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Daihatsu Copen 2004 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Copen Year: 2004 Chassis Code: L880 Codes Engine Code Primary: JB-DET 👋 Introduction Market Position Vehicle Segment: Kei car convertible sports car Niche...
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Mots clés: 2004 Car Cars Copen Daihatsu
Daihatsu Copen 2004 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Copen
Year:
2004
Chassis Code:
L880
Codes
Engine Code Primary:
JB-DET
👋 Introduction
Market Position
Vehicle Segment:
Kei car convertible sports car
Niche Appeal:
Unique, compact, performance-oriented convertible
Competitive Analysis
Direct Competitors Approximate:
Limited direct competitors in its niche, but generally competes with small roadsters and sporty compacts.
Key Features
Convertible Top:
Electrically operated retractable hardtop
Engine Type:
Turbocharged inline-3 cylinder
Design Philosophy:
Compact, lightweight, fun-to-drive sports convertible
📋 Manual Details
Coverage Areas
Primary Focus:
Full Service Repair and Maintenance
Secondary Focus:
Diagnostics, Troubleshooting, Electrical Systems
Page Count
Estimated Pages:
Extensive (Specific number not provided, but described as 'very detailed' and covering 'everything you will ever need')
Manual Type
Type:
Full Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
Delivery Method:
Instant Download
Print Quality:
Full Printable
Requirements
Software Requirements:
Adobe PDF Reader, WinRAR
Operating System Compatibility:
All Versions of Windows & Mac
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, diagnosis, repair of engine components, timing, cooling, lubrication.
Engine Electrical:
Ignition system, fuel injection system, starting and charging system, ECU diagnosis.
Transmission:
Automatic and Manual Transmission repair, fluid changes, internal component overhaul.
Drivetrain:
Differential, axles, driveshafts, wheel bearings.
Suspension:
Front and rear suspension components, shock absorbers, springs, alignment.
Steering:
Power steering system, steering rack, linkages, alignment.
Brakes:
Disc brakes, ABS system, hydraulic circuits, parking brake.
Bodywork:
Exterior panels, convertible roof mechanism, interior trim, doors, windows, locks.
Electrical System General:
Lighting, wipers, horn, power accessories, battery, fuses, relays.
Climate Control:
Air conditioning and heating system, refrigerant, components.
Procedures Included
Preventive Maintenance:
Scheduled maintenance, fluid changes, filter replacements, inspections.
Diagnostic Procedures:
System diagnosis, error code interpretation, component testing.
Repair Procedures:
Step-by-step instructions for component removal, installation, and repair.
Rebuilding Procedures:
Detailed guidance for rebuilding key components like engines and transmissions.
Refurbishment Procedures:
Guidance for restoring components to original specifications.
Restoration Procedures:
Comprehensive procedures applicable to restoring the vehicle.
Troubleshooting:
Specific troubleshooting guides for common and complex issues.
Electrical Troubleshooting:
Combined with detailed wiring diagrams for ease of diagnosis.
Wiring Diagrams:
Comprehensive and detailed electrical wiring schematics.
Technical Depth
Target Audience Professional:
Prepared primarily for professional technicians, offering in-depth information.
Target Audience Diy:
Adequate data provided for most DIY mechanics.
Detail Level:
Detailed sub-steps, notes, cautions, warnings, numbered instructions, bold figure numbers.
Illustrations:
Detailed illustrations, drawings, and photos; enlarged insets for detailed part examination.
📊 Manual Specifications
File Format
Type:
PDF
Print Quality
Printability:
All pages are printable
Binding Type
Binding Type:
Digital (Downloadable)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
JB-DET
Configuration:
Inline 3-cylinder, 12-valve, DOHC
Displacement:
659 cc (0.7 L)
Aspiration:
Turbocharged and Intercooled
Performance
Horsepower:
64 PS (47 kW; 63 hp) @ 7200 rpm (Class-limited for Kei vehicles)
Torque:
10.5 kg⋅m (103 N⋅m; 76 lb⋅ft) @ 3200 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Recommended Fuel:
Unleaded Gasoline (Octane rating typically 91 or higher recommended)
🔧 Transmission
Standard
Transmission Type:
4-speed Automatic
Optional
Transmission Type:
5-speed Manual
Features
Drive Layout:
Front-engine, Front-wheel drive (FWD)
📐 Dimensions
Exterior
Length:
3,395 mm (133.7 in)
Width:
1,475 mm (58.1 in)
Height:
1,245 mm (49.0 in)
Wheelbase:
2,280 mm (90 in)
Weights
Curb Weight:
Approx. 750-830 kg (1650-1830 lbs) depending on transmission and options
🛡️ Safety Features
Ratings
Crash Test Standard:
N/A (Kei car regulations differ from major market crash test standards; focused on structural integrity for its class)
Active Features
ABS:
Anti-lock Braking System (ABS) available on certain trims/options
Passive Features
Airbags:
Driver and passenger airbags standard
Rollover Protection:
Integrated roll-bar structure within the windshield frame and behind the seats
💡 Technology Features
Infotainment
Audio System:
Factory fitted AM/FM radio with CD player or cassette, speaker system (number varies by trim).
Driver Assistance
Cruise Control:
Not commonly available on the 2004 model, especially in base trims.
Connectivity
Auxiliary Input:
Rarely present on factory head units for this era; aftermarket solutions are common.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 7,500-10,000 km (4,500-6,000 miles) or 6-12 months, depending on driving conditions.
Air Filter:
Replace every 20,000-30,000 km (12,000-18,000 miles) or as needed.
Spark Plugs:
Replace typically every 40,000-60,000 km (24,000-36,000 miles) for standard plugs, longer for iridium/platinum.
Fluid Specifications
Engine Oil:
API SG/SH/SJ or higher, SAE 0W-20 or 5W-30 recommended for optimal performance and fuel economy (check manual for precise spec).
Coolant:
Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Refer to manual for specific type (e.g., pink or green).
Transmission Fluid Auto:
Dexron III/VI equivalent or specified Daihatsu ATF (check manual for exact part number/type).
Brake Fluid:
DOT 3 or DOT 4 recommended (check manual for specific requirements).
Known Issues
Turbocharger Wear:
Premature wear or failure can occur if oil changes are neglected or if the turbo is overheated.
Convertible Top Mechanism:
Potential issues with hydraulic leaks, motor failure, or binding in the roof mechanism due to age or lack of lubrication.
Ignition Coil Packs:
Misfires can sometimes be attributed to failing ignition coils on the 3-cylinder engine.
📚 Vehicle History
Brand Heritage
Brand Focus:
Daihatsu is known for producing small, economical, and reliable vehicles, often in the Kei car segment.
Model Evolution
Generation 1 Start:
June 2002
Generation 1 End:
October 2012
2004 Model Year Updates:
Typically minor feature adjustments or package updates within the first generation's lifecycle.
Production
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Kei Car Awards:
Often cited as a benchmark for sporty and stylish Kei cars.
Ratings
Reliability:
Generally considered reliable within its class, though specific component longevity can vary.
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