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    DAIHATSU TERIOS J100 Service Repair Workshop Manual 1997-2000

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    The Daihatsu Terios, produced from 1997 to 2000, is a compact SUV renowned for its practicality, affordability, and genuine four-wheel-drive capability. Designed as a lightweight and agile off-roader, it offered...
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    The Daihatsu Terios, produced from 1997 to 2000, is a compact SUV renowned for its practicality, affordability, and genuine four-wheel-drive capability. Designed as a lightweight and agile off-roader, it offered go-anywhere utility in a small package, making it an appealing choice for budget-conscious consumers seeking versatility. Its engineering emphasizes reliability and straightforward functionality, with a robust ladder frame chassis and a capable 1.3L engine. Key features include its compact dimensions, efficient operation, and a true 4WD system, setting it apart from many contemporary competitors. This comprehensive service and repair workshop manual is specifically tailored for the Daihatsu Terios J100 chassis codes, covering all models and repairs from A to Z. It serves as an essential resource for dealership technicians and anyone involved in maintaining or repairing this vehicle. The manual details engine mechanical and electrical systems, transmission and drivetrain, suspension and steering, brakes, HVAC, fuel, and cooling systems. It also provides in-depth coverage of scheduled maintenance, troubleshooting procedures, repair and overhaul instructions, technical specifications, and detailed wiring diagrams, ensuring the vehicle's optimal performance and longevity.
    🏷️ Basic Information
    Identification
    Make:
    Daihatsu
    Model:
    Terios
    Generation:
    J100
    Production Years Covered:
    1997-2000
    Codes
    Chassis Codes:
    J100G, J102G, J122G (depending on specific market and configuration)
    👋 Introduction
    Market Position
    Segment:
    Compact SUV / Mini SUV
    Target Audience:
    Budget-conscious consumers seeking an affordable, capable, and relatively compact all-wheel-drive vehicle for light off-roading and general utility.
    Competitive Analysis
    Key Competitors:
    Suzuki Vitara, Honda CR-V (first generation), Toyota RAV4 (first generation), Mitsubishi Pajero/Montero (smaller variants).
    Key Features
    Differentiating Factors:
    Compact dimensions, genuine four-wheel-drive system (often with a locking center differential on some variants), affordability, and Daihatsu's reputation for reliable, small-displacement engines.
    Design Philosophy:
    Practicality, utility, and go-anywhere capability in a small package, often with a body-on-frame construction (common for this era's compact SUVs).
    📋 Manual Details
    Coverage Areas
    General Coverage:
    All models and all repairs A-Z
    Specific Coverage:
    Vehicle/Model Specific, Not Generic
    Page Count
    Estimated Page Count:
    Extensive (typical workshop manuals for this era are 500+ pages, specific count not provided in product info)
    Manual Type
    Type:
    Service Repair Workshop Manual
    Intended User:
    Dealership Technicians
    Language
    Language:
    English (assumed based on product description context)
    Format
    Format:
    Likely PDF, or digital format accessible by technicians (specific format not detailed, but implied professional use)
    📖 Manual Coverage
    Systems Covered
    Engine Mechanical:
    Engine assembly, disassembly, overhaul, tuning, cooling system, lubrication system, fuel system, intake and exhaust systems.
    Engine Electrical:
    Ignition system, starting system, charging system, engine control unit (ECU), sensor diagnostics, wiring diagrams.
    Transmission Drivetrain:
    Manual and automatic transmission overhaul, clutch system, transfer case, differential, driveshafts, axles.
    Suspension Steering:
    Front and rear suspension components, shock absorbers, springs, control arms, steering gearbox, power steering system, wheel alignment.
    Brakes:
    Front and rear brake systems (disc/drum), hydraulic system, ABS (if equipped), parking brake, brake fluid specifications.
    Electrical Body:
    Lighting systems, power windows, door locks, mirrors, horn, wipers, interior and exterior trim, body panel repair, chassis electrical.
    HVAC:
    Heating, ventilation, and air conditioning (HVAC) system diagnosis and repair, refrigerant handling.
    Fuel System:
    Fuel pump, fuel injectors, fuel tank, fuel lines, emissions control systems.
    Cooling System:
    Radiator, water pump, thermostat, coolant specifications, fan operation.
    Procedures Included
    Maintenance:
    Scheduled maintenance, oil changes, filter replacements, fluid checks, tune-ups.
    Troubleshooting:
    Diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable).
    Repair Overhaul:
    Complete step-by-step repair instructions for all major components and systems, including engine rebuilds and transmission overhauls.
