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ECHO & Prius

WARNING: This page does not describe the selected car, but rather 10 other vehicles, including the 2002 Toyota Tacoma, 2002 Toyota RAV4, 2002 Toyota Prius, 2002 Toyota MR2, and 2002 Toyota Highlander. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS .
  1. On ECHO, remove No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover. On Prius, remove air cleaner assembly located above the valve cover. On all models, disconnect electrical connectors at ignition coils mounted on top of valve cover. Remove bolts and ignition coils from valve cover. Disconnect PCV hoses from valve cover.
  2. Remove valve cover bolts/nuts, seal washers, valve cover and gasket. Rotate crankshaft clockwise (viewed from timing chain end of engine) until crankshaft pulley timing mark (groove) aligns with "0" mark on timing chain cover and cylinder No. 1 is at TDC on compression stroke. Cylinder No. 1 is front cylinder at timing chain end of engine.
  3. Ensure timing marks on camshaft sprockets are facing upward at 12 o'clock position. See Fig 1. If timing marks are not as specified, rotate crankshaft clockwise one full revolution (360 degrees) and realign crankshaft pulley timing mark (groove) with "0" mark on timing chain cover and then recheck timing mark alignment.
    Fig 1: Checking Timing Mark Alignment (ECHO & Prius)
    G99E52856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. With cylinder No. 1 at TDC on compression stroke, use feeler gauge to measure valve clearance between valve lifter and camshaft on specified valves. Perform STEP 1 in illustration. See Fig 2. Record valve clearance.
  5. To check remaining valves, rotate crankshaft clockwise one full revolution (360 degrees) and realign crankshaft pulley timing mark (groove) with "0" mark on timing chain cover. Using feeler gauge, measure valve clearance between valve lifter and camshaft on specified valves. Perform STEP 2 in illustration. See Fig 2. Record valve clearance.
    Fig 2: Identifying Cylinder Numbers & Checking Valve Clearance (ECHO & Prius)
    G99F52857Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Ensure valve clearance is within specification. See VALVE CLEARANCE SPECIFICATIONS (ECHO & PRIUS)  table.
    VALVE CLEARANCE SPECIFICATIONS (ECHO & PRIUS)

    Application (1) In. (mm)
    Intake .006-.010 (.15-.25)
    Exhaust .010-.014 (.25-.35)
    (1) Adjust valve clearance with engine cold. Verify valve clearance listed with valve clearance listed on underhood label (if available). If valve clearance on underhood label differs from valve clearance listed, use specification on underhood label.
  7. If valve clearance requires adjustment, camshafts must be removed for access to valve lifters. Different thickness valve lifters are used. Rotate crankshaft clockwise (viewed from timing chain end of engine) until crankshaft pulley timing mark (groove) aligns with "0" mark on timing chain cover and cylinder No. 1 is at TDC on compression stroke. Ensure camshafts are positioned so timing marks on camshaft sprockets are facing upward at 12 o'clock position. See Fig 1.
  8. Place reference marks on timing chain at both camshaft sprockets. See Fig 3. Rotate crankshaft counterclockwise 40 degrees from TDC. Remove timing chain cover plug from front of timing chain cover. See Fig 3.
  9. Using screwdriver, rotate stopper plate on timing chain tensioner upward while rotating exhaust camshaft slightly clockwise and pushing plunger on timing chain tensioner inward. See Fig 3. Once plunger on timing chain tensioner is pushed inward, move stopper plate downward and install a .08-.12" (2.0-3.0 mm) pin through stopper plate and into hole on timing chain tensioner to retain the plunger in retracted position. See Fig 3. Use tape to secure pin in place.
    Fig 3: Installing Reference Marks, Locating Timing Chain Cover Plug & Releasing Timing Chain Tensioner (ECHO & Prius)
    G00015579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. Manufacturer recommends removing camshaft sprockets and camshafts with timing chain still engaged with crankshaft sprocket for access to valve lifter. To remove camshafts, see appropriate article in ENGINES. Secure timing chain aside to prevent timing chain from becoming disengaged from crankshaft sprocket. DO NOT allow timing chain to become disengaged from crankshaft sprocket.
  11. Remove valve lifter from cylinder head. Using micrometer, measure thickness of valve lifter. See Figure. Using thickness of used valve lifter and measured clearance, determine correct thickness of valve lifter to be used for proper valve by using following equation, or using valve lifter selection charts. For intake valves, "N" (new valve lifter thickness) = "T" (used valve lifter thickness) + "A" (measured clearance) minus .0080" (.200 mm). For exhaust valves, "N" (new valve lifter thickness) = "T" (used valve lifter thickness) + "A" (measured clearance) minus .0120" (.300 mm). Valve lifters are available in 35 sizes ranging from .1992" (5.060 mm) to .2260" (5.740 mm) in increments of .0008" (.020 mm). For valve lifter selection charts, see Figure and Figure .
  12. Install replacement valve lifter, camshafts and timing chain. Remove pin from timing chain tensioner. Ensure timing marks on camshaft sprockets are facing upward at 12 o'clock position and reference marks on timing chain at both camshaft sprockets are aligned when crankshaft pulley timing mark (groove) is aligned with "0" mark on timing chain cover and cylinder No. 1 is at TDC on compression stroke. See Fig 1 and Fig 3 .
  13. Install NEW timing chain cover plug and tighten to specification. See TORQUE SPECIFICATIONS . Recheck valve clearance. Before installing valve cover and gasket, apply sealant at specified areas on cylinder head. See Figure. Install gasket, valve cover, seal washers, bolts and nuts. Tighten valve cover bolts/nuts to specification in sequence. See Fig 4. See TORQUE SPECIFICATIONS . To install remaining components, reverse removal procedure. Tighten ignition coil bolts to specification. See TORQUE SPECIFICATIONS .
    Fig 4: Valve Cover Bolt/Nut Tightening Sequence (ECHO & Prius)
    G99A52860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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