2005 Toyota Echo Service & Repair Manual

IN00U−88 N17080 Filler Cap Float Reservoir Tank z Grommet Clip Slotted Spring Pin : Specified torque z Non−reusable part Cylinder Piston Push Rod Washer Snap Ring Boot z Gasket Lock Nut Clevis Pin Clevis N·m (kgf·cm, ft·lbf) 12 (120, 9) 15 (155, 11) − INTRODUCTION HOW TO USE THIS MANUAL IN−1 1 Author: Date: 2005 ECHO (RM1119U) HOW TO USE THIS MANUAL GENERAL INFORMATION 1. INDEX An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you in finding your way through the manual, the section title and major heading are given at the top of every page. 2. PRECAUTION At the beginning of each section, PRECAUTIONs that pertain to repair operations contained in that section are given. Read these precautions before starting any repair work. 3. TROUBLESHOOTING The TROUBLESHOOTING tables are included for each system. Be sure to read the fundamentals of how to proceed with troubleshooting on page IN−21. 4. PREPARATION The Preparation section lists the Special Service Tools (SST), recommended tools, equipment, lubricants and Special Service Materials (SSM) that should be prepared before beginning. It also explains the purpose of each one. 5. REPAIR PROCEDURES Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together. Example:

Illustration: what to do and where 21. CHECK PISTON STROKE OF OVERDRIVE BRAKE (a) Task heading:what to do SST 09350−30020 (09350−06120) Set part No. Component part No. Detailed text:how to do task (b) Piston stroke: 1.40 Ċ 1.70 mm (0.0551 Ċ 0.0669 in.) Specification Place SST and a dial indicator onto the overdrive brake piston as shown in the illustration. Measure the stroke applying and releasing the compressed air (392 Ċ 785 kPa, 4 Ċ 8 kgf/cm 2 or 57 Ċ 114 psi) as shown in the illustration. IN−2 − INTRODUCTION HOW TO USE THIS MANUAL 2 Author: Date: 2005 ECHO (RM1119U) The procedures are presented in a step−by−step format: S The illustration shows what to do and where to do it. S The task heading briefly describes what you will be doing. S The detailed text tells how to perform the task and gives information such as specifications and warnings. Example: This format provides the experienced technician with a FAST TRACK to the information needed. The upper case task headings are easy to read and the text below it provides detailed information. Important specifications and warnings are always written in bold−faced text. 6. REFERENCES References are instances where you are given a page to refer to for more information. They have been kept to a minimum. 7. SPECIFICATIONS Specifications are printed in bold−faced text throughout the text where needed. They are also found in Ser- vice Specifications section for quick reference. 8. CAUTIONS, NOTICES, HINTS: S CAUTIONS are in bold type text, and indicate there is a possibility of injury to you or other people. S NOTICES are also presented in bold−faced text, and indicate the possibility of damage to the components being repaired. S HINTS are separated from the detailed text but are not in bold−faced text. HINTS provide additional information to help you perform repairs. 9. SI UNIT The UNITS used in this manual comply with the SI UNITS (International System of Units) standard. For your convenience, we also provide units from the metric system and the English system. Example: Torque: 30 N·m (310 kgf·cm, 22 ft·lbf)

PP151−01 − PREPARATION MANUAL TRANSAXLE PP−35 86 Author: Date: 2005 ECHO (RM1119U) LUBRICANT Item Capacity Classification Manual transaxle oil (w/ Differential oil) 1.9 liters (2.0 US qts, 1.7 Imp. qts) API GL−4 or GL−5 SAE 75W−90

PP152−02 PP−36 − PREPARATION MANUAL TRANSAXLE 87 Author: Date: 2005 ECHO (RM1119U) SSM (Special Service Materials) 08826−00090 Seal Packing 1281, THREE BOND 1281 or equivalent (FIPG) Transmission case x Transaxle case Transmission case x Transmission case cover 08833−00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent

PP2F1−01 − PREPARATION AUTOMATIC TRANSAXLE PP−37 88 Author: Date: 2005 ECHO (RM1119U) AUTOMATIC TRANSAXLE SST (Special Service Tools) 09308−00010 Oil Seal Puller Side gear shaft oil seal 09350−32014 TOYOTA Automatic Transmission Tool Set (09351−32010) One−way Clutch Test Tool (09351−32020) Stator Stopper 09992−00095 Automatic Transmission Oil Pressure Gauge Set Line pressure (09992−00231) Adaptor C Line pressure (09992−00271) Gauge Assy Line pressure

PP26J−04 PP−38 − PREPARATION AUTOMATIC TRANSAXLE 89 Author: Date: 2005 ECHO (RM1119U) RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester. 09090−04020 Engine Sling Device

PP26K−01 − PREPARATION AUTOMATIC TRANSAXLE PP−39 90 Author: Date: 2005 ECHO (RM1119U) EQUIPMENT Straight edge Torque converter clutch Vernier calipers Torque converter clutch Dial indicator or dial indicator with magnetic base Drive plate Punch Torque wrench

PP26L−04 PP−40 − PREPARATION AUTOMATIC TRANSAXLE 91 Author: Date: 2005 ECHO (RM1119U) LUBRICANT Item Capacity Classification Automatic transaxle fluid Dry fill Drain and refill 6.85 liters (7.24 US qts, 6.03 lmp.qts) 2.9 liters (3.1 US qts, 2.6 lmp.qts) ATF Type T−IV

PP26M−01 − PREPARATION AUTOMATIC TRANSAXLE PP−41 92 Author: Date: 2005 ECHO (RM1119U) SSM (Special Service Materials) 08833−00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent

PP2EG−01 PP−42 − PREPARATION SUSPENSION AND AXLE 93 Author: Date: 2005 ECHO (RM1119U) SUSPENSION AND AXLE SST (Special Service Tools) 09023−00100 Union Nut Wrench 10 mm Rear suspension 09214−76011 Crankshaft Pulley Replacer Rear axle 09240−00020 Wire Gauge Set Front drive shaft 09309−37010 Transmission Bearing Replacer Rear suspension 09520−00031 Rear Axle Shaft Puller (09520−00040) Shocker Front axle Rear axle (09521−00010) Attachment Front axle (09521−00020) Rod with Grip Front axle Rear axle 09520−01010 Drive Shaft Remover Attachment Front drive shaft 09520−24010 Differential Side Gear Shaft Puller Front drive shaft (09520−32040) Shocker Set 09521−24010 Drive Shaft Boot Clamping Tool Front drive shaft

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2005 Toyota Echo Service & Repair Manual

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