    Specifications:
    Torque specifications, clearances, tolerances, fluid capacities, electrical specifications.
    Wiring Diagrams:
    Detailed electrical schematics for all vehicle systems.
    Body And Frame:
    Body panel alignment, repair, and replacement, structural integrity information.
    Technical Depth
    Depth:
    Comprehensive: Covers everything from basic scheduled maintenance to complete engine and transmission rebuilds, including advanced diagnostics and electrical troubleshooting.
    📊 Manual Specifications
    File Format
    Digital Format:
    PDF (standard for such manuals, often with searchable text)
    Print Quality
    Quality:
    High quality, designed for clarity and ease of use in a workshop environment.
    Binding Type
    Physical Format If Applicable:
    If printed, likely spiral-bound or case-bound for durability and ease of opening flat on a workbench.
    Paper Type
    Paper Quality If Applicable:
    Durable, often glossy or semi-gloss paper to withstand workshop conditions.
    ⚙️ Engine Specifications
    Primary Engine
    Engine Code And Type:
    1.3L (1298cc) 4-cylinder, SOHC, 16-valve, naturally aspirated (common for early J100 models, e.g., K3-VE engine family).
    Displacement:
    1.3 Liters (1298 cc)
    Bore X Stroke:
    Typically around 72.0 mm x 79.6 mm (for K3-VE family)
    Compression Ratio:
    Approx. 9.5:1 to 10.0:1 (varies slightly by specific engine version)
    Horsepower:
    Approximately 85-95 PS (63-70 kW) at around 6000 RPM (varies by market and specific engine variant)
    Torque:
    Approximately 115-125 Nm (85-92 lb-ft) at around 3200-4000 RPM (varies)
    Performance
    Top Speed:
    Around 140-150 km/h (87-93 mph)
    Acceleration 0 100Kmh:
    Approximately 12-14 seconds (highly dependent on transmission and load)
    Fuel System
    Fuel Delivery:
    Electronic Fuel Injection (EFI)
    Fuel Type:
    Unleaded Petrol (Octane rating varies by market, typically 91-95 RON)
    Emissions Control:
    Catalytic converter, EGR (Exhaust Gas Recirculation), O2 sensors (typical for Euro 2/3 or equivalent standards of the era).
    Engine Cooling
    Cooling Type:
    Liquid-cooled
    Engine Lubrication
    Oil Capacity:
    Approx. 3.5 - 4.0 liters with filter (specifics in manual)
    Recommended Oil Viscosity:
    API SG or SH, SAE 10W-30 or 10W-40 (check manual for precise grades and specifications)
    🔧 Transmission
    Standard
    Type:
    5-speed Manual Transmission
    Optional
    Type:
    4-speed Automatic Transmission
    Features
    Drive System:
    Full-time 4WD with optional locking center differential (often via a button or lever).
    Transfer Case:
    Integrated with transmission, providing power distribution to front and rear axles.
    Gear Ratios
    Manual Gear Ratios:
    Specific ratios vary but typical for this class (e.g., 1st: ~3.5, 2nd: ~2.0, 3rd: ~1.3, 4th: ~1.0, 5th: ~0.8)
    Final Drive Ratio:
    Typically around 4.100:1 or 4.300:1 (depends on tire size and market)
    Fluid Specifications
    Manual Transmission Fluid:
    API GL-4, SAE 75W-90 or 80W-90 gear oil (check manual for specific part numbers and grades)
    Automatic Transmission Fluid:
    Dexron II/III compatible fluid (check manual for specific DEXRON specification or equivalent)
    📐 Dimensions
    Exterior
    Length:
    Approx. 3,750 mm (147.6 inches)
    Width:
    Approx. 1,600 mm (63.0 inches)
    Height:
    Approx. 1,690 mm (66.5 inches) (without roof rails)
    Wheelbase:
    Approx. 2,430 mm (95.7 inches)
    Ground Clearance:
    Approx. 195-200 mm (7.7-7.9 inches) (unloaded)
    Weights
    Curb Weight:
    Approx. 1100-1250 kg (2425-2755 lbs), depending on trim and transmission
    Gross Vehicle Weight Rating Gvwr:
    Typically around 1600-1700 kg (check manual for exact figure)
    Towing Capacity:
    Typically limited for this class, often around 500-1000 kg (unbraked/braked, check local regulations and manual).
    Cargo
    Cargo Volume Rear Seats Up:
    Modest, typically sufficient for daily use and light shopping. Specific cubic footage often not published but is compact.
    Cargo Volume Rear Seats Down:
    Significantly increased, allowing for more substantial loads like camping gear or larger items.
