float position mm (in.)
Resistance (Ω)
F: Approx. 83.8 (3.30) ± 3 (0.12)
Approx. 4.0 ± 1
FUEL SENDER GAUGE
1/2: Approx. 18.9 (0.74) ± 3 (0.12)
Approx. 55.0 ± 3
E: Approx. 55.2 (2.17) ± 3 (0.12)
Approx. 107.0 ± 1
ENGINE COOLANT TEMPERATURE SENDER GAUGE Temperature °C (°F)
Resistance (Ω)
50 (122.0)
160 - 240
120 (248.0)
17.1 - 21.2
2002 ECHO (RM884U)
Author:
Date:
166
SS-34 SERVICE SPECIFICATIONS
-
BRAKE
BRAKE SS0M2-09
SERVICE DATA Brake pedal height (from dash panel)
124.3 - 134.3 mm (4.89 - 5.287 in.)
Brake pedal free play
1 - 3 mm (0.04 - 0.12 in.)
Brake pedal reserve distance at 490 N (50 kgf, 110.2 lbf)
More than 48 mm (1.89 in.)
Parking brake lever travel at 196 N (20 kgf, 44.1 lbf)
6 - 9 clicks
Front brake pad thickness Front brake pad thickness Front brake disc thickness
STD
11.0 mm (0.433 in.)
Minimum 1.0 mm (0.039 in.) STD
18.0 mm (0.709 in.)
Front brake disc thickness
Minimum 16.0 mm (0.630 in.)
Front brake disc runout
Maximum 0.05 mm (0.0020 in.)
Rear brake drum inside diameter Rear brake drum inside diameter Rear brake shoe lining thickness Rear brake shoe lining thickness Rear brake drum to shoe clearance
STD
180.0 mm (7.087 in.)
Maximum 181.0 mm (7.126 in.) STD
4.0 mm (0.157 in.)
Minimum 1.0 mm (0.039 in.) 0.6 mm (0.024 in.)
2002 ECHO (RM884U)
Author:
Date:
160
SS-35 SERVICE SPECIFICATIONS
-
BRAKE SS0M3-08
TORQUE SPECIFICATION Part tightened
N·m
kgf·cm
ft·lbf
Bleeder plug
8.3
85
73 in.·lbf
Parking brake equalizer lock nut
5.4
55
48 in.·lbf
Master cylinder x Brake booster
13
130
9
Brake line union nut
15
155
11
Brake booster clevis lock nut
26
260
19
Brake booster installation nut
13
130
9
19.5
200
14
Brake pedal x Pedal Bracket
37
375
27
Front brake caliper installation bolt
34
350
25
Front brake torque plate x Steering knuckle
88
900
65
Front brake caliper x Flexible hose
30
310
22
Rear drum brake wheel cylinder x Backing plate
10
100
7
ABS actuator assembly x Body
19
195
14
ABS actuator assembly x Clamp
19
195
14
ABS actuator x Actuator bracket
4.7
48
42 in.·lbf
Front speed sensor x Steering knuckle
8.0
82
71 in.·lbf
Front speed sensor wire harness clamp x Shock absorber
29
300
22
Front speed sensor wire harness clamp x Body
8.0
82
71 in.·lbf
Rear axle hub installation bolt
52
526
38
Brake pedal assembly x Reinforcement
2002 ECHO (RM884U)
Author:
Date:
161
SS-23 SERVICE SPECIFICATIONS
-
CHARGING
CHARGING SS0YW-06
SERVICE DATA Battery
Drive belt
Alternator
Specific gravity Voltage Tension (Reference)
Rated output Rotor coil resistance Slip ring diameter Brush exposed length
IC regulator
Regulating voltage
at 20°C (68°F) at 20°C (68°F) New belt Used belt
at 20°C (68°F) STD Minimum STD Minimum at 25 °C (77 °F)
1.25 - 1.29 12.5 - 12.9 V 540 - 640 N (55 - 65 kgf) 250 - 390 N (35 - 40 kgf) 12 V 70 A, 12 V 90 A 2.7 - 3.1 Ω 14.2 - 14.4 mm (0.559 - 0.567 in.) 12.8 mm (0.504 in.) 10.5 mm (0.413 in.) 1.5 mm (0.059 in.) 13.5 - 15.1 V
2002 ECHO (RM884U)
Author:
Date:
149
SS-24 SERVICE SPECIFICATIONS
-
CHARGING SS0YX-06
TORQUE SPECIFICATION Part tightened
N·m
kgf·cm
ft·lbf
Bearing retainer x Drive end frame
3.0
31
27 in.·lbf
Rectifier end frame without wire clip x Drive end frame
4.5
46
40 in.·lbf
Rectifier end frame with wire clip x Drive end frame
5.4
55
48 in.·lbf
Alternator pulley x Rotor
111
1,125
81
Rectifier holder x Lead wire on rectifier end frame
2.9
30
26 in.·lbf
IC regulator x Rectifier end frame
2.0
20
17 in.·lbf
IC regulator x Rectifier holder
2.0
20
17 in.·lbf
Brush holder x Rectifier holder
2.0
20
17 in.·lbf
Brush holder x IC regulator
2.0
20
17 in.·lbf
4.4 3.9
45 39
39 in.·lbf 35 in.·lbf
4.1
42
36 in.·lbf
Rear end cover x Rectifier holder
Terminal insulator x Rectifier holder
Nut Bolt
2002 ECHO (RM884U)
Author:
Date:
150
SS-25 SERVICE SPECIFICATIONS
-
CLUTCH
CLUTCH SS09Q-04
SERVICE DATA Pedal height from dash panel
134.3 - 144.3 mm (5.287 - 5.681 in.)
Pedal free play
5.0 - 15.0 mm (0.197 - 0.591 in.)
Push rod play at pedal top
1.0 - 5.0 mm (0.039 - 0.197 in.)
Clutch release point from pedal full stroke end position
25 mm (0.98 in.) or more
Slotted spring pin protrusion Disc rivet head depth
1.5 - 3.5 mm (0.059 - 0.138 in.) Min. 0.3 mm (0.012 in.)
Disc runout
Max.
0.8 mm (0.031 in.)
Flywheel runout
Max.
0.1 mm (0.004 in.)
Diaphragm spring finger wear
Max. depth
0.5 mm (0.020 in.)
Diaphragm spring finger wear
Max. width
6.0 mm (0.236 in.)
Max.
0.5 mm (0.020 in.)
