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Daihatsu Terios 1997 1998 1999 2000 2001 2002 2003 2004 2005 Service Repair Workshop Manual

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This workshop service repair manual provides comprehensive guidance for the Daihatsu Terios, specifically covering models produced between 1997 and 2005, including chassis codes J100, J102, and J122. The Daihatsu Terios...
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Daihatsu Terios 1997 1998 1999 2000 2001 2002 2003 2004 2005 Service Repair Workshop Manual
This workshop service repair manual provides comprehensive guidance for the Daihatsu Terios, specifically covering models produced between 1997 and 2005, including chassis codes J100, J102, and J122. The Daihatsu Terios is recognized as a capable and practical compact SUV, often praised for its affordability and suitability for light off-road excursions. This manual encompasses both the 3-door and 5-door body styles across all trim levels, offering detailed information on its robust engineering and reliable performance. The purpose of this extensive English-language manual is to serve as an indispensable resource for owners, mechanics, and technicians. It details essential maintenance procedures, from routine oil changes to critical timing belt replacements, and provides in-depth repair instructions for all major vehicle systems, including the powertrain, chassis, and electrical components. Furthermore, the manual includes diagnostic troubleshooting guides and technical specifications, supported by a high volume of detailed illustrations and diagrams, ensuring users can effectively maintain, diagnose, and repair their Daihatsu Terios.
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Terios
Generation:
J100
Body Styles Covered:
3-door and 5-door SUV
Codes
Chassis Codes:
J100, J102, J122
👋 Introduction
Market Position
Segment:
Compact SUV / Mini SUV
Target Audience:
DIY enthusiasts, independent repair shops, owners seeking in-depth maintenance and repair knowledge
Competitive Analysis
Key Competitors:
Suzuki Vitara, Honda CR-V (earlier generations), Toyota RAV4 (earlier generations), Mitsubishi Pajero Mini
Key Features
Manual Value Proposition:
Comprehensive A-Z coverage of all mechanical and electrical repairs, extensive photographic and diagrammatic support, suitability for all models within the specified years
Vehicle Appeal:
Affordable, capable compact SUV with a focus on practicality and off-road ability for its size
📋 Manual Details
Coverage Areas
Market Coverage:
Global (specific regional variations may exist, but manual aims for comprehensive coverage)
Model Years:
1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005
Trim Levels Covered:
All trim levels
Page Count
Estimated Page Count:
High (likely 1000+ pages based on scope)
Manual Type
Manual Classification:
Workshop Service Repair Manual
Language
Language:
English
Format
Digital Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (mechanical and electrical), transmission (manual and automatic), drivetrain, exhaust system
Chassis:
Suspension (front and rear), steering, brakes, wheels, tires
Electrical:
Full vehicle electrical system, wiring diagrams, lighting, instrumentation, accessories, ECUs
Body:
Body construction, exterior trim, interior trim, doors, windows, HVAC system
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, tune-ups, lubrication
Repair:
Engine overhaul, transmission rebuilds, brake caliper replacement, suspension component repair, electrical component troubleshooting and replacement
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based diagnosis
Special Procedures:
Wheel alignment, clutch replacement, timing belt replacement, fuel system cleaning
Technical Depth
Depth Of Coverage:
Comprehensive: from basic fluid checks to complete engine and transmission rebuilds, including detailed electrical diagnostics
Diagnostic Capabilities:
Detailed fault code interpretations and troubleshooting trees
Illustration Quality:
High volume of detailed pictures and diagrams, including exploded views and wiring schematics
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Print Quality
Printability:
All pages printable, allowing users to print specific sections or the entire manual
Searchability:
Likely text-searchable PDF for easy navigation and information retrieval
Binding Type
Digital Binding:
N/A (as it's a digital file)
Paper Type
Digital Paper Type:
N/A (as it's a digital file)
⚙️ Engine Specifications
Primary Engine
Engine Code:
G13BA (1.3L), G16A (1.6L), G16B (1.6L DOHC)
Engine Type:
Inline 4-cylinder, SOHC or DOHC (depending on variant)
Displacement:
1298 cc (1.3L) or 1590 cc (1.6L)
Performance
Horsepower Range:
Approx. 70-100 hp (depending on engine and market)
Torque Range:
Approx. 100-130 Nm (depending on engine and market)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Maintenance Specs
Ignition Timing:
Refer to manual for specific engine and model
Spark Plug Gap:
Refer to manual for specific engine and model
Compression Ratio:
Refer to manual for specific engine and model
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission
Optional
Transmission Type Optional:
4-speed Automatic Transmission
Features
Drivetrain Options:
4WD (Four-Wheel Drive) is standard or commonly available on most models; 2WD variants may exist
Maintenance Specs
Manual Transmission Fluid:
API GL-4 SAE 75W-90 or SAE 80W-90
Automatic Transmission Fluid:
Dexron III or equivalent
📐 Dimensions
Exterior
Length:
Approx. 3,735 mm (3-door), 3,945 mm (5-door)
Width:
Approx. 1,600 mm
Height:
Approx. 1,705 mm
Wheelbase:
Approx. 2,415 mm
Weights
Curb Weight:
Approx. 1,050 - 1,200 kg (depending on configuration)
Gross Vehicle Weight Rating:
Refer to manual for specific GVWR
Towing Capacity:
Refer to manual for specific towing limits
🛡️ Safety Features
Ratings
Crash Test Ratings:
Information may vary by market; generally not a focus for this era/segment of vehicle in achieving high international safety ratings compared to modern standards.
