🏷️ Basic Information

Make:

Daihatsu

Model:

Copen

Year:

2002

Chassis Code:

L880K

Engine Code Primary:

JB-DET

👋 Introduction

Positioning:

The Daihatsu Copen (2002 model) was positioned as a compact, sporty, and stylish Kei car (in Japan) or a small convertible sports car in international markets. It competed with other small roadsters and performance-oriented compacts.

Competitors:

Key competitors included the Honda Beat (previous generation), Suzuki Cappuccino, and Mazda MX-5 Miata (though typically in a larger class).

Features:

Unique selling points included its compact size, turbocharged engine, distinctive styling, and innovative electric retractable hardtop roof.

📋 Manual Details

Systems Covered:

Engine Mechanical, Intake, Exhaust, Lubrication, Cooling, Fuel, Engine Control, Emission Control, Ignition, Starting/Charging, Engine Mounting, Front Suspension, Rear Suspension, Wheel & Tire, Drive Shaft/Axle, Brakes, Parking Brake, Brake Control, Clutch, Manual Transmission/Transaxle, Steering, Power Steering, SRS Airbag, Body, Exterior/Interior, Windshield/Windowglass/Mirror, Door Lock & Theft Deterrent, Sunroof/T-Bar Roof/Convertible, Lighting, Wiper & Washer, Meter, Audio & Visual System

Estimated Pages:

Varies, typically 800-1500+ pages for comprehensive factory service manuals.

Type:

Factory Service Manual / Repair Manual

Language:

English (assuming translated from original Japanese)

Format:

PDF

Guarantee:

30 days money back guarantee.

Delivery Method:

Instant Download.

📖 Manual Coverage

Engine Mechanical:

Detailed diagrams, specifications, and procedures for internal engine components (pistons, rings, connecting rods, crankshaft, camshafts, valve train, cylinder head, block).

Intake System:

Turbocharger operation, intercooler, intake manifold, throttle body, air intake piping, sensors (MAF/MAP).

Exhaust System:

Exhaust manifold, catalytic converter, muffler, exhaust sensors (O2), turbo exhaust housing.

Lubrication System:

Oil pump, oil filter, oil pan, oil cooler, oil pressure specifications, oil change procedures and fluid types.

Cooling System:

Radiator, water pump, thermostat, cooling fans, coolant types and capacities, flush and refill procedures.

Fuel System:

Fuel pump, fuel injectors, fuel pressure regulator, fuel filter, fuel tank, fuel delivery system diagnosis.

Engine Control System:

ECU (Engine Control Unit) functions, sensor inputs (crankshaft, camshaft, knock, lambda), actuator outputs (injectors, ignition coils), diagnostic trouble codes (DTCs), wiring diagrams.

Emission Control System:

EVAP system, EGR system (if applicable), catalytic converter monitoring, emission related sensor diagnostics.

Ignition System:

Ignition coils, spark plugs, ignition timing, coil-on-plug system diagnostics.

Starting Charging System:

Starter motor, battery specifications, alternator output, charging system diagnosis, wiring.

Engine Mounting:

Engine mounts, transmission mounts, diagnosis of vibration and noise issues related to mounts.

Front Suspension:

MacPherson strut design, control arms, ball joints, bushings, wheel bearing replacement, alignment specifications.

Rear Suspension:

Independent rear suspension design (often multi-link or trailing arm based), shock absorbers, springs, bushings, alignment specifications.

Wheel Tire:

Wheel specifications (bolt pattern, offset), tire size recommendations, rotation procedures, balancing.

Drive Shaft Axle:

Front drive axles (CV joints), axle boots inspection and replacement, wheel hub bearing replacement.

Brake System:

Front disc brakes, rear disc brakes (often), brake caliper overhaul, rotor replacement, brake pad replacement, bleeding procedures, master cylinder, brake fluid specifications.

Parking Brake:

Parking brake mechanism, cable adjustment, operation and diagnosis.

Brake Control:

ABS (Anti-lock Braking System) components and diagnosis, EBD (Electronic Brakeforce Distribution) if equipped.

Clutch:

Clutch disc, pressure plate, release bearing, clutch hydraulics (master and slave cylinders), fluid type, bleeding procedures.

Manual Transmission:

Gearbox internal components, gear ratios, shift mechanism, transmission fluid type and capacity, overhaul procedures, diagnosis of shifting issues.

Steering:

Steering rack, tie rods, steering column, wheel alignment specifications.

Power Steering:

Power steering pump, fluid reservoir, steering rack seals, power steering fluid type and capacity, diagnosis of leaks and assistance issues.

Srs Airbag System:

Airbag modules (driver, passenger, side), SRS control unit, seat belt pre-tensioners, impact sensors, diagnostic procedures for airbag warning lights, safety precautions for working with airