1997 Daihatsu Terios J100 Factory Service Repair Manual

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Sku: 136972

Tags: 1997 Car Cars Daihatsu Terios Terios J100

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Description

The Daihatsu Terios, specifically the J100 generation produced from 1997 to 2002, is a compact crossover SUV recognized for its distinctive three-door body style and impressive capability for its size. Often categorized as a mini-SUV, it was engineered to offer an affordable and maneuverable option for individuals seeking an all-wheel-drive vehicle suitable for both urban environments and light off-road excursions. Powered by a 659 cc inline 3-cylinder HDE engine, this vehicle emphasizes practicality and reliability, characteristic of its commitment to quality engineering. Its design, featuring a high roofline and a rear-mounted spare wheel, contributes to its robust and functional aesthetic, making it a unique offering in its market segment. This comprehensive factory service and repair manual provides in-depth guidance for the Daihatsu Terios J100, covering all essential aspects of its maintenance and repair. The manual details procedures for powertrain systems, including engine mechanicals, EFI, transmission, and driveline components, as well as chassis systems such as suspension and brakes, and body and electrical systems. It includes scheduled maintenance, diagnostics, troubleshooting, and component repair or rebuild instructions, making it an indispensable resource for owners and technicians. The high-resolution format ensures clarity and legibility, facilitating efficient upkeep and repair to maintain the vehicle's optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Daihatsu

Model:

Terios

Generation:

Year:

Codes

Chassis Code:

J100G

Engine Code Primary:

👋 Introduction

Market Position

Vehicle Segment:

Compact Crossover SUV (often referred to as a mini-SUV or Kei SUV outside Japan)

Target Audience:

Individuals seeking an affordable, capable, and compact all-wheel-drive vehicle for urban and light off-road use.

Competitive Analysis

Key Competitors Era:

Suzuki Vitara, Mitsubishi Pajero Mini, Honda CR-V (smaller variants), Subaru Forester (earlier models)

Key Features

Powertrain Layout:

Available in 2WD and 4WD configurations with a longitudinally mounted engine and transfer case.

Body Style:

Three-door compact SUV with a high roofline and a rear-mounted spare wheel.

📋 Manual Details

Coverage Areas

Main Coverage:

Full Factory Service and Repair

Region Applicability:

Global (based on J100 chassis)

Page Count

Estimated Pages:

Comprehensive (specific count not provided, typical for factory manuals of this era)

Manual Type

Type:

Factory Service Repair Manual

Language

Primary Language:

English

Format

Delivery Method:

Digital Download

File Format:

📖 Manual Coverage

Systems Covered

Powertrain:

Engine Mechanical, Engine Control, EFI System, Lubrication System, Cooling System, Ignition System, Starting System, Charging System, Clutch, Manual Transmission, Automatic Transmission, Transmission7transfer, Propeller Shaft

Chassis:

Front Axle & Suspension, Rear Axle & Suspension, Brake, Steering

Body And Electrical:

Body, Body Electrical, Harness & Wiring Diagram

Procedures Included

Maintenance:

Scheduled maintenance, fluid changes, filter replacements, tune-ups

Diagnostics And Troubleshooting:

Systematic fault finding, diagnostic trouble codes (DTCs), common issue resolution

Repair And Rebuild:

Component disassembly, inspection, repair, and reassembly for all covered systems

Electrical And Wiring:

Wiring diagrams, component location, testing procedures for electrical systems

Technical Depth

Depth:

Comprehensive, from basic adjustments to full component overhauls, suitable for professional mechanics and advanced DIYers

📊 Manual Specifications

File Format

Quality:

High-resolution PDF, designed for clarity and legibility. Text is likely searchable.

Print Quality

Reproducibility:

Suitable for printing individual pages or sections for workshop use.

Binding Type

Physical Binding:

N/A (Digital Format)

Paper Type

Physical Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

Engine Type:

Inline 3-cylinder, SOHC, 12-valve

Displacement:

659 cc

Bore X Stroke:

69.0 mm x 73.1 mm

Compression Ratio:

9.5:1

Performance

Horsepower Ps Approx:

60 PS @ 7000 rpm

Torque Nm Approx:

74 Nm @ 4000 rpm

Fuel System

Induction:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline

Engine Ancillaries

Cooling System:

Water-cooled, pressurized system with radiator and fan.