Diaphragm spring tip non-alignment
2002 ECHO (RM884U)
Author:
Date:
151
SS-26 SERVICE SPECIFICATIONS
-
CLUTCH SS09R-03
TORQUE SPECIFICATION Part tightened
N·m
kgf·cm
ft·lbf
Master cylinder installation nut
12
120
9
Clutch line
15
155
11
Release cylinder installation bolt
12
120
9
Union bolt
24.5
250
18
Bleeder plug
8.4
85
74 in.·lbf
49
500
36
Flywheel set bolt
1st 2nd
Turn 90°
Release fork support
37
375
27
Clutch cover x Flywheel
19
195
14
2002 ECHO (RM884U)
Author:
Date:
152
SS-15 SERVICE SPECIFICATIONS
-
COOLING
COOLING SS176-01
SERVICE DATA Thermostat
Valve opening temperature at 90°C (199°F)
Radiator cap Electric cooling fan
Relief valve opening pressure
Amperage
80.0 - 84.0°C (176 - 183°F) 8.5 mm (0.345 in.) or more
STD 93 - 123 kPa (0.95 - 1.25 kgf/cm2, 13.5 - 17.8 psi) Minimum 78 kPa (0.8kgf/cm2, 11.3 psi) STD
7.8 - 11.8 A
2002 ECHO (RM884U)
Author:
Date:
141
SS-16 SERVICE SPECIFICATIONS
-
COOLING SS177-01
TORQUE SPECIFICATION Part tightened Drain plug
N·m
kgf·cm
ft·lbf
13
130
9
Water pump x Timing chain cover
11
110
8
Pump pulley x Water pump
15
150
11
Water inlet x Cylinder block
9.0
90
80 in.·lbf
A/T oil cooler x Lower tank
8.34
85
74 in.·lbf
Water filer x Radiator upper tank
7.5
76
66 in.·lbf
Electric cooling fan assembly x Radiator
7.5
76
66 in.·lbf
2.65 3.98
27 41
23 in.·lbf 35 in.·lbf
6.4
66
57 in.·lbf
Fan motor x Fan shroud
Fan x Fan motor
w/ A/C w/o A/C
2002 ECHO (RM884U)
Author:
Date:
142
SS-12 SERVICE SPECIFICATIONS
-
EMISSION CONTROL
EMISSION CONTROL SS17E-01
TORQUE SPECIFICATION Part tightened PCV valve x Cylinder head cover
N·m
kgf·cm
ft·lbf
27
275
20
2002 ECHO (RM884U)
Author:
Date:
138
SS-6 SERVICE SPECIFICATIONS
-
ENGINE MECHANICAL
ENGINE MECHANICAL SS174-01
SERVICE DATA at 250 rpm STD 1,471 kPa (15.0 kgf/cm2, 213 psi) Minimum 1,079 kPa (11.0 kgf/cm2, 156 psi) Difference between each cylinder 98 kPa (1.0 kgf/cm2, 14 psi)
Compression pressure
at cold Intake Exhaust No. 06 No. 08 No. 10 No. 12 No. 14 No. 16 No. 18 No. 20 No. 22 No. 24 No. 26 No. 28 No. 30 No. 32 No. 34 No. 36 No. 38 No. 40 No. 42 No. 44 No. 46 No. 48 No. 50 No. 52 No. 54 No, 56 No. 58 No. 60 No. 62 No. 64 No. 66 No. 68 No. 70 No. 72 No. 74
Valve lifter for repair part
Valve clearance
8 - 12° BTDC @ idle
Ignition timing w/ Cooling fan off
Idle speed Chain and timing sprocket Chain tensioner slipper and vibration damper
0.15 - 0.25 mm (0.006 - 0.010 in.) 0.25 - 0.35 mm (0.010 - 0.014 in.) 5.060 mm (0.1992 in.) 5.080 mm (0.2000 in.) 5.100 mm (0.2008 in.) 5.120 mm (0.2016 in.) 5.140 mm (0.2024 in.) 5.160 mm (0.2031 in.) 5.180 mm (0.2039 in.) 5.200 mm (0.2047 in.) 5.220 mm (0.2055 in.) 5.240 mm (0.2063 in.) 5.260 mm (0.2071 in.) 5.280 mm (0.2079 in.) 5.300 mm (0.2087 in.) 5.320 mm (0.2094 in.) 5.340 mm (0.2102 in.) 5.360 mm (0.2110 in.) 5.380 mm (0.2118 in.) 5.400 mm (0.2126 in.) 5.420 mm (0.2134 in.) 5.440 mm (0.2142 in.) 5.460 mm (0.2150 in.) 5.480 mm (0.2157 in.) 5.500 mm (0.2165 in.) 5.520 mm (0.2173 in.) 5.540 mm (0.2181 in.) 5.560 mm (0.2189 in.) 5.580 mm (0.2197 in.) 5.600 mm (0.2205 in.) 5.620 mm (0.2213 in.) 5.640 mm (0.2220 in.) 5.660 mm (0.2228 in.) 5.680 mm (0.2236 in.) 5.700 mm (0.2244 in.) 5.720 mm (0.2252 in.) 5.740 mm (0.2260 in.)
A/T 700 ± 50 rpm M/T 650 ± 50 rpm
Chain length at 16 links Camshaft timing sprocket wear (w/ chain) Crankshaft timing sprocket wear (w/ chain)
Maximum 123.2 mm (4.850 in.) Minimum 96.2 mm (3.787 in.) Minimum 50.5 mm (1.988 in.)
Wear
Maximum 1.0 mm (0.039 in.)
2002 ECHO (RM884U)
Author:
Date:
132
SS-7 SERVICE SPECIFICATIONS
Cylinder head
Valve guide bushing
Warpage Valve seat Refacing angle Contacting angle Contacting width Valve guide bushing bore diameter
Valve face angle Stem diameter Valve Stem oil clearance
Margin thickness
Valve lifter
ENGINE MECHANICAL
Maximum 0.05 mm (0.0020 in.)
STD O/S 0.05
Inside diameter Protrusion height Valve overall length
Valve spring
-
20°, 45°, 75° 45° 1.0 - 1.4 mm (0.039 - 0.055 in.) 9.685 - 9.706 mm (0.38130 - 0.38213 in.) 9.735 - 9.756 mm (0.38327 - 0.38493 in.) 5.010 - 5.030 mm (0.19724 - 0.19803 in.) 9.0 - 9.4 mm (0.354 - 0.370 in.)
STD Intake Exhaust Minimum Intake Exhaust
89.25 mm (3.5138 in.) 87.90 mm (3.4606 in.) 88.75 mm (3.4941 in.) 87.40 mm (3.4409 in.) 44.5° Intake 4.970 - 4.985 mm (0.19567 - 0.19626 in.) Exhaust 4.965 - 4.980 mm (0.19547 - 0.19606 in.) STD Intake 0.025 - 0.060 mm (0.00098 - 0.00236 in.) Exhaust 0.030 - 0.065 mm (0.00118 - 0.00256 in.) Maximum Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in.) STD 1.00 - 1.15 mm (0.039 - 0.045 in.) Minimum 0.7 mm (0.028 in.)
Deviation Maximum 1.6 mm (0.063 in.) Angle (Reference) Maximum 2° Free length 45.1 mm (1.776 in.) Installed tension at 32.5 mm (1.280 in.) 149 - 165 N (15.2 - 16.8 kgf, 33.5 - 37.1 lbf) Maximum working tension at 23.9 mm (0.941 in.) 286 - 316 N (29.1 - 32.2 kgf, 64.2 - 71.0 lbf) Lifter diameter Lifter bore diameter Oil clearance
Thrust clearance Journal oil clearance Journal diameter Camshaft Circle run out Cam lobe height
30.966 - 30.976 mm (1.21913 - 1.21952 in.) 31.000 - 31.025 mm (1.22047 - 1.22145 in.) STD 0.024 - 0.059 mm(0.00094 - 0.00232 in.) Maximum 0.1 mm (0.004 in.) STD Maximum STD Maximum No.1 Others Maximum STD Exhaust Minimum Intake Exhaust
0.040 - 0.095 mm (0.0016 - 0.0037 in.) 0.11 mm (0.0043 in.) 0.040 - 0.095 mm (0.00157 - 0.00374 in.) 0.115 mm (0.00453 in.) 34.449 - 34.465 (1.35626 - 1.35689 in.) 22.949 - 22.965 (0.90350 - 0.90413 in.) 0.03 mm (0.0012 in.) 44.617 - 44.717 mm (1.75657 - 1.76051 in.) 44.666 - 44.766 mm (1.75850 - 1.76244 in.) 44.47 mm (1.7508 in.) 44.52 mm (1.7528 in.)
Intake manifold
Warpage
Maximum 0.10 mm (0.0039 in.)
Exhaust manifold
Warpage
Maximum 0.70 mm (0.0276 in.)
2002 ECHO (RM884U)
Author:
Date:
133
SS-8 SERVICE SPECIFICATIONS
-
ENGINE MECHANICAL
Cylinder head surface warpage Cylinder bore diameter
Cylinder block
Maximum STD Maximum Main journal bore diameter Mark 0 Mark 1 mark 2 Mark 3 Mark 4 Mark 5 Mark 6 12 pointed head bearing cap sub-assembly bolt diameter at tension portion STD Minimum
0.05 mm (0.0020 in.) 75.000 - 75.013 mm (2.95275 - 2.95326 in.) 75.013 mm (2.95326 in.) 50.000 - 50.003 mm (1.96850 - 1.96862 in.) 50.003 - 50.005 mm (1.96862 - 1.96870 in.) 50.005 - 50.007 mm (1.96870 - 1.96878 in.) 50.007 - 50.010 mm (1.96878 - 1.96889 in.) 50.010 - 50.012 mm (1.96889 - 1.96897 in.) 50.012 - 50.014 mm (1.96897 - 1.96905 in.) 50.014 - 50.016 mm (1.96905 - 1.96913 in.) 7.3 - 7.5 mm (0.287 - 0.295 in.) 7.3 mm (0.287 in.)
Piston diameter
Piston and Piston ring
at 27 mm (1.063 in.) from the piston head Piston oil clearance STD Maximum Piston ring groove clearance Piston ring end gap STD No. 1 No. 2 Oil Maximum No. 1 No. 2 Oil Thrust clearance Connecting rod thickness Connecting rod bearing center wall thickness Reference
Connecting rod
74.945 - 74.955 mm (2.95058 - 2.95098 in.) 0.045 - 0.068 mm (0.00177 - 0.00268 in.) 0.08 mm (0.0031 in.) 0.030 - 0.070 mm (0.0012 - 0.0028 in.) 0.25 - 0.35 mm (0.0098 - 0.0138 in.) 0.35 - 0.50 mm (0.0138 - 0.0197 in.) 0.10 - 0.35 mm (0.0039 - 0.0138 in.) 0.91 mm (0.0358 in.) 1.06 mm (0.0417 in.) 0.82 mm (0.0323 in.)
STD 0.16 - 0.36 mm (0.0063 - 0.0142 in.) Maximum 0.36 mm (0.0142 in.) 19.788 - 19.840 mm (0.779 - 0.781 in.)
Mark 1 Mark 2 Mark 3 Connecting rod oil clearance STD Maximum Rod out-of-alignment Maximum per 100 mm (3.94 in.) Rod twist Maximum per 100 mm (3.94 in.) Bushing inside diameter Piston pin diameter Bushing oil clearance STD Maximum Connecting rod bolt diameter at tension portion STD Minimum
1.488 - 1.492 mm (0.0586 - 0.0587 in.) 1.492 - 1.496 mm (0.0587 - 0.0589 in.) 1.496 - 1.500 mm (0.0589 - 0.0591 in.) 0.016 - 0.040 mm (0.0006 - 0.0016 in.) 0.06 mm (0.0024 in.) 0.05 mm (0.0020 in.) 0.05 mm (0.0020 in.) 18.010 - 18.019 mm (0.7091 - 0.7094 in.) 17.988 - 18.007 mm (0.7086 - 0.7089 in.) 0.009 - 0.015 mm (0.0003 - 0.0006 in.) 0.05 mm (0.0020 in.) 6.6 - 6.7 mm (0.260 - 0.264 in.) 6.4 mm (0.252 in.)
2002 ECHO (RM884U)
Author:
Date:
134
SS-9 SERVICE SPECIFICATIONS Thrust clearance Thrust washer thickness Main journal oil clearance Main journal diameter Reference
Crankshaft Main bearing center wall thickness Reference
Crank pin diameter Circle run out Main journal taper and out-of round Crank pin taper and out-of round
-
ENGINE MECHANICAL
STD 0.090 - 0.190 mm (0.00354 - 0.00748 in.) Maximum 0.30 mm (0.012 in.) 2.430 - 2.480 mm (0.09567 - 0.09764 in.) STD 0.010 - 0.023 mm (0.0004 - 0.0009 in.) Maximum 0.07 mm (0.0028 in.) Mark 0 Mark 1 Mark 2 Mark 3 Mark 4 Mark 5
46.000 - 46.002 mm (1.81102 - 1.81110 in.) 46.002 - 46.004 mm (1.81110 - 1.81118 in.) 46.004 - 46.006 mm (1.81118 - 1.81126 in.) 46.006 - 46.008 mm (1.81126 - 1.81133 in.) 46.008 - 46.010 mm (1.81133 - 1.81141 in.) 46.010 - 46.012 mm (1.81141 - 1.81149 in.)
Mark 1 Mark 2 Mark 3 Mark 4
1.992 - 1.995 mm (0.07843 - 0.07854 in.) 1.995 - 1.998 mm (0.07854 - 0.07866 in.) 1.998 - 2.001 mm (0.07866 - 0.07878 in.) 2.001 - 2.004 mm (0.07878 - 0.07890 in.) 39.992 - 40.000 mm (1.5745 - 1.5748 in.) Maximum 0.03 mm (0.0012 in.) Maximum 0.02 mm (0.0008 in.) Maximum 0.02 mm (0.0008 in.)
