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1998-2002 DAIHATSU TERIOS Master Service Repair Manual

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The Daihatsu Terios, produced from 1998 to 2002, is a compact crossover SUV renowned for its go-anywhere capability, fuel efficiency, and reliability. Built on the J100 series chassis and primarily...
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Sku: 139680
1998-2002 DAIHATSU TERIOS Master Service Repair Manual
The Daihatsu Terios, produced from 1998 to 2002, is a compact crossover SUV renowned for its go-anywhere capability, fuel efficiency, and reliability. Built on the J100 series chassis and primarily equipped with 1.3L SOHC or DOHC petrol engines (H1, H2), this versatile vehicle offers a practical blend of compact size and surprising off-road prowess, making it a capable companion for both urban commuting and light trail exploration. Its straightforward engineering, affordability, and a focus on functional utility positioned it as a strong contender against other compact SUVs of its era, appealing to a wide range of drivers seeking dependable transportation. This comprehensive Master Service Repair Manual, presented in English, provides essential technical information for the Daihatsu Terios. It covers an extensive range of systems, including powertrain, transmission, drivetrain, chassis, suspension, steering, brakes, and electrical systems, along with body and interior components. The manual details routine maintenance, diagnostics and troubleshooting, major repairs, and component replacement, offering specific torque specifications and fluid capacities. With an estimated 800-1200 pages, this searchable and printable digital resource is designed to empower owners, mechanics, and technicians in effectively maintaining, diagnosing, and repairing their Daihatsu Terios, ensuring its longevity and optimal performance.
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Terios
Years Covered:
1998, 1999, 2000, 2001, 2002
Codes
Chassis Code:
J100 series (primarily)
Engine Codes Covered:
H1, H2 (primarily 1.3L SOHC/DOHC petrol)
👋 Introduction
Market Position
Vehicle Segment:
Compact Crossover SUV / Kei SUV (primarily)
Target Audience:
DIY mechanics, independent repair shops, and enthusiasts seeking in-depth maintenance and repair knowledge for the Daihatsu Terios.
Competitive Analysis
Key Competitors:
Suzuki Jimny, Daihatsu Feroza, Toyota RAV4 (early generations), Honda CR-V (early generations), Mitsubishi Pajero Mini
Key Features
Vehicle Selling Points:
Compact size, go-anywhere capability (especially with 4WD), fuel efficiency, reliability, affordability
Manual Value Proposition:
Provides essential factory-level technical information for maintaining and repairing the Daihatsu Terios, crucial given its relative rarity in some markets and the challenge of finding specialized knowledge.
📋 Manual Details
Coverage Areas
Manual Type:
Master Service Repair Manual
Language:
English
Format:
Digital (likely PDF)
Page Count
Estimated Page Count:
800-1200 pages (typical for comprehensive service manuals of this era)
Format
Searchability:
Searchable text (typical for PDF manuals)
Printability:
Printable pages
Manual Type
Manual Category:
Factory Authorized Service Manual
📖 Manual Coverage
Systems Covered
Powertrain:
Engine Mechanical, Fuel System, Ignition System, Exhaust System, Cooling System, Lubrication System, Emission Control Systems
Transmission & Drivetrain:
Manual Transmission, Automatic Transmission, Transfer Case, Front Differential, Rear Differential, Drive Shafts, Axles
Chassis & Suspension:
Front Suspension, Rear Suspension, Steering System, Brake System, Wheels & Tires
Electrical System:
Wiring Diagrams, Charging System, Starting System, Lighting System, Ignition System, Instrumentation, Audio System, Power Accessories
Body & Interior:
Body Panels, Doors, Windows, Seats, Trim, HVAC System, Body Electrical Components
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and changes, tune-ups, belt inspection and replacement, brake pad replacement
Diagnostics & Troubleshooting:
Fault code diagnosis, symptom-based troubleshooting, electrical system diagnostics
Major Repairs:
Engine overhauls, transmission rebuilds, suspension component replacement, brake caliper and master cylinder service, electrical component repair
Component Replacement:
Detailed instructions for replacing all major and minor components
Specifications & Tolerances:
Torque specifications, clearances, fluid capacities, electrical resistance values
Technical Depth
Depth Level:
Comprehensive (from basic maintenance to full engine/transmission rebuilds)
📊 Manual Specifications
File Format
Digital Format Details:
PDF (Portable Document Format) – universally compatible, allows for easy searching and printing of specific sections.
Print Quality
Image Resolution:
High-resolution diagrams and schematics, typically scanned from original factory service manuals.
Binding Type
Physical Manual Binding:
Not applicable for digital format, but original factory manuals were typically professionally bound or ring-bound.
Paper Type
Physical Manual Paper:
Not applicable for digital format, but original factory manuals used durable paper stock suitable for workshop environments.