Active Features
Active Safety Systems:
ABS (Anti-lock Braking System) often available as an option, particularly on higher trims or later models.
Passive Features
Passive Safety Features:
Seatbelts, reinforced body structure, potentially driver airbag (market dependent)
Child Seat Anchors:
Likely equipped with rear seatbelt anchors for child restraint systems.
💡 Technology Features
Infotainment
Infotainment System:
Basic radio/cassette player or CD player, often with optional 4-speaker or 6-speaker system. Manual may cover basic wiring for aftermarket head unit installation.
Driver Assistance
Driver Assistance Features:
Limited to available ABS; no advanced driver-assistance systems (ADAS) present on this generation.
Connectivity
Connectivity Options:
N/A (no integrated Bluetooth, USB, or smartphone integration from factory).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-10,000 km or 6-12 months, depending on driving conditions (refer to manual for exact recommendation).
Air Filter Replacement:
Every 15,000-30,000 km, or as needed based on conditions.
Spark Plug Replacement:
Every 30,000-60,000 km (depending on spark plug type, e.g., copper vs. platinum).
Timing Belt Replacement:
Crucial: Typically around 80,000-100,000 km or 5-7 years for interference engines. Manual will specify exact interval and procedure.
Fluid Specifications
Engine Oil Capacity:
Approx. 3.4 - 4.0 liters (with filter), depending on engine variant. Refer to manual.
Engine Oil Viscosity:
Typically 5W-30 or 10W-40, depending on climate and engine. Manual for precise recommendation.
Coolant Type:
Ethylene glycol based, often a silicate-free or hybrid OAT coolant. Manual for specification.
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Common Wear Items:
Clutch wear (manual transmission), suspension bushings, exhaust components, catalytic converter (depending on mileage/maintenance).
Potential Electrical Issues:
Corrosion on connectors, aging wiring looms, issues with starter motor or alternator.
Engine Specific Considerations:
Timing belt integrity is critical. Regular maintenance of the cooling system prevents overheating.
📚 Vehicle History
Brand Heritage
Daihatsu Specialty:
Daihatsu is known for producing small, fuel-efficient vehicles, kei cars, and light commercial vehicles, often with a focus on affordability and practicality.
Model Evolution
Terios Purpose:
The Terios was designed as a compact, affordable, and relatively capable small SUV/off-roader, often based on a ladder-frame chassis for durability and off-road prowess.
Production
Production Period:
First generation produced from 1997 to 2006. This manual covers the initial segment of this generation.
Manufacturing Location:
Primarily Japan, but also produced in other Daihatsu facilities and licensed production in various countries (e.g., India by Premier Automobiles Ltd. as Premier P4).
🏆 Awards & Recognition
Recognitions
Notable Awards:
While the Terios may not have received numerous high-profile international awards, its consistent sales in many markets, particularly in Asia and Europe, attest to its value and utility within its segment.
Ratings
Consumer Ratings:
Generally regarded by owners as a reliable, economical, and capable small SUV, particularly for light off-roading and city use. Longevity and ease of maintenance are often cited positives.
Certifications
Certifications:
Vehicle certifications are market-specific and generally pertain to emissions and safety standards applicable in the region of sale.
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