Daihatsu Terios J100 Service & Repair Manual

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Tipo: Car

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SKU: 149688

Etiquetas: Car Cars Daihatsu Terios J100 Wiring Diagrams

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Descripción

The Daihatsu Terios, model code J100, represents the first generation of this capable compact SUV, produced between 1997 and 2006. Known for its robust construction and surprising off-road prowess, the Terios was designed as a durable and versatile vehicle suitable for both urban navigation and light trails. Its compact dimensions, typically around 3,745 mm in length and 1,600 mm in width, make it easy to maneuver and park, while its typically available 4WD systems and respectable ground clearance of approximately 195 mm provide confidence in varied conditions. Engine options often included reliable inline 4-cylinder units, such as the 1.6L (1590cc) or 2.0L (1998cc) H20A or G16A, delivering power in the range of 90-115 hp, making it a practical choice for budget-conscious owners seeking an affordable and dependable vehicle. This comprehensive Service & Repair Manual in English provides detailed guidance for all workshop procedures, maintenance, and repair of the Daihatsu Terios (J100). It covers essential areas including engine mechanicals, EFI system, lubrication, cooling, ignition, starting and charging systems, clutch, manual and automatic transmissions, transfer case, differentials, axles, suspension, brakes (including ABS), steering, and body systems. The manual also details body electrical components and provides crucial harness and wiring diagrams for accurate diagnostics. With step-by-step instructions for maintenance, troubleshooting, and repair, this manual is an indispensable resource for owners, mechanics, and technicians aiming to keep their Terios in optimal working condition.

🏷️ Basic Information

Identification

Make:

Daihatsu

Model:

Terios

Model Code:

Generation

Generation:

First Generation (J100)

Production Years:

1997-2006

👋 Introduction

Market Position

Segment:

Compact SUV, often marketed as a small, capable off-roader.

Target Audience:

Individuals seeking an affordable, durable, and versatile vehicle for urban and light off-road use, often budget-conscious owners.

Competitive Analysis

Competitors:

Suzuki Vitara, Toyota RAV4 (early models), Honda CR-V (early models), Mitsubishi Pajero Mini.

Key Features

Durability:

Known for its robust construction and reliable mechanicals.

Off Road Capability:

Part-time or full-time 4WD systems available, good ground clearance for its class.

Compact Size:

Easy to maneuver and park in urban environments.

📋 Manual Details

Coverage Areas

Coverage Scope:

All workshop procedures, maintenance, repair, diagnostics.

Page Count

Estimated Page Count:

Detailed sections suggest a comprehensive manual, likely exceeding 1000 pages, common for full workshop manuals.

Manual Type

Type:

Service & Repair Manual

Language

Language:

English

Format

Format:

PDF Download

Compatibility

Operating Systems:

All Versions of Windows & Mac

Requirements

Software Requirements:

Adobe PDF Reader

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul procedures, component testing, timing, compression.

Emission Control:

Diagnosis and repair of emissions-related systems, catalytic converter, O2 sensors.

Efi System:

Fuel injection system components, sensors, actuators, control unit diagnosis, fuel pressure.

Lubrication System:

Oil pump, oil filter, oil passages, oil pressure specifications.

Cooling System:

Radiator, water pump, thermostat, coolant specifications, pressure testing.

Ignition System:

Spark plugs, ignition coils, ignition timing, distributor (if applicable), sensor testing.

Starting System:

Starter motor, solenoid, battery testing, charging system interaction.

Charging System:

Alternator, voltage regulator, battery diagnosis, output testing.

Clutch:

Clutch disc, pressure plate, release bearing, hydraulic system, adjustment, bleeding.

Manual Transmission:

Gearbox overhaul, component identification, fluid specifications, shift mechanism.

Automatic Transmission:

ATF specifications, fluid change procedures, torque converter, shift control.

Transmission And Transfer:

Transfer case operation, lubrication, 4WD system components, engagement/disengagement.

Propeller Shaft:

U-joints, driveshaft balance, removal and installation.

Front And Rear Differential:

Differential fluid type, backlash, gear inspection, seal replacement.

Front Axle And Suspension:

CV joints, control arms, ball joints, strut replacement, alignment specifications.

Rear Axle And Suspension:

Shock absorbers, coil springs, trailing arms, alignment specifications.

Brake Including ABS:

Brake pad replacement, rotor resurfacing/replacement, caliper service, ABS sensor diagnosis, hydraulic system.

Steering:

Steering rack, power steering pump, fluid, tie rods, steering column.

Body:

Body panel repair, door mechanisms, glass replacement, interior trim removal.

Body Electrical:

Lighting systems, power windows, central locking, wiper motors, horn.

Harness And Wiring Diagram:

Detailed electrical schematics for all vehicle systems, troubleshooting by circuit.

Procedures Included

Maintenance:

Scheduled maintenance (oil changes, filter replacements, fluid checks), inspections.

Troubleshooting:

Diagnostic charts for common symptoms, fault finding procedures.

