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DAIHATSU TERIOS Service Repair Manual 1997-2005

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The Daihatsu Terios, produced between 1997 and 2005, is a compact SUV renowned for its robust 4WD system, good ground clearance, and affordable entry into the off-road-capable vehicle market. Built...
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SKU: 137279
DAIHATSU TERIOS Service Repair Manual 1997-2005
The Daihatsu Terios, produced between 1997 and 2005, is a compact SUV renowned for its robust 4WD system, good ground clearance, and affordable entry into the off-road-capable vehicle market. Built on a durable ladder chassis, the Terios offered a practical and agile solution for individuals seeking a vehicle suitable for light off-roading and everyday use, distinguishing itself from many monocoque crossovers of its era. Available with various inline 4-cylinder engines ranging from 1.3L to 1.6L, and offered with either manual or automatic transmissions, the Terios provided a blend of utility and value, supported by a reputation for producing reliable and economical compact vehicles. This comprehensive service repair workshop manual covers all Daihatsu Terios models from 1997 to 2005, providing in-depth technical information essential for maintenance and repair. It details routine maintenance procedures, engine and transmission overhauls, drivetrain systems, suspension, steering, brakes, and the complete electrical system. The manual also includes diagnostic troubleshooting guides, component removal and installation instructions, and detailed specifications, ensuring that owners, mechanics, and technicians have the necessary resources to keep the vehicle in optimal condition. Its extensive coverage and expert-level detail make it an invaluable tool for understanding and servicing the Terios.
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Terios
Codes
Model Code Range:
J100, J122, J138 (depending on market and generation)
👋 Introduction
Market Position
Vehicle Segment:
Compact SUV / Mini SUV
Target Audience:
Individuals seeking a compact, capable, and affordable off-road-oriented vehicle, often used as a first SUV or for light off-roading.
Competitive Analysis
Key Competitors:
Early Suzuki Vitara, Honda CR-V (first generation), Toyota RAV4 (first generation), Mitsubishi Pajero/Montero iO, Isuzu VehiCROSS (in some markets).
Key Features
Vehicle Strengths:
Compact size, robust 4WD system (often with center differential lock), affordable price point, good ground clearance for its class, durable reputation.
Manual Value Proposition:
Empowers owners and independent mechanics with the same technical information used by professionals, enabling efficient and accurate maintenance and repairs.
📋 Manual Details
Coverage Areas
Product Name:
DAIHATSU TERIOS Service Repair Manual 1997-2005
Years Covered:
1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005
Models Covered:
All Terios models within the specified year range (e.g., 2-door, 4-door, 4WD variants)
Page Count
Estimated Page Count:
Highly comprehensive; typically 1500+ pages for a full service manual of this era.
Manual Type
Type:
Service Repair Workshop Manual
Language
Language:
English (assumed, standard for professional manuals)
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, cylinder block, pistons, crankshaft, camshafts, timing systems, lubrication, cooling system, intake and exhaust manifolds.
Engine Management:
Fuel system (injection, carburetor where applicable), ignition system, emissions control, sensors, ECU diagnostics.
Transmission Manual:
Clutch system, gearbox assembly, gear selection, overhaul procedures.
Transmission Automatic:
Automatic transmission assembly, valve body, torque converter, shift control, overhaul procedures.
Drivetrain:
Front-wheel drive, rear-wheel drive, 4-wheel drive (4WD) system, transfer case, differentials, drive shafts, CV joints.
Suspension:
Front suspension (e.g., MacPherson strut), rear suspension (e.g., multi-link, coil spring), shock absorbers, springs, control arms, anti-roll bars.
Steering:
Steering system components, steering rack/box, power steering system (hydraulic), alignment specifications.
Brakes:
Front and rear brake systems (disc/drum), hydraulic system, brake fluid, ABS system (if equipped), parking brake.
Electrical System:
Battery, charging system (alternator), starting system, lighting system, wipers, horn, power windows, central locking.
Body And Chassis:
Body panels, doors, hood, tailgate, interior trim, seats, glass, chassis structure, corrosion protection.
Heating Ventilation Air Conditioning HVAC:
HVAC system operation, components, refrigerant system, cabin air filter.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug service, fluid checks and top-offs, tire rotation.
Troubleshooting:
Diagnostic procedures for common and uncommon issues across all major systems, symptom-based guides.
Component Removal Installation:
Step-by-step instructions for removing and installing virtually every serviceable component.
Rebuilding Overhaul:
Detailed instructions for rebuilding engines, transmissions, differentials, and other major assemblies.
Diagnostics Testing:
Procedures for testing electrical components, sensors, actuators, and mechanical systems using appropriate tools.
Specifications Data:
Torque values, clearances, fluid capacities, timing marks, alignment settings, electrical resistance values.
