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DAIHATSU TERIOS 2000-2004 Workshop Service Repair Manual

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The Daihatsu Terios, produced between 2000 and 2004, is a capable compact SUV known for its practical utility and maneuverability in both urban environments and light off-road conditions. Built by...
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DAIHATSU TERIOS 2000-2004 Workshop Service Repair Manual
The Daihatsu Terios, produced between 2000 and 2004, is a capable compact SUV known for its practical utility and maneuverability in both urban environments and light off-road conditions. Built by a company with a strong heritage in producing reliable and fuel-efficient vehicles, the Terios offered a blend of affordability and versatility, making it a popular choice in its segment. This model, often featuring a 1.3-liter engine and available in both two-wheel drive and four-wheel drive configurations, embodies a commitment to functional design and dependable performance, positioning it as a sensible option against competitors like the Suzuki Vitara and early models of the Toyota RAV4. This comprehensive workshop service repair manual provides detailed guidance for the maintenance and repair of the Daihatsu Terios (J100 Series) across global markets. It covers a vast array of systems, including engine mechanicals, EFI systems, fuel, cooling, lubrication, ignition, starting, charging, transmission, drivetrain, suspension, steering, brakes, body, chassis, and the complete electrical system with wiring diagrams. The manual offers step-by-step procedures for general maintenance, disassembly, assembly, and repair, alongside troubleshooting advice and specifications for special service tools, empowering owners, mechanics, and technicians to effectively service and maintain their vehicles.
🏷️ 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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