2002 ECHO (RM884U)
Author:
Date:
135
SS-10 SERVICE SPECIFICATIONS
-
ENGINE MECHANICAL SS175-01
TORQUE SPECIFICATION Part tightened
N·m
kgf·cm
ft·lbf
Plug x Timing chain cover
15
150
11
Chain vibration damper x Cylinder block
9.0
92
80 in .·lbf
Chain tensioner
9.0
92
80 in .·lbf
11 24 11 24 11 24 11
112 245 112 245 112 245 112
8 18 8 18 8 18 8
55
561
41
7.5 11
76 112
66 in .·lbf 8
Oil control valve
8.0
82
71 in .·lbf
Crankshaft pulley x Crankshaft
128
1,300
94
Cylinder head cover x Cylinder
10
100
7
45 52 52
459 530 530
33 38 38
29.4 Turn 90° Turn 90°
300 Turn 90° Turn 90°
22 Turn 90° Turn 90°
Timing chain cover
Bolt A Bolt B Bolt C Bolt D Bolt E Nut F Nut G
RH engine mounting bracket x Timing chain cover Crankshaft position sensor x Timing chain cover
RH engine mounting insulator
Cylinder head x Cylinder block
Bolt A Bolt B
Bolt A Bolt B Nut 1st 2nd 3rd
Water bypass pipe x Cylinder head
9.0
92
80 in .·lbf
No. 1 camshaft bearing cap x Cylinder head
23
235
17
No. 2 camshaft bearing cap x Cylinder head
12.7
130
10
Camshaft timing sprocket x Camshaft
64
650
47
Valve timing controller assembly x Camshaft
64
650
47
Intake manifold x Cylinder head
30
300
22
Exhaust manifold x Cylinder head
27
275
20
Upper heat insulator x Exhaust manifold
8.0
82
71 in .·lbf
Exhaust manifold stay x Cylinder block
37
377
27
Front exhaust pipe x Exhaust manifold
62
630
46
Water filler x Cylinder head
7.5
76
66 in .·lbf
Engine hanger x Cylinder head
38
388
28
LH engine mounting
49
500
36
Rear engine mounting bracket
49
500
36
62 32
630 330
46 24
Clutch release cylinder x Transaxle
12
120
9
Clutch release cylinder bracket x Transaxle
4.9
50
43 in.·lbf
A/C compressor x Engine
25
250
18
Air cleaner case
7.5
76
66 in.·lbf
Air cleaner inlet assembly
7.5
76
66 in.·lbf
15 Turn 90°
150 Turn 90°
11 Turn 90°
Front exhaust pipe x Tailpipe
Connecting rod cap x Connecting rod
Bolt A Bolt B
1st 2nd
2002 ECHO (RM884U)
Author:
Date:
136
SS-1 1 SERVICE SPECIFICATIONS Bearing cap x Cylinder block
-
ENGINE MECHANICAL 22 Turn 90°
220 Turn 90°
16 Turn 90°
Oil pan No. 1 x Cylinder block
24
245
18
Oil strainer x Oil pan No. 1
11
112
8
Oil pan No. 2 x Oil pan No. 1
9.0
92
80 in.·lbf
Oil filter union x Oil pan No. 1
30
306
21
Engine coolant drain union x Cylinder block
35
350
25
Knock sensor x Cylinder block
39
400
29
Water bypass pipe x Cylinder block
9.0
90
80 in.·lbf
49 Turn 90°
500 Turn 90°
36 Turn 90°
88
890
65
Flywheel x Crankshaft
Drive plate x Crank shaft
1st 2nd
1st 2nd
2002 ECHO (RM884U)
Author:
Date:
137
SS-19 SERVICE SPECIFICATIONS
-
IGNITION
IGNITION SS17A-01
SERVICE DATA Recommended spark plug Spark plug
DENSO NGK
Electrode gap
SK16R11 IFR5A11 1.1 mm (0.043 in.)
Camshaft position sensor
Resistance
at cold at hot
1,630 - 2,740 Ω 2,065 - 3,225 Ω
Crankshaft position sensor
Resistance
at cold at hot
985 - 1,600 Ω 1,265 - 1,890 Ω
2002 ECHO (RM884U)
Author:
Date:
145
SS-20 SERVICE SPECIFICATIONS
-
IGNITION SS17B-01
TORQUE SPECIFICATION Part tightened
N·m
kgf·cm
ft·lbf
Spark plug x Cylinder head
18
184
13
Ignition coil x Cylinder head
9.0
92
80 in.·lbf
Camshaft position sensor x Cylinder head
8.0
82
71 in.·lbf
Crankshaft position sensor x Cylinder block
7.5
76
66 in.·lbf
2002 ECHO (RM884U)
Author:
Date:
146
SS-17 SERVICE SPECIFICATIONS
-
LUBRICATION
LUBRICATION SS178-01
SERVICE DATA at idle speed at 3,000 rpm
Oil pressure Side clearance
Oil pump
Tip clearance Body clearance
STD Maximum STD Maximum STD Maximum
29 kPa (0.3 kgf/cm2,4.3 psi) or more 150 - 550 kPa (1.5 - 5.6 kgf/cm2, 22 - 80 psi) 0.03 - 0.09 mm (0.0012 - 0.0035 in.) 0.15 mm (0.0059 in.) 0.060 - 0.180 mm (0.0024 - 0.0071 in.) 0.28 mm (0.0110 in.) 0.250 - 0.325 mm (0.00984 - 0.01280 in.) 0.425 mm (0.01673 in.)
2002 ECHO (RM884U)
Author:
Date:
143
SS-18 SERVICE SPECIFICATIONS
-
LUBRICATION SS179-01
TORQUE SPECIFICATION Part tightened
N·m
kgf·cm
ft·lbf
Oil pressure switch x Cylinder block
13
130
9
Oil drain plug x Oil pan
38
387
28
Plug x Oil pump body
24
245
18
9.0 11
92 110
80 in.·lbf 8
Oil pump cover x Timing chain cover
Bolt Screw
2002 ECHO (RM884U)
Author:
Date:
144
SS-4 SERVICE SPECIFICATIONS
-
MAINTENANCE
MAINTENANCE SS17C-01
SERVICE DATA Front axle and suspension Ball joint vertical play
Maximum 0 mm (0 in.)
2002 ECHO (RM884U)
Author:
Date:
130
SS-5 SERVICE SPECIFICATIONS
-
MAINTENANCE SS17D-01
TORQUE SPECIFICATION Part tightened Front seat mounting bolts
N·m
kgf·cm
ft·lbf
37
375
27
2002 ECHO (RM884U)
Author:
Date:
131
SS-27 SERVICE SPECIFICATIONS
-
MANUAL TRANSAXLE
MANUAL TRANSAXLE SS0KT-04
SERVICE DATA Input shaft roller bearing journal diameter
Min. 24.967 mm (0.9830 in.)
Input shaft 3rd gear journal diameter
Min. 30.985 mm (1.2199 in.)
Input shaft 4th gear journal diameter
Min. 28.985 mm (1.1411 in.)
