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DAIHATSU TERIOS 2000-2004 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Year Range: 2000-2004 Codes Chassis Codes: J100 Series (specific codes vary by region and configuration) 👋 Introduction Market Position Segment: Compact SUV...
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DAIHATSU TERIOS 2000-2004 Workshop Service Repair ManualDAIHATSU TERIOS 2000-2004 Workshop Service Repair ManualDAIHATSU TERIOS 2000-2004 Workshop Service Repair ManualDAIHATSU TERIOS 2000-2004 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Terios
Year Range:
2000-2004
Codes
Chassis Codes:
J100 Series (specific codes vary by region and configuration)
👋 Introduction
Market Position
Segment:
Compact SUV / Mini SUV
Target Audience:
Owners seeking to perform DIY maintenance and repairs, independent repair shops, automotive enthusiasts.
Competitive Analysis
Key Competitors:
Suzuki Vitara, Toyota RAV4 (early models), Honda CR-V (early models), Mitsubishi Pajero Mini.
Key Features
Vehicle Identity:
Known for its compact size, fuel efficiency, and practical utility in urban and light off-road environments.
📋 Manual Details
Coverage Areas
Markets Covered:
Global (reflecting common specifications across various markets)
Regions Covered:
Asia, Europe, Australia, other markets where the Terios was sold
Page Count
Estimated Pages:
Likely 500+ pages (typical for comprehensive workshop manuals)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF likely, based on industry trends for such manuals)
📖 Manual Coverage
Systems Covered
Engine Mechanicals:
Complete overhaul, timing belt replacement, piston and ring service, valve train, cylinder head, crankshaft, camshafts, oil pump.
Efi Systems:
Fuel injection control, sensors (MAP, TPS, O2, ECT), injectors, fuel pump, ECU diagnosis and troubleshooting.
Fuel System:
Fuel tank, fuel lines, fuel filter replacement, fuel pump operation, evaporative emission control (EVAP) system.
Emission Control Systems:
Catalytic converter, EGR system, PCV system, emission sensors and control modules.
Cooling System:
Radiator, water pump, thermostat, coolant hoses, fan operation, heater core, coolant flush and fill procedures.
Lubrication System:
Oil pan, oil pump, oil filter replacement, oil pressure diagnosis, lubrication passages.
Ignition System:
Spark plugs, ignition coils/wires, distributor (if applicable), ignition timing, coil-on-plug (COP) systems.
Starting System:
Starter motor, starter solenoid, battery testing, ignition switch.
Charging System:
Alternator, voltage regulator, battery charging, drive belt inspection and replacement.
Transmission:
Manual and Automatic transmission disassembly, assembly, service, fluid changes, clutch service (manual).
Drivetrain:
Front and rear differentials, driveshafts, CV joints, transfer case (if 4WD).
Suspension:
Front and rear suspension components, shock absorbers, struts, springs, bushings, wheel alignment specifications.
Steering:
Power steering system, steering rack, tie rods, steering column, steering wheel removal.
Brakes:
Front and rear brake systems (disc and drum), brake pads, rotors, calipers, wheel cylinders, brake fluid service, ABS (if equipped).
Body And Chassis:
Body panel removal and installation, door mechanisms, interior trim, chassis components, rust prevention.
Electrical System:
Lighting, horn, wipers, power windows, central locking, fuses, relays, battery, starter, alternator.
Wiring Diagrams:
Comprehensive electrical wiring schematics for all major systems.
Procedures Included
General Maintenance:
Oil changes, filter replacements, fluid level checks, tire rotation, brake inspections.
Troubleshooting:
Diagnostic procedures for common and uncommon faults across all vehicle systems.
Disassembly And Assembly:
Step-by-step instructions for removing and reinstalling major components.
Repair Procedures:
Detailed guides for repairing or rebuilding various vehicle systems.
Special Service Tools:
Identification and usage of specialized tools (SST) required for certain procedures.
Technical Depth
Depth:
Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds, including diagnostic procedures.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Likely searchable text, allowing quick access to information.
