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Daihatsu Terios Service Repair Workshop Manual 97-05

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The Daihatsu Terios, produced from 1997 to 2005, is a compact SUV known for its affordability, practicality, and genuine off-road capability for its class. Designed as a response to the...
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Daihatsu Terios Service Repair Workshop Manual 97-05
The Daihatsu Terios, produced from 1997 to 2005, is a compact SUV known for its affordability, practicality, and genuine off-road capability for its class. Designed as a response to the growing demand for versatile yet economical vehicles, it offered a higher driving position and the option of four-wheel drive, making it suitable for both urban environments and light off-road excursions. Its compact dimensions ensured maneuverability and ease of parking, while its interior provided decent cargo space for its size. Competing with early models of popular compact SUVs, the Terios distinguished itself with its value proposition and the engineering heritage of a company renowned for producing reliable and efficient smaller vehicles. This comprehensive service and repair workshop manual provides detailed information for all global markets where the Daihatsu Terios was sold between 1997 and 2005. It covers essential areas including engine diagnostics and repair, transmission maintenance for both manual and automatic variants, brake system servicing, suspension and steering system overhauls, and extensive electrical system schematics. Additionally, the manual details body and chassis repairs, HVAC system servicing, and routine maintenance procedures such as oil changes and filter replacements. Troubleshooting guides, major repair instructions, component replacement steps, and critical torque specifications are included, empowering owners and technicians to effectively maintain, diagnose, and repair their vehicles.
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Terios
Generation:
First Generation
Production Years Covered:
1997-2005
Codes
Chassis Codes:
J100, J102, J122, J138, J140
👋 Introduction
Market Position
Segment:
Compact SUV / Crossover
Target Audience:
Individuals seeking an affordable, practical, and capable compact SUV for urban and light off-road use.
Competitive Analysis
Key Competitors Era:
Suzuki Vitara/Grand Vitara, Toyota RAV4 (early models), Honda CR-V (early models), Mitsubishi Pajero Mini/Pajero IO, Nissan Terrano/X-Trail (early models).
Key Features
Drivetrain Options:
Available in both 2WD (rear-wheel drive) and 4WD configurations, offering versatility.
Compact Size:
Maneuverable in urban environments and easy to park.
Practicality:
Offers decent cargo space and seating for its class.
Affordability:
Known for its competitive pricing and lower running costs compared to larger SUVs.
📋 Manual Details
Coverage Areas
Market Segments Covered:
All global markets where the Daihatsu Terios was sold during the specified years.
Page Count
Estimated Page Count:
Likely 1000+ pages (typical for comprehensive service manuals of this era)
Manual Type
Type:
Service and Repair Workshop Manual
Language
Language:
English
Format
Format:
Digital Download (PDF or similar e-book format)
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnostics, repair, and overhaul procedures for all engine variants, including timing belt replacement, cooling system, lubrication system, fuel system, and emissions control.
Transmission:
Repair and maintenance for both manual and automatic transmissions, including clutch, gearbox, transfer case, driveshafts, and differentials.
Brakes:
Front and rear brake system diagnostics, repair, bleeding procedures, ABS system, parking brake.
Suspension Steering:
Front and rear suspension components, alignment procedures, power steering system, steering rack, steering column.
Electrical:
Comprehensive electrical system schematics, lighting, ignition system, charging system, starter motor, wiring diagrams, fuse box locations, body control modules.
Body Chassis:
Body panel repair, door mechanisms, glass replacement, interior trim, underbody components, frame straightening (if applicable).
HVAC:
Heating, Ventilation, and Air Conditioning system diagnostics and repair, refrigerant handling, component replacement.
Fuel System:
Fuel tank, fuel pump, injectors, fuel filter replacement, fuel pressure testing.
Cooling System:
Radiator, thermostat, water pump, hoses, coolant specifications and flushing procedures.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, brake pad replacement.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting for common and complex issues.
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement, major electrical system repairs.
Component Replacement:
Detailed steps for replacing virtually every component of the vehicle.
Tightening Torques:
Specific torque specifications for all critical fasteners.
Wiring Diagrams:
Complete and detailed wiring diagrams for all vehicle systems.
Technical Depth
Diagnostic Capabilities:
Advanced diagnostic procedures, including using scan tools and interpreting diagnostic trouble codes (DTCs).
Rebuild Procedures:
Full engine and transmission rebuild instructions, including component specifications and tolerances.
Special Tools:
Identification and usage of specialized tools required for specific repair procedures.
📊 Manual Specifications
File Format
Format Details:
Typically PDF, allowing for search functionality, zooming, and printing.
Print Quality
Quality:
High-resolution scans with clear text and legible diagrams.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
G13BB (most common)
Engine Type:
Inline 4-cylinder, SOHC, 16-valve
Displacement:
1.3 Liters (1300 cc)
Bore X Stroke:
72.0 mm x 78.2 mm (typical for G13BB)
Compression Ratio:
9.5:1 (typical for G13BB)
Performance
Horsepower:
Approx. 85-90 PS (63-66 kW) at 6000 rpm (depending on market and specific tune)
Torque:
Approx. 110-120 Nm (81-89 lb-ft) at 3500-4000 rpm (depending on market and specific tune)
Fuel System
Induction:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (Octane rating as per local market recommendations)
Other Engines
Engine Options:
1.3L (G13BB), 1.3L (G13A - carbureted, earlier models), 1.3L DOHC (G13B), 1.3L VVT-i (1SZ-FE by Daihatsu, also used by Toyota), 1.3L Turbocharged (for specific performance variants/markets), 1.5L (G15A, G15SB, 3SZ-VE for later models not covered in this specific manual range).