Input shaft 5th gear journal diameter
Min. 24.885 mm (0.9797 in.)
Input shaft runout
Max.
Output shaft roller bearing journal diameter
Min. 32.985 mm (1.2986 in.)
Output shaft 1st gear journal diameter
Min. 37.985 mm (1.4955 in.)
Output shaft 2nd gear journal diameter
Min. 31.985 mm (1.2592 in.)
Output shaft runout
Max.
0.03 mm (0.0012 in.)
Gear thrust clearance 1st
STD Max.
0.10 - 0.40 mm (0.0039 - 0.0157 in.) 0.40 mm (0.0157 in.)
Gear thrust clearance 2nd
STD Max.
0.10 - 0.55 mm (0.0039 - 0.0217 in.) 0.55 mm (0.0217 in.)
Gear thrust clearance 3rd
STD Max.
0.10 - 0.35 mm (0.0039 - 0.0138 in.) 0.35 mm (0.0138 in.)
Gear thrust clearance 4th
STD Max.
0.10 - 0.55 mm (0.0039 - 0.0217 in.) 0.55 mm (0.0217 in.)
Gear thrust clearance 5th
STD Max.
0.10 - 0.57 mm (0.0039 - 0.0224 in.) 0.57 mm (0.0224 in.)
1st, 2nd, 3rd, 4th and 5th gear radial clearance (KOYO made)
STD Max.
0.015 - 0.058 mm (0.0006 - 0.0023 in.) 0.058 mm (0.0023 in.)
1st, 2nd, 3rd, 4th and 5th gear radial clearance (NSK made)
STD Max.
0.015 - 0.056 mm (0.0006 - 0.0022 in.) 0.056 mm (0.0022 in.)
No. 3 shift fork to No. 3 hub sleeve clearance
Max.
0.5 mm (0.020 in.)
No. 2 shift fork to No. 2 hub sleeve clearance
Max.
0.35 mm (0.014 in.)
No. 1 shift fork to reverse gear clearance
Max.
0.35 mm (0.014 in.)
Synchronizer ring to gear clearance
0.03 mm (0.0012 in.)
Min. 0.75 mm (0.0295 in.)
Drive in depth Input shaft front oil seal Control shaft cover oil seal Select inner lever slotted spring pin No. 1 shift inner lever slotted spring pin No. 2 shift inner lever slotted spring pin Transmission case oil seal Transaxle case oil seal
15.8 ± 0.2 mm (0.622 ± 0.008 in.) 1.0 - 2.0 mm (0.039 - 0.079 in.) 0 ± 0.5 mm (0 ± 0.020 in.) 0 ± 0.5 mm (0 ± 0.020 in.) 0 ± 0.5 mm (0 ± 0.020 in.) 2.4 ± 0.3 mm (0.094 ± 0.012 in.) 1.9 ± 0.3 mm (0.075 ± 0.012 in.)
Differential side gear backlash
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Differential side gear thrust washer thickness
1.50 mm (0.0591 in.) 1.55 mm (0.0610 in.) 1.60 mm (0.0630 in.) 1.65 mm (0.0650 in.) 1.70 mm (0.0669 in.) 1.75 mm (0.0689 in.)
Differential side bearing preload (at starting) (For use with SST) New bearing Reused bearing
0.8 - 1.6 N·m (8 - 16 kgf·cm, 6.9 - 13.9 in.·lbf) 0.5 - 1.0 N·m (5 - 10 kgf·cm, 4.3 - 8.7 in.·lbf)
2002 ECHO (RM884U)
Author:
Date:
153
SS-28 SERVICE SPECIFICATIONS Input shaft snap ring thickness No. 2 clutch hub
No. 3 clutch hub
Input shaft rear bearing
Output shaft snap ring thickness No. 1 clutch hub
-
MANUAL TRANSAXLE
Mark 0 Mark 1 Mark 2 Mark 3 Mark 4 Mark 5 Mark A Mark B Mark C Mark D Mark E Mark F Mark G Mark A Mark B Mark C Mark D Mark E Mark F
2.30 mm (0.0906 in.) 2.36 mm (0.0929 in.) 2.42 mm (0.0953 in.) 2.48 mm (0.0976 in.) 2.54 mm (0.1000 in.) 2.60 mm (0.1024 in.) 2.25 mm (0.0886 in.) 2.31 mm (0.0909 in.) 2.37 mm (0.0933 in.) 2.43 mm (0.0957 in.) 2.49 mm (0.0980 in.) 2.55 mm (0.1004 in.) 2.61 mm (0.1028 in.) 2.29 mm (0.0902 in.) 2.35 mm (0.0925 in.) 2.41 mm (0.0949 in.) 2.47 mm (0.0972 in.) 2.53 mm (0.0996 in.) 2.59 mm (0.1020 in.)
Mark A Mark B Mark C Mark D Mark E Mark F
2.50 mm (0.0984 in.) 2.56 mm (0.1008 in.) 2.62 mm (0.1031 in.) 2.68 mm (0.1055 in.) 2.74 mm (0.1079 in.) 2.80 mm (0.1102 in.)
Mark AA Mark BB Mark CC Mark DD Mark EE Mark FF Mark GG Mark HH Mark JJ Mark KK Mark LL Mark MM Mark NN Mark PP Mark QQ Mark RR Mark SS Mark TT Mark UU
2.10 mm (0.0827 in.) 2.15 mm (0.0846 in.) 2.20 mm (0.0866 in.) 2.25 mm (0.0886 in.) 2.30 mm (0.0906 in.) 2.35 mm (0.0925 in.) 2.40 mm (0.0945 in.) 2.45 mm (0.0965 in.) 2.50 mm (0.0984 in.) 2.55 mm (0.1004 in.) 2.60 mm (0.1024 in.) 2.65 mm (0.1043 in.) 2.70 mm (0.1063 in.) 2.75 mm (0.1083 in.) 2.80 mm (0.1102 in.) 2.85 mm (0.1122 in.) 2.90 mm (0.1142 in.) 2.95 mm (0.1161 in.) 3.00 mm (0.1181 in.)