Lubrication System:

Forced lubrication via oil pump, full-flow oil filter.

🔧 Transmission

Standard

Transmission Type:

5-speed Manual Transmission

Optional

Transmission Type:

4-speed Automatic Transmission

Features

Drive System:

Full-time 4WD with center differential (optional for some markets/trims), or Part-time 4WD with selectable transfer case (more common)

Transfer Case:

Two-speed transfer case with Neutral position likely available for 4WD models.

Fluid Specifications

Manual Transmission Fluid:

GL-4, SAE 75W-90 (typical specification, consult manual for precise OEM part number)

Automatic Transmission Fluid:

Dexron II or equivalent (typical specification, consult manual for precise OEM part number)

Transfer Case Fluid:

GL-4, SAE 75W-90 (typical specification, consult manual for precise OEM part number)

📐 Dimensions

Exterior

Length:

Approx. 3,295 mm (Japanese Kei car regulations)

Width:

Approx. 1,395 mm (Japanese Kei car regulations)

Height:

Approx. 1,630 mm (depending on roof rack/options)

Weights

Curb Weight Approx:

800 - 900 kg (depending on configuration)

🛡️ Safety Features

Ratings

Crash Test Data:

Limited public data for this specific model year and region. Likely meets Japanese safety standards of the era.

Active Features

Brakes Front:

Ventilated Disc Brakes

Brakes Rear:

Drum Brakes

ABS Availability:

Optional on higher trims or later production runs.

Passive Features

Seatbelts:

Front and rear seatbelts.

Airbags:

Driver airbag likely standard or optional. Passenger airbag availability varies by market and trim.

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM radio with cassette player. CD player may have been an option on higher trims.

Speakers:

Typically 2 or 4 speakers.

Driver Assistance

Cruise Control Availability:

Rarely fitted on this model, likely an aftermarket addition if present.

Connectivity

Usb Bluetooth:

Not available from factory. Aftermarket head unit required.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 5,000 km to 10,000 km or 6 months, whichever comes first (refer to manual for exact OEM recommendation).

Air Filter Replacement:

Every 20,000 km to 40,000 km or as needed based on operating conditions.

Spark Plug Replacement:

Typically 40,000 km to 60,000 km (dependent on spark plug type specified).

Fluid Specifications

Engine Oil Type:

API SJ or higher, Viscosity SAE 10W-30 or 10W-40 (refer to manual for exact OEM recommendation and capacity).

Coolant Type:

Ethylene Glycol based, permanent type antifreeze/coolant (typically a pink or green formula, check manual for specific Daihatsu coolant type and capacity).

Brake Fluid Type:

DOT 3 or DOT 4 (refer to manual for exact OEM recommendation and capacity).

Known Issues

Common Wear Items:

Suspension bushings, exhaust system components, clutch wear (especially if used for off-roading/towing), radiator hoses.

Engine Specific:

Timing belt replacement is critical at specified intervals (typically 90,000-100,000 km) to prevent catastrophic engine damage. Coil pack failure can occur.

Transmission Specific:

Manual transmission synchros can wear over time, leading to difficult shifting. Automatic transmission fluid should be regularly checked and changed.

📚 Vehicle History

Brand Heritage

Manufacturer:

Daihatsu Motor Co., Ltd., a Japanese automobile manufacturer, subsidiary of Toyota Motor Corporation.

Model Evolution

Introduction Year:

The first generation (J100) was introduced in 1997.

Platform Sharing:

Shared platform and components with other Daihatsu models and potentially some early Toyota models in specific markets.

Production

Production Location:

Japan

Production Period:

1997-2002 (for J100 generation)

🏆 Awards & Recognition

Recognitions

Market Perception:

Praised for its compact size, maneuverability, surprisingly capable 4WD system for its class, and affordability.

Ratings

Reliability General:

Generally considered reliable with proper maintenance, typical of Japanese manufacturers.

Certifications

Emission Standards:

Meets Japanese emission standards of the late 1990s.