🔧 Transmission
Standard
Transmission Type Standard:
5-Speed Manual Transmission
Optional
Transmission Type Optional:
4-Speed Automatic Transmission
Features
4Wd System:
Selectable 4WD system (usually with high/low range transfer case) for 4WD variants.
📐 Dimensions
Exterior
Length:
Approx. 3,750 - 3,800 mm (varies slightly by model and bumper design)
Width:
Approx. 1,600 - 1,650 mm
Height:
Approx. 1,690 - 1,710 mm
Wheelbase:
Approx. 2,400 mm
Ground Clearance:
Approx. 190 - 200 mm (significant for its class)
Weights
Curb Weight:
Approx. 1050 - 1150 kg (depending on configuration)
Gross Vehicle Weight:
Approx. 1500 - 1600 kg (typical)
Cargo
Cargo Volume Rear Seats Up:
Approx. 300-350 Liters (varies with configuration)
Cargo Volume Rear Seats Down:
Approx. 750-850 Liters (estimated)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Varies by market and specific testing organization. Early 2000s vehicles often had less stringent testing standards than modern vehicles. Refer to specific market NCAP reports if available.
Active Features
ABS:
Available on higher trim levels and later models.
Traction Control:
Rarely standard, potentially available on very high-spec variants or later models.
Passive Features
Airbags:
Driver and passenger airbags were becoming standard or optional during this period. Side airbags were rare.
Seatbelts:
Three-point seatbelts with pretensioners for front occupants.
Child Seat Anchors:
ISOFIX or similar anchor points for child safety seats may be present depending on market and year.
💡 Technology Features
Infotainment
Audio System:
Typically a basic AM/FM radio with CD player. Some higher trims may feature cassette players or multiple speakers. Aux-in ports or Bluetooth were uncommon in this generation.
Driver Assistance
Cruise Control:
Optional on higher trim levels and later models.
Connectivity
Connectivity Features:
Very limited by modern standards. Primarily basic vehicle functions and audio. No integrated navigation, smartphone mirroring, or advanced telematics.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000 - 10,000 km or 6-12 months, whichever comes first (refer to manual for exact spec).
Oil Filter Replacement:
At every engine oil change.
Air Filter Replacement:
Every 20,000 - 30,000 km or annually.
Spark Plug Replacement:
Every 40,000 - 60,000 km (depending on plug type, e.g., standard vs. iridium).
Timing Belt Replacement:
Crucial: Typically every 60,000 - 90,000 km or 4-5 years for this era. Failure can cause catastrophic engine damage.
Fluid Specifications
Engine Oil:
API SJ/SL or higher, SAE 10W-30 or 10W-40 (check manual for exact viscosity based on climate).
Coolant:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. Use Toyota Super Long Life Coolant or equivalent for later models if specified.
Transmission Fluid Manual:
API GL-4 SAE 75W-90 or 75W-85 gear oil (check manual).
Transmission Fluid Automatic:
Dexron III / Mercon equivalent automatic transmission fluid (ATF).
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid:
Dexron II or III equivalent ATF, or specific power steering fluid as per manual.
Known Issues
Timing Belt Wear:
Critical maintenance item. Premature wear or failure can lead to severe engine damage. Adherence to replacement intervals is paramount.
Clutch Wear:
As with many vehicles with manual transmissions, clutch wear is a common maintenance item, especially with extensive city driving or off-road use.
Suspension Bushings:
Bushings in the suspension and steering components can wear over time, leading to noise and handling degradation.
Ignition Coil Failure:
Individual ignition coils can fail, leading to misfires and rough running.
Rust Corrosion:
Depending on climate and maintenance, rust can affect body panels, exhaust systems, and undercarriage components.
📚 Vehicle History
Brand Heritage
Daihatsu Focus:
Daihatsu, a subsidiary of Toyota, has a long history specializing in small, affordable, and reliable vehicles, often with a focus on compact and fuel-efficient designs.
Model Evolution
First Generation Launch:
The Daihatsu Terios was first introduced in 1997 as a response to the growing demand for compact SUVs and crossovers.
Design Philosophy:
Designed to offer the functionality and higher driving position of an SUV in a compact, city-friendly package with available 4WD capability.
Production
Manufacturing Locations:
Primarily manufactured in Japan by Daihatsu, with some production or assembly also occurring in other markets through licensing or joint ventures.
🏆 Awards & Recognition
Recognitions
Awards And Accolades:
While specific awards are not widely publicized for the first-generation Terios, it was generally well-regarded for its value, practicality, and capability in the compact SUV segment, particularly for its price point.
Ratings
Reliability Perception:
Daihatsu vehicles are generally perceived as reliable and economical, often benefitting from Toyota's engineering influence.
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