Differential side bearing adjusting shim thickness
2002 ECHO (RM884U)
Author:
Date:
154
SS-29 SERVICE SPECIFICATIONS
-
MANUAL TRANSAXLE SS0KU-04
TORQUE SPECIFICATION Part tightened
N·m
kgf·cm
ft·lbf
No. 2 cylinder head cover
7.0
71
62 in.·lbf
Clutch line bracket set bolt
4.9
50
43 in.·lbf
Clutch release cylinder x Transaxle
12
120
9
Transaxle x Engine
33
340
25
Starter x Transaxle
39
400
29
No. 1 engine hanger
40
400
29
Engine left mounting bracket x Engine left mounting insulator
49
490
35
Engine rear mounting insulator x Engine rear mounting bracket
64
650
47
Engine rear mounting bracket x Transaxle
49
500
36
Shift lever assembly x Body
12
120
9
Shift and select control cable x Body
4.9
50
43 in.·lbf
Clutch release fork support
37
375
27
Filler and drain plugs
39
400
29
Vehicle speed sensor
11
115
8
Back-up light switch
40
410
30
Control lever housing support bracket x Transaxle case
11
115
8
Selecting bellcrank assembly x Transmission case
25
250
18
Transmission case x Transmission case cover
18
185
13
Shift and select lever shaft assembly lock bolt
29
300
22
Shift and select lever assembly
20
200
14
Output shaft lock nut
118
1,200
87
Shift fork and shift head x Shift fork shaft
16
160
12
Rear bearing retainer
27
280
20
Reverse idler gear shaft lock bolt
29
300
22
Straight screw plug (Shift fork shaft)
25
250
18
Lock ball assembly
39
400
29
Transmission case x Transaxle case
29
300
22
Oil receiver pipe x Transmission case
17
175
13
Reverse shift arm bracket
17
175
13
Output shaft front bearing lock plate set bolt
11
115
8
Transaxle case receiver x Transaxle case
11
115
8
Straight screw plug (Reverse restrict pin)
13
130
9
Ring gear x Differential case
124
1,260
91
2002 ECHO (RM884U)
Author:
Date:
155
SS-13 SERVICE SPECIFICATIONS
-
SFI
SFI SS102-04
SERVICE DATA Fuel pump
Resistance
at 20°C (68°F)
0.2 - 3.0 Ω
Injector
Resistance Injection volume Difference between each cylinder Fuel leakage
at 20 °C(68 °F)
13.4 - 14.2 Ω 47 - 58 cm3 (2.7 - 3.3 cu in.) per 15 sec. 10 cm3 (0.7 cu in.) or less 1 drop or less per 12 minutes
Resistance at -20°C (-4°F) at 20°C (68°F) at 60°C (140°F)
THA - E2 THA - E2 THA - E2
13.6 - 18.4 kΩ 2.21 - 2.69 kΩ 0.49 - 0.67 kΩ
Throttle position sensor
Resistance Throttle valve fully closed Throttle valve fully open -
VTA - E2 VTA - E2 VC - E2
0.2 - 5.7 kΩ 2.0 - 10.2 kΩ 2.5 - 5.9 kΩ
VSV for EVAP
Resistance
at 20°C (68°F)
ECT sensor
Resistance
at -20°C (-4°F) at 0°C (32°F) at 20°C (68°F) at 40°C (104°F) at 60°C (140°F) at 80°C (176°F)
Vapor pressure sensor
Power source voltage Remove fuel tank cap
Terminal 2 - 3
4.5 - 5.5 V 3.0 - 3.6 V
Heated oxygen sensor
Heater coil resistance
at 20°C (68°F)
11 - 16 Ω
Fuel cut rpm
Fuel return rpm
Air flow meter
27 - 33 Ω 10 - 20 kΩ 4 - 7 kΩ 2 - 3 kΩ 0.9 - 1.3 kΩ 0.4 - 0.7 kΩ 0.2 - 0.4 kΩ
1,400 rpm
2002 ECHO (RM884U)
Author:
Date:
139
SS-14 SERVICE SPECIFICATIONS
-
SFI SS103-04
TORQUE SPECIFICATION Part tightened
N·m
kgf·cm
ft·lbf
Fuel pump assembly x Fuel tank
4.0
40
35 in.·lbf
Delivery pipe x Cylinder head
19
190
14
Fuel tank x Body
32
325
24
Fuel inlet pipe x Body
34
345
25
Throttle body x Intake manifold
30
305
22
Camshaft timing oil control valve x Cylinder head
4.0
40
35 in.·lbf
Knock sensor x Cylinder block
39
400
29
Heated oxygen sensor (Bank1 sensor1) x Exhaust manifold
44
440
31
Heated oxygen sensor (Bank1 sensor2) x Exhaust pipe
44
440
31
2002 ECHO (RM884U)
Author:
Date:
140
SS-1 SERVICE SPECIFICATIONS
-
STANDARD BOLT
STANDARD BOLT SS0ZS-01
HOW TO DETERMINE BOLT STRENGTH Bolt Type Hexagon Head Bolt Normal Recess Bolt
Deep Recess Bolt
Stud Bolt
Weld Bolt
4
Class
4T No Mark
No Mark
No Mark
5
5T
6
6T w/ Washer
w/ Washer
7
7T
8
8T
9
9T
10
10T
11
11T
B06431
2002 ECHO (RM884U)
Author:
Date:
127
SS-3 SERVICE SPECIFICATIONS
-
STANDARD BOLT SS0ZU-01
HOW TO DETERMINE NUT STRENGTH Nut Type Present Standard Hexagon Nut
Old Standard Hexagon Nut Cold Forging Nut
Class
Cutting Processed Nut
4N No Mark
5N (4T) No Mark (w/ Washer)
No Mark (w/ Washer)
No Mark
6N 6N
7N (5T) *
8N 8N
10N (7T) 10N
No Mark
11N 11N
12N 12N
*: Nut with 1 or more marks on one side surface of the nut. B06432
HINT: Use the nut with the same number of the nut strength classification or the greater than the bolt strength classification number when tightening parts with a bolt and nut. Example: Bolt = 4T Nut = 4N or more 2002 ECHO (RM884U)
Author:
Date:
129
SS-2 SERVICE SPECIFICATIONS
-
STANDARD BOLT SS0ZT-01
SPECIFIED TORQUE FOR STANDARD BOLTS Specified torque Class
Diameter mm
Pitch mm
Hexagon head bolt
Hexagon flange bolt
N·m
kgf·cm
ft·lbf
N·m
kgf·cm
ft·lbf
4T
6 8 10 12 14 16
1 1.25 1.25 1.25 1.5 1.5
5 12.5 26 47 74 115
55 130 260 480 760 1,150
48 in.·lbf 9 19 35 55 83
6 14 29 53 84 -
60 145 290 540 850 -
52 in.·lbf 10 21 39 61 -
5T
6 8 10 12 14 16
1 1.25 1.25 1.25 1.5 1.5
6.5 15.5 32 59 91 140
65 160 330 600 930 1,400
56 in.·lbf 12 24 43 67 101
7.5 17.5 36 65 100 -
75 175 360 670 1,050 -
65 in.·lbf 13 26 48 76 -
6T
6 8 10 12 14 16
1 1.25 1.25 1.25 1.5 1.5
8 19 39 71 110 170
80 195 400 730 1,100 1,750
69 in.·lbf 14 29 53 80 127
9 21 44 80 125 -
90 210 440 810 1,250 -
78 in.·lbf 15 32 59 90 -
7T
6 8 10 12 14 16
1 1.25 1.25 1.25 1.5 1.5
10.5 25 52 95 145 230
110 260 530 970 1,500 2,300
8 19 38 70 108 166
12 28 58 105 165 -
120 290 590 1,050 1,700 -
9 21 43 76 123 -
8T
8 10 12
1.25 1.25 1.25
29 61 110
300 620 1,100
22 45 80
33 68 120
330 690 1,250
24 50 90
9T
8 10 12
1.25 1.25 1.25
34 70 125
340 710 1,300
25 51 94
37 78 140
380 790 1,450
27 57 105
10T
8 10 12
1.25 1.25 1.25
38 78 140
390 800 1,450
28 58 105
42 88 155
430 890 1,600
31 64 116
11T
8 10 12
1.25 1.25 1.25
42 87 155
430 890 1,600
31 64 116
47 97 175
480 990 1,800
35 72 130
2002 ECHO (RM884U)
Author:
Date:
128
SS-21 SERVICE SPECIFICATIONS
-
STARTING
STARTING SS0NF-03
SERVICE DATA Rated voltage and output power Starter
Circle runout No-load characteristics Carrier shaft diameter Center bearing inside diameter Center bearing oil clearance
USA Canada, Puerto Rico Maximum Current rpm
12 V 0.8 kW 12 V 1.0 kW 0.05 mm (0.0020 in.) 90 A or less at 11.5 V 3,000 rpm or more 14.980 - 15.000 mm (0.5898 - 0.5906 in.) 15.008 - 15.050 mm (0.5908 -0.5925 in.) STD 0.01 - 0.06 mm (0.0004 -0.0024 in.) Maximum 0.2 mm (0.0078 in.)