Technical Depth
Depth:
Comprehensive, from basic maintenance to full engine/transmission rebuilds and advanced diagnostics.
Detail Level:
Expert-level detail, equivalent to factory service manuals used by dealership technicians.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Likely text-searchable if created from digital sources or properly OCR'd, enabling quick navigation.
Print Quality
Quality:
High-resolution images, clear diagrams, and readable text, suitable for on-screen viewing and printing.
Binding Type
Digital Format:
N/A (Digital PDF)
Paper Type
Digital Format:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code Common:
G13BA (1.3L I4), G15A (1.5L I4), G16A/G16B (1.6L I4), 3SZ-VE (1.5L I4 - later models).
Displacement Range:
1.3L, 1.5L, 1.6L
Engine Configuration:
Inline 4-cylinder (I4)
Performance
Horsepower Range:
Approx. 70-115 hp depending on engine and market.
Torque Range:
Approx. 100-140 Nm depending on engine and market.
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) for most models; some early variants may have carbureted options in certain markets.
Fuel Type:
Unleaded Gasoline
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission
Optional
Transmission Type Optional:
4-speed Automatic Transmission
Features
Drivetrain Options:
Part-time 4WD (often with selectable 2WD/4WD modes and low-range gearing); some markets may have offered 2WD variants.
📐 Dimensions
Exterior
Length Range:
Approx. 3,700-4,000 mm (varies by body style, e.g., 3-door vs 5-door).
Width Range:
Approx. 1,600-1,700 mm
Height Range:
Approx. 1,600-1,700 mm
Ground Clearance:
Typically around 180-200 mm, excellent for its class.
Weights
Curb Weight Range:
Approx. 1,000-1,200 kg
🛡️ Safety Features
Ratings
Crash Test Data:
Limited public crash test data available for this era; refer to specific market regulatory body reports if available.
Active Features
ABS:
Available on higher trim levels or as an option.
Traction Control:
Rarely featured on models from this period.
Passive Features
Airbags:
Driver and passenger airbags standard on later models/higher trims; older models may have only a driver airbag or none.
Seatbelts:
All seating positions equipped with seatbelts; pre-tensioners may be present on front belts.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with CD player or cassette player; aftermarket unit options common.
Driver Assistance
Cruise Control:
Available on some higher trim levels or as an aftermarket addition.
Parking Assist:
Not typically equipped with factory parking sensors or cameras.
Connectivity
Bluetooth:
Not factory-equipped; requires aftermarket installation.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000-10,000 km or 6-12 months, depending on driving conditions and oil type used.
Air Filter Replacement:
Every 20,000-30,000 km or as needed based on inspection.
Spark Plug Replacement:
Every 40,000-60,000 km for standard plugs, or 80,000-100,000 km for iridium/platinum plugs (check specific engine).
Coolant Flush:
Every 40,000-80,000 km or 2-4 years.
Fluid Specifications
Engine Oil Type:
API SG/SH or higher, viscosity typically 10W-30 or 5W-30 (refer to owner's manual for exact specification).
Transmission Fluid Manual:
API GL-4, SAE 75W-90 or 80W-90 gear oil.
Transmission Fluid Automatic:
Dexron II/III or equivalent ATF (Automatic Transmission Fluid).
Brake Fluid Type:
DOT 3 or DOT 4.
Coolant Type:
Ethylene glycol based, typically a 50/50 mix with deionized water (refer to manual for specific type).
Known Issues
Common Wear Items:
Clutch wear (manual), front brake pads/rotors, CV joint boots, exhaust system components, suspension bushings.
Potential Issues:
Rust/corrosion on chassis and bodywork in humid/salty environments, occasional head gasket issues on older/high-mileage engines, minor electrical gremlins.
📚 Vehicle History
Brand Heritage
Daihatsu Focus:
Daihatsu is a Japanese automobile manufacturer with a long history, specializing in compact and light commercial vehicles. It is a subsidiary of Toyota Motor Corporation.
Model Evolution
First Generation Introduction:
The first generation Daihatsu Terios (also known as Toyota Cami/Duet in some markets) was introduced in 1997.
Platform Development:
Developed as a compact, body-on-frame (ladder chassis) SUV, providing genuine off-road capability unlike many monocoque crossovers of the time.
Production
Manufacturing Locations:
Primarily Japan, with production also occurring in other Daihatsu plants globally and through licensing agreements.
🏆 Awards & Recognition
Recognitions
Model Awards:
Generally recognized for its value, compact size, and off-road capability in its segment rather than winning major awards.
Ratings
Reliability Reputation:
Generally considered reliable with proper maintenance, especially the mechanical components. Durability is a strong point for its class.
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