Repair:

Step-by-step instructions for component removal, repair, and reinstallation.

Installation:

Instructions for fitting new or replacement parts.

Technical Depth

Depth:

Comprehensive, covering basic DIY maintenance to complex engine and transmission rebuilds, including electrical diagnostics.

📊 Manual Specifications

File Format

Format Details:

PDF, allowing for easy searching, zooming, and printing of specific pages.

Print Quality

Quality:

Digital, with clear diagrams and text, comparable to original factory publications.

Binding Type

Binding:

Not applicable (Digital download)

Paper Type

Paper:

Not applicable (Digital download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

Typically H20A or G16A (depending on market and year)

Engine Type:

Inline 4-cylinder, DOHC, 16-valve

Displacement:

1.6L (1590cc) or 2.0L (1998cc)

Performance

Horsepower:

Approx. 90-115 hp (depending on engine variant and tuning)

Torque:

Approx. 130-170 Nm (depending on engine variant and tuning)

Fuel System

Induction:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Petrol

Technical Details

Bore X Stroke:

Refer to manual for specific engine code (e.g., 80.0 mm x 81.5 mm for H20A)

Compression Ratio:

Refer to manual for specific engine code (e.g., 9.5:1 for H20A)

🔧 Transmission

Standard

Transmission Type:

5-speed Manual Transmission

Optional

Transmission Type:

4-speed Automatic Transmission

Features

Drivetrain:

Selectable 4WD or Full-time 4WD with viscous coupling center differential.

Fluid Specifications

Manual Transmission Fluid:

API GL-4, SAE 75W-90 or 80W-90 (refer to manual for exact specification and capacity)

Automatic Transmission Fluid:

Dexron II/III or equivalent (refer to manual for exact specification and capacity)

Transfer Case Fluid:

API GL-4, SAE 75W-90 or 80W-90 (refer to manual for exact specification and capacity)

Differential Fluid:

API GL-5, SAE 80W-90 (refer to manual for exact specification and capacity)

📐 Dimensions

Exterior

Length:

Approx. 3,745 mm

Width:

Approx. 1,600 mm

Height:

Approx. 1,695 mm

Wheelbase:

Approx. 2,430 mm

Ground Clearance:

Approx. 195 mm (unladen)

Weights

Curb Weight:

Approx. 1,150 - 1,250 kg (depending on configuration)

Gross Vehicle Weight Rating:

Refer to vehicle plate or manual

Cargo

Cargo Volume:

Compact, but versatile with folding rear seats. Exact figures vary, refer to owner's manual.

🛡️ Safety Features

Ratings

Crash Test Ratings:

Likely limited or no official NHTSA/Euro NCAP ratings for this specific older generation and model, refer to specific market data if available.

Active Features

Available on some models/trims.

Passive Features

Airbags:

Driver and passenger airbags typically standard on later models.

Seatbelts:

3-point seatbelts with pretensioners.

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM radio with CD player, potentially cassette tape on early models. Aux input or USB generally not standard.

Driver Assistance

Optional feature, enhancing braking stability.

Connectivity

Connectivity Features:

Limited to basic audio connectivity. No advanced smartphone integration or Bluetooth typically found on this generation.

🔧 Maintenance

Service Intervals

Engine Oil And Filter:

Every 5,000-7,500 miles or 6-12 months, whichever comes first (refer to manual for precise intervals based on driving conditions).

Air Filter:

Inspect every 15,000 miles, replace as needed or every 30,000 miles.

Spark Plugs:

Replace every 30,000-50,000 miles (depending on plug type, consult manual).

Transmission Fluid Change:

Manual: Inspect every 30,000 miles, consider replacement. Automatic: Every 30,000-50,000 miles (refer to manual).

Fluid Specifications

Engine Oil Type:

API SL/SM/SN, SAE 10W-30 or 10W-40 (check manual for specific viscosity and API rating, oil capacity ~3.8-4.0 liters).

Coolant Type:

Ethylene glycol-based, typically a red or pink long-life coolant (refer to manual for specific type and capacity).

Known Issues

Common Problems:

CV joint wear, rear differential leaks, minor electrical issues, potential for aging rubber components (suspension bushings, hoses).

Rust Susceptibility:

Can be susceptible to rust in areas with heavy road salt usage, especially on the chassis and exhaust system.

📚 Vehicle History

Brand Heritage

Daihatsu Specialty:

Daihatsu is known for producing small, reliable, and fuel-efficient vehicles, often with a focus on compact SUVs and kei cars.

Model Evolution

J100 Positioning:

The J100 generation established the Terios nameplate as Daihatsu's entry into the compact SUV market, emphasizing practicality and light off-road ability.

J100 Design Philosophy:

Designed with an emphasis on a ladder-frame chassis for durability and off-road capability, unusual for compact SUVs of its era which increasingly moved to unibody construction.

Production

Manufacturing Locations:

Primarily Japan, with significant production also in Indonesia (as Daihatsu Taruna) and licensed production in other countries.