⚙️ Engine Specifications
Primary Engine
Engine Displacement:
1.3L (1300cc)
Engine Configuration:
Inline-4 Cylinder
Valve Train:
SOHC (Single Overhead Camshaft) or DOHC (Double Overhead Camshaft) - depending on specific engine variant
Performance
Horsepower Range:
Approx. 70-83 HP (depending on engine variant and tuning)
Torque Range:
Approx. 100-115 Nm (depending on engine variant and tuning)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Engine Codes Covered
Common Engine Codes:
HC-C, HD-E, HD-F (refer to manual for exact applicability)
🔧 Transmission
Standard
Transmission Type Standard:
5-Speed Manual Transmission
Optional
Transmission Type Optional:
4-Speed Automatic Transmission
Features
Drivetrain Options:
Rear-Wheel Drive (RWD) and Full-Time Four-Wheel Drive (4WD) with center differential
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-90 (verify with specific manual section for exact part number and capacity)
Automatic Transmission Fluid:
Dexron II or III equivalent (verify with specific manual section for exact part number and capacity)
📐 Dimensions
Exterior
Length:
Approx. 3,680 - 3,700 mm
Width:
Approx. 1,550 - 1,600 mm
Height:
Approx. 1,680 - 1,700 mm
Wheelbase:
Approx. 2,280 mm
Weights
Curb Weight:
Approx. 1,050 - 1,200 kg (depending on configuration)
Gross Vehicle Weight Rating:
Refer to vehicle data plate or manual for specific GVWR
Cargo
Cargo Volume:
Approx. 300 - 400 liters (with rear seats up, varies with configuration)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Limited official independent crash test data available for this specific generation and market; refer to regional safety authorities if available.
Active Features
Braking System:
Front Disc Brakes, Rear Drum Brakes (standard). Some models may have optional ABS.
Passive Features
Airbags:
Driver's airbag standard on many models; passenger airbag availability varied by market and trim.
Seatbelts:
3-point seatbelts with pretensioners for front occupants; 2-point lap belts for rear occupants (varies by region).
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM radio with cassette player or CD player depending on trim level. Basic speaker configuration.
Display:
Simple dashboard-mounted display for radio and climate controls. No central touchscreen or advanced navigation in this generation.
Driver Assistance
ABS:
Optional Anti-lock Braking System (ABS) available on higher trim levels or specific market configurations.
4Wd System:
Full-time 4WD with viscous coupling center differential, providing enhanced traction in varying conditions.
Connectivity
Connectivity Options:
Limited to basic auxiliary inputs or aftermarket solutions for modern device connectivity.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000 - 10,000 km or 6-12 months (refer to manual for exact interval based on driving conditions and oil type)
Air Filter Replacement:
Every 20,000 - 30,000 km or as needed based on inspection
Spark Plug Replacement:
Every 40,000 - 60,000 km (depending on spark plug type - standard vs. platinum/iridium)
Timing Belt Replacement:
Crucial: If applicable (some early models might use timing chains), typically every 80,000 - 100,000 km. Refer to manual for confirmation.
Fluid Specifications
Engine Oil Spec:
API SG/SH/SJ, SAE 10W-30 or 5W-30 (refer to manual for specific viscosity recommendations based on climate and exact engine code)
Coolant Spec:
Ethylene Glycol-based, P-OAT or HOAT (long-life) coolant, typically a 50/50 mix with distilled water. Refer to manual for specific type.
Brake Fluid Spec:
DOT 3 or DOT 4 (verify with manual)
Known Issues
Common Wear Items:
Clutch wear (manual transmission), suspension bushings, CV joint boots, exhaust system components, radiator.
Electrical Quirks:
Potential for aging wiring harness issues, minor sensor failures (e.g., ABS sensors, crankshaft position sensor).
Engine Performance Notes:
Early models might experience minor performance degradation due to carbon buildup or aging ignition components. Ensure proper maintenance of fuel injectors and air intake system.
📚 Vehicle History
Brand Heritage
Daihatsu Focus:
Daihatsu has a long history of producing small, reliable, and often off-road capable vehicles, particularly in the Japanese domestic market (Kei car segment).
Model Evolution
Generation 1 Terios:
The first-generation Terios (J100) was introduced in 1997, aiming to capitalize on the growing demand for compact SUVs. It offered a robust construction and modest off-road capabilities.
Global Markets:
The Terios was sold in numerous global markets, often under different brand names or badges (e.g., Toyota Cami).
Production
Manufacturing Locations:
Primarily manufactured in Japan by Daihatsu Motor Co., Ltd.
🏆 Awards & Recognition
Recognitions
Vehicle Awards:
Specific individual awards for the 1998-2002 Terios are not widely documented; however, Daihatsu vehicles of this era are generally recognized for their reliability and value for money in their segments.
Ratings
Reliability Perception:
Generally considered a reliable vehicle when properly maintained, with a focus on practical functionality over luxury or cutting-edge technology.
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