Brush length
Spring installed load Commutator Diameter Undercut depth
STD Minimum STD Minimum
14.0 mm (0.551 in.) 9.0 mm (0.354 in.) 13.7 - 17.6 N (1.4 - 1.8 kgf, 3.1 - 4.0 lbf) 8.8 N (0.9 kgf, 2.0 lbf)
STD Minimum STD Minimum
28.0 mm (1.102 in.) 27.0 mm (1.063 in.) 0.6 mm (0.024 in.) 0.2 mm (0.008 in.)
2002 ECHO (RM884U)
Author:
Date:
147
SS-22 SERVICE SPECIFICATIONS
-
STARTING SS0NG-03
TORQUE SPECIFICATION Part tightened
N·m
kgf·cm
ft·lbf
End cover x Brush holder
1.5
15
13 in.·lbf
End cover x Starter housing
5.9
60
52 in.·lbf
Magnetic switch x Starter housing
8.3
85
73 in.·lbf
Lead wire of field frame x Magnetic switch
9.8
100
87 in.·lbf
2002 ECHO (RM884U)
Author:
Date:
148
SS-36 SERVICE SPECIFICATIONS
-
STEERING
STEERING SS0MY-10
SERVICE DATA DRIVE BELT *Drive belt tension
New belt Used belt
440 - 540 N (45 - 55 kgf) 240 - 340 N (25 - 35 kgf)
POWER STEERING FLUID Fluid level rise
Maximum 5 mm (0.20 in.) Minimum 5,400 kPa (55 kgf/cm2, 781 psi)
Fluid pressure at idle speed with valve closed STEERING WHEEL Steering wheel freeplay
Maximum 30 mm (1.18 in.)
Steering effort at idle speed
Reference Manual steering 28 N·m (285 kgf·cm, 21 ft·lbf) Power steering 6.5 N·m (65 kgf·cm, 58 in.·lbf)
POWER STEERING VANE PUMP Vane pump rotating torque
0.27 N·m (2.8 kgf·cm, 2.4 in.·lbf) or less
Vane pump shaft and front housing bushing oil clearance
STD 0.021 - 0.043 mm (0.0008 - 0.0017 in.) Maximum 0.07 mm (0.0028 in.)
Vane plate height
Minimum 7.6 mm (0.299 in.)
Vane plate thickness
Minimum 1.405 mm (0.0553 in.)
Vane plate length
Minimum 11.993 mm (0.4722 in.)
Vane plate and vane pump rotor groove clearance Vane plate length
Spring free length
Maximum 0.03 mm (0.0012 in.)
Pump rotor and cam ring mark 0
12.001 - 12.003 mm (0.47248 - 0.47256 in.)
1
11.999 - 12.001 mm (0.47240 - 0.47248 in.)
2
11.997 - 11.999 mm (0.47232 - 0.47240 in.)
3
11.995 - 11.997 mm (0.47224 - 0.47232 in.)
4
11.993 - 11.995 mm (0.47216 - 0.47224 in.)
Minimum 35.8 mm (1.409 in.)
MANUAL STEERING GEAR Steering rack runout Total preload
Maximum 0.15 mm (0.0059 in.) Turning 0.6 - 1.5 N·m (6 - 15 kgf·cm, 5.2 - 13.0 in.·lbf)
POWER STEERING GEAR Steering rack runout Total preload
Maximum 0.1 mm (0.004 in.) Turning 1.2 - 1.4 N·m (12 - 14 kgf·cm, 10.4 - 12.2 in.·lbf)
* For use with belt tension gauge
2002 ECHO (RM884U)
Author:
Date:
162
SS-37 SERVICE SPECIFICATIONS
-
STEERING SS141-07
TORQUE SPECIFICATION Part tightened
N·m
kgf·cm
ft·lbf
TILT STEERING COLUMN Adjusting nut
See page SR-18
No. 2 tilt lever lock bolt
5.4
55
48 in.·lbf
No. 2 intermediate shaft assembly x Main shaft assembly
28
290
21
Column assembly set bolt
21
210
15
Sliding yoke x No. 3 intermediate shaft assembly
28
290
21
No. 2 intermediate shaft assembly x Sliding yoke
28
290
21
Steering wheel set nut
50
510
37
Steering wheel pad set screw (Torx screw)
8.8
90
78 in.·lbf
Rear housing x Front housing
22
220
16
Oil pressure sensor
21
210
15
Pressure port union
69
700
51
Front and rear bracket x Pump housing
44
440
32
Heat insulator and rear stay x Rear housing
44
440
32
Oil reservoir x Pump housing
9.0
90
78 in.·lbf
44 44 44
440 440 440
32 32 32
41 (44)
420 (450)
30 (33)
POWER STEERING VANE PUMP
Pump assembly set bolt
Bolt A Bolt B Bolt C
Pressure feed tube x Pump assembly MANUAL STEERING GEAR Engine hanger set bolt
20
200
15
Rack guide spring cap lock nut
36 (49)
365 (500)
26 (36)
Rack end x Rack
62 (83)
630 (850)
46 (61)
Tie rod end lock nut
47
480
35
Engine rear mount bracket set bolt
49
500
36
Engine rear mount bracket x Engine rear mount insulator
64
650
47
No. 3 intermediate shaft assembly x Steering pinion
28
290
21
Manual steering gear assembly set bolt
74
750
54
116 70
1,180 710
86 52
Front suspension member x Frame
Bolt A Bolt B
Engine rear mount insulator x Front suspension member
80
810
59
Lower suspension arm x Steering knuckle
98
1,000
72
Engine hood x Hinge
11
110
8
Tie rod end x Steering knuckle
49
500
36
Engine hanger set bolt
20
200
15
Control valve housing x Rack housing
21
220
15
Rack guide spring cap lock nut
28 (39)
290 (400)
21 (29)
Rack end x Rack
62 (83)
630 (850)
46 (61)
POWER STEERING GEAR
Tie rod end lock nut
47
480
35
Turn pressure tube x Rack housing
11 (13)
110 (130)
8 (9)
Engine rear mount bracket set bolt
49
500
36
Engine rear mount bracket x Engine rear mount insulator
64
650
47
2002 ECHO (RM884U)
Author:
Date:
163
SS-38 SERVICE SPECIFICATIONS
-
STEERING
Part tightened
N·m
kgf·cm
ft·lbf
No. 3 intermediate shaft assembly x Control valve shaft
28
290
21
PS gear assembly set bolt
74
750
54
Dynamic damper (with rack housing heat insulator) set bolt
18
180
13
Rack housing heat insulator set bolt
35
360
26
116 70
1,180 710
86 52
Engine rear mount insulator x Front suspension member
80
810
59
Lower suspension arm x Steering knuckle
98
1,000
72
Engine hood x Hinge
11
110
8
Tube clamp
7.8
80
69 in.·lbf
27 (25)
280 (250)
20 (18)
Front suspension member x Frame
Pressure feed and return tube
Bolt A Bolt B
( ): For use without SST
2002 ECHO (RM884U)
Author:
Date:
164
SS-39 SERVICE SPECIFICATIONS
-
SUPPLEMENTAL RESTRAINT SYSTEM
SUPPLEMENTAL RESTRAINT SYSTEM SS061-55
TORQUE SPECIFICATION Part tightened
N·m
kgf·cm
ft·lbf
Steering wheel
50
510
37
Steering wheel pad
8.8
90
78 in.·lbf
Front passenger airbag assembly x Instrument panel reinforcement
18
185
13
Airbag sensor assembly
20
205
15
Front airbag sensor
20
205
15
Seat cushion assembly x Body
37
375
27
Seatback assembly x Seat cushion assembly
43
440
32
Front seat inner belt set bolt
41
420
30
20
205
15
20
205
15
Door side airbag sensor x Door Side airbag sensor x Body
2-Door
2002 ECHO (RM884U)
Author:
Date:
165
SS-32 SERVICE SPECIFICATIONS
-
SUSPENSION AND AXLE
SUSPENSION AND AXLE SS13W-07
SERVICE DATA Cold tire inflation pressure
Front 220 kPa (2.2 kgf/cm2, 32 psi) Rear 220 kPa (2.2 kgf/cm2, 32 psi)
Tire size: P175/65R14 81S
Vehicle height P175/65R14
Front*1 Rear*2
Camber Right-left error
187 mm (7.36 in.) 264 mm (10.39 in.) -0 °37’ ± 45’ (-0.62° ± 0.75°) 45’ (0.75°) or less
Caster Manual steering Power steering Front wheel alignment li t
Right-left error
45’ (0.75°) or less
Right-left error
10°08’ ± 45’ (10.13° ± 0.75°) 45’ (0.75°) or less
Steering axis inclination
Toe-in (total)
Wheel angle Manual steering Power steering
0° ± 12’ (0° ± 0.2°, 0 ± 2 mm, 0 ± 0.08 in.) Rack end length difference 1.5 mm (0.059 in.) or less
Inside wheel Outside wheel: Reference Inside wheel Outside wheel: Reference
Camber Rear wheel alignment
F t axle Front l
Front drive shaft Front suspension R Rear axle l
0°48’ ± 45’ (0.80° ± 0.75°) 1°46’ ± 45’ (1.77° ± 0.75°)
Right-left error
36°56’ ± 2° (36.44° ± 2°) 32°07’ (32.12°) 36°56’ ± 2° (36.93° ± 2°) 32°17’ (32.28°) -0 °57’ ± 45’ (-0.95° ± 0.75°) 45’ (0.75°) or less 0°21’ ± 20’ (0.35° ± 0.33°) 3.3 ± 3.0 mm (0.13 ± 0.12 in.)
Toe-in (total)
Axle bearing backlash
Maximum 0.05 mm (0.0020 in.)
Axle hub deviation
Maximum 0.05 mm (0.0020 in.)
Drive shaft standard length
Lower suspension arm ball joint turning torque
LH RH
574.3 ± 5.0 mm (22.610 ± 0.197 in.) 813.3 ± 5.0 mm (32.020 ± 0.197 in.) 0.59 - 3.43 N·m (6 - 35 kgf·cm, 5.2 - 30 in.·lbf)
Axle bearing backlash
Maximum 0.05 mm (0.0020 in.)
Axle hub deviation
Maximum 0.07 mm (0.0028 in.)
*1: Front measuring point Measure the distance from the ground to the head center of the front side lower suspension arm mounting bolt. *2: Rear measuring point Measure the distance from the ground to the center of the rear axle beam mounting bolt.
2002 ECHO (RM884U)
Author:
Date:
158
SS-33 SERVICE SPECIFICATIONS
-
SUSPENSION AND AXLE SS13X-05
TORQUE SPECIFICATION Part tightened
N·m
kgf·cm
ft·lbf
Hub nut
103
1,050
76
Tie rod end lock nut
47
480
35
Steering knuckle x Shock absorber
132
1,350
97
Steering knuckle x Brake caliper
88
900
65
Steering knuckle x Tie rod end
49
500
36
Axle hub x Drive shaft
216
2,200
159
Lower suspension arm x Steering knuckle
98
1,000
72
Steering knuckle x Dust cover
8.3
85
74 in.·lbf
ABS speed sensor set bolt
8.0
82
71 in.·lbf
Suspension support x Body
39
400
29
Suspension support x Piston rod
33
340
24
Flexible hose and ABS speed sensor wire harness clamp x Shock absorber
29
300
22
Lower suspension arm front side set bolt
88
900
65
Lower suspension arm rear side set bolt
132
1,350
97
Engine rear mount x Suspension member
80
810
59
70 116
715 1,185
52 86
Stabilizer bar bracket set bolt
19
190
14
Stabilizer bar link set nut
18
180
13
Hub nut
103
1,050
76
Axle hub set bolt
52
526
38
Shock absorber x Body
25
250
18
Shock absorber x Rear axle beam
49
500
36
Seat belt set bolt
41
420
30
Rear seatback set bolt
37
380
27
Brake line x Flexible hose
15
155
11
ABS speed sensor wire harness clamp set bolt
5.4
55
48 in.·lbf
Parking brake cable clamp set nut
5.4
55
48 in.·lbf
Axle beam x Body
82
837
60
FRONT AXLE
FRONT SUSPENSION
Suspension member set bolt
Front side Rear side
REAR AXLE
REAR SUSPENSION
2002 ECHO (RM884U)
Author:
Date:
159