    Wheels Tires
    Wheel Size:
    Typically 15-inch or 16-inch alloy or steel wheels.
    Tire Size:
    Commonly 205/70 R15 or 215/65 R16 (verify with specific vehicle)
    Bolt Pattern:
    Typically 5x114.3 (5 lug, 114.3mm bolt circle diameter)
    🛡️ Safety Features
    Ratings
    Crash Test Ratings:
    Limited comprehensive official ratings available for this specific model and era from major bodies like NHTSA/Euro NCAP. Typically considered basic safety for its class and time.
    Active Features
    ABS:
    Optional on some models, typically a 4-channel system.
    Traction Control:
    Rarely equipped on this generation.
    Passive Features
    Airbags:
    Driver airbag standard, passenger airbag optional on some later models.
    Seatbelts:
    3-point seatbelts with pretensioners for front occupants, 2-point or 3-point for rear occupants (depending on seating position).
    Rollover Protection:
    Body-on-frame construction and moderate ride height inherent to SUVs may increase rollover risk compared to sedans. Manual will detail any specific reinforcement.
    💡 Technology Features
    Infotainment
    Audio System:
    Basic AM/FM radio with CD player or cassette tape player. Speaker count typically 4 or 6.
    Display:
    Simple digital or analog displays for climate control and radio functions. No central touchscreen infotainment.
    Driver Assistance
    ABS:
    As mentioned, optional on some models, providing anti-lock braking functionality.
    Connectivity
    Auxiliary Input:
    Unlikely to be standard, potentially an aftermarket addition or very late production models might have a rudimentary auxiliary input.
    Bluetooth:
    Not available from factory for this era.
    🔧 Maintenance
    Service Intervals
    Oil And Filter Change:
    Typically every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, whichever comes first.
    Air Filter Replacement:
    Every 15,000-20,000 miles (24,000-32,000 km) or annually.
    Spark Plug Replacement:
    Typically every 30,000-40,000 miles (48,000-64,000 km) depending on plug type (copper vs. platinum).
    Coolant Flush And Replace:
    Every 30,000-40,000 miles (48,000-64,000 km) or 2-3 years.
    Transmission Fluid Change:
    Manual: every 40,000-60,000 miles (64,000-96,000 km). Automatic: every 30,000-40,000 miles (48,000-64,000 km), or more frequently under severe use.
    Fluid Specifications
    Brake Fluid:
    DOT 3 or DOT 4 (check manual for specific DOT rating and type)
    Power Steering Fluid:
    Dexron II/III compatible fluid or specific Daihatsu fluid (check manual)
    Coolant:
    Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Specific color/type may be required (consult manual).
    Known Issues
    Engine Performance:
    Potential for slight power loss over time due to carbon buildup or worn ignition components. Timing belt replacement is crucial and failure can be catastrophic.
    Transmission:
    Manual transmissions generally robust. Automatic transmissions may exhibit harsh shifts or slippage if fluid is neglected. Clutch wear is a common maintenance item.
    Suspension Steering:
    Wear in ball joints, tie rod ends, and bushings can lead to knocking noises and imprecise steering. Power steering pumps can sometimes leak.
    Electrical:
    Corrosion on electrical connectors, especially in humid or salty environments, can cause intermittent issues with lights or sensors. Alternator and starter motor lifespan are typical wear items.
    Rust Corrosion:
    Body panels and undercarriage can be susceptible to rust, particularly in regions with harsh winters or coastal exposure. Regular inspection and preventative treatment are advised.
    📚 Vehicle History
    Brand Heritage
    Daihatsu Legacy:
    Daihatsu, a subsidiary of Toyota, has a long history in producing small, economical, and durable vehicles, often with a focus on reliability and value for money.
    Model Evolution
    J100 Generation:
    The first generation Terios (J100) was launched in 1997, designed as a lightweight, compact SUV aimed at filling a niche for a more agile and fuel-efficient off-roader than larger models. It utilized a ladder frame chassis, shared with its sibling the Toyota Cami.
    Production
    Manufacturing Location:
    Primarily manufactured in Japan by Daihatsu.
    Lifespan Of Generation:
    The J100 generation ran from 1997 to 2006 globally, with significant updates and facelifts. The manual covers the initial 1997-2000 period.
    🏆 Awards & Recognition
    Recognitions
    Market Perception:
    Often praised for its compact size, maneuverability, and genuine 4WD capability in challenging conditions for its class. Considered a cost-effective alternative to larger SUVs.
    Ratings
    Reliability:
    Generally considered reliable due to its simple construction and Toyota's influence on Daihatsu's engineering practices. However, maintenance is key to longevity.
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