Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Toyota Echo 2000-2002 Approved ileaf 02toyrm 02toypdf 02rmsour 2002 02echorm em cylhea insp

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                     ENGINE MECHANICAL   -   CYLINDER HEAD

                                 1.    CLEAN TOP SURFACES OF PISTONS AND CYL-
                                       INDER BLOCK
                                 (a)   Turn the crankshaft, and bring each piston to top dead
                                       center (TDC). Using a gasket scraper, remove all the car-
                                       bon from the piston surface.


                                 (b)  Using a gasket scraper, remove all the gasket material
                                      from the cylinder block surface.
                                 (c) Using compressed air, blow carbon and oil from the bolt
                                 Protect your eyes when using high pressure compressed


                                 2.    REMOVE GASKET MATERIAL
                                 Using a gasket scraper, remove all the gasket material from the
                                 cylinder block contact surface.
                                 Be careful not to scratch the cylinder block contact sur-


                                 3.    CLEAN COMBUSTION CHAMBERS
                                 Using a wire brush, remove all the carbon from the combustion
                                 Be careful not to scratch the cylinder block contact sur-


                                 4.    CLEAN CYLINDER HEAD
                                 Using a soft brush and solvent, thoroughly clean the cylinder


2002 ECHO (RM884U)

                                                   Author :             Date :              646
                        ENGINE MECHANICAL   -   CYLINDER HEAD

                                    5.   CLEAN VALVE GUIDE BUSHINGS
                                    Using a valve guide bushing brush and solvent, clean all the
                                    guide bushings.


                                    6.    INSPECT FOR FLATNESS
                                    Using a precision straight edge and feeler gauge, measure the
                                    surface contacting the cylinder block and the manifolds for war-
                                          Maximum warpage: 0.05 mm (0.0020 in.)
                                    If warpage is greater than maximum, replace the cylinder head.
Cylinder Block Side

Intake Manifold Side

Exhaust Manifold Side


                                    7.     INSPECT FOR CRACKS
                                    Using a dye penetrant, check the combustion chamber, intake
                                    ports, exhaust ports and cylinder block surface for cracks.
                                    If cracked, replace the cylinder head.


                                    8.    CLEAN VALVES
                                    (a)   Using a gasket scraper, chip off any carbon from the valve
                                    (b)   Using a wire brush, thoroughly clean the valve.


2002 ECHO (RM884U)

                                                      Author :            Date :              647
                             ENGINE MECHANICAL   -   CYLINDER HEAD

                                         9.    INSPECT VALVE STEMS AND GUIDE BUSHINGS
                                         (a)   Using a caliper gauge, measure the inside diameter of the
                                               guide bushing.
                                               Bushing inside diameter:
                                               5.010 - 5.030 mm (0.19724 - 0.19803 in.)


                                         (b)    Using a micrometer, measure the diameter of the valve
                                                Valve stem diameter:
                                                Intake 4.970 - 4.985 mm (0.19567 - 0.19626 in.)
                                                Exhaust 4.965 - 4.980 mm (0.19547 - 0.19606 in.)
                                         (c) Subtract the valve stem diameter measurement from the
                                                guide bushing inside diameter measurement.
                                                Standard oil clearance:
                                Z00052          Intake 0.025 - 0.060 mm (0.00098 - 0.00236 in.)
                                                Exhaust 0.030 - 0.065 mm (0.00118 - 0.00256 in.)
                                                Maximum oil clearance:
                                                Intake 0.08 mm (0.0031 in.)
                                                Exhaust 0.10 mm (0.0039 in.)
                                         If the clearance is greater than maximum, replace the valve and
                                         guide bushing.

                                         10.    INSPECT VALVES
                                         (a)    Check the valve is ground to the correct valve face angle.
                                                Valve face angle: 44.5

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