Print Quality
Quality:
High resolution, suitable for printing individual pages or sections.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
G13B (commonly found in early models)
Engine Type:
Inline-4 Cylinder, SOHC, 16-Valve
Displacement:
1.3 Liters (1300cc)
Bore X Stroke:
74.0 mm x 77.0 mm (typical for G13B)
Compression Ratio:
9.3:1 (typical for G13B)
Horsepower Bhp:
Approx. 80-85 bhp @ 6000 RPM (G13B)
Torque Lb-Ft:
Approx. 75-80 lb-ft @ 3500 RPM (G13B)
Performance
Fuel Type:
Unleaded Gasoline
Fuel System
Induction:
Electronic Fuel Injection (EFI)
Engine Codes Alternative
Engine Code:
J13 (another common designation)
Engine Type:
Inline-4 Cylinder, SOHC, 16-Valve
Displacement:
1.3 Liters (1300cc)
Horsepower Bhp:
Approx. 70-75 bhp (depending on regional tuning)
Torque Lb-Ft:
Approx. 70-75 lb-ft
Fuel System:
Electronic Fuel Injection (EFI)
🔧 Transmission
Standard
Type:
5-Speed Manual
Optional
Type:
4-Speed Automatic
Features
Drive Type:
Available in 2WD (Rear-Wheel Drive) and 4WD (Four-Wheel Drive, often with a selectable transfer case)
Fluid Specifications
Manual Transmission Fluid Type:
API GL-4, SAE 75W-90 or 80W-90 (check specific manual for exact viscosity and API rating)
Automatic Transmission Fluid Type:
Dexron III or equivalent (check specific manual for exact type)
📐 Dimensions
Exterior
Length:
Approx. 3,730 mm (146.9 in)
Width:
Approx. 1,600 mm (63.0 in)
Height:
Approx. 1,695 mm (66.7 in)
Wheelbase:
Approx. 2,430 mm (95.7 in)
Weights
Curb Weight:
Approx. 950 - 1050 kg (2094 - 2315 lbs) depending on configuration
🛡️ Safety Features
Ratings
Crash Test Results:
Limited official crash test data available for this model and era, often based on regional assessments. Refer to specific market safety reports if available.
Active Features
ABS:
Optional or standard on higher trims, depending on market.
Passive Features
Airbags:
Driver airbag standard, passenger airbag optional or standard on higher trims.
Seatbelts:
Three-point seatbelts for front and rear occupants.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with CD player or cassette player, depending on trim level and market.
Speakers:
Typically 4-speaker system.
Driver Assistance
Cruise Control:
Available on some higher trim levels.
Connectivity
Power Accessories:
Power windows, power door locks, and power mirrors were often optional or standard on higher trims.
🔧 Maintenance
Service Intervals
Engine Oil And Filter:
Every 5,000-10,000 km (3,000-6,000 miles) or 6-12 months, whichever comes first (refer to manual for exact specification).
Air Filter:
Inspect every 10,000 km (6,000 miles), replace as needed or at intervals specified in the manual.
Spark Plugs:
Replace every 40,000-60,000 km (25,000-37,000 miles), depending on plug type.
Timing Belt:
Replace at approximately 80,000-100,000 km (50,000-60,000 miles) or every 5-7 years. Critical for G13B engine to prevent catastrophic failure.
Fluid Specifications
Engine Oil Type:
API SG or higher, SAE 10W-30 or 10W-40 recommended (check manual for specific viscosity and API rating based on climate).
Engine Oil Capacity:
Approx. 3.5 Liters (3.7 Quarts) with filter change (verify in manual).
Coolant Type:
Ethylene Glycol based, Toyota Super Long Life Coolant (SLLC) or equivalent (often a 50/50 mix with distilled water).
Brake Fluid Type:
DOT 3 or DOT 4 (check manual).
Known Issues
Timing Belt Wear:
Critical to follow replacement schedule for the G13B engine; failure can cause severe engine damage.
Suspension Bushings:
Wear and tear on suspension bushings can lead to noise and degraded handling over time.
Oil Leaks:
Potential for minor oil leaks from valve cover gaskets or oil pan seals over higher mileage.
Rust And Corrosion:
As with many vehicles of this era, rust can be a concern, especially in areas with harsh winters or coastal environments.
📚 Vehicle History
Brand Heritage
Daihatsu Legacy:
Daihatsu, a subsidiary of Toyota, has a long history of producing small, reliable, and fuel-efficient vehicles.
Model Evolution
First Generation:
The Daihatsu Terios (first generation) was launched in 1997 and sold globally, becoming a popular choice in the mini SUV segment.
Production
Manufacturing Locations:
Primarily manufactured in Japan, with some assembly potentially occurring in other markets.
🏆 Awards & Recognition
Recognitions
Market Reputation:
Generally regarded as a robust and practical small SUV, particularly appreciated for its affordability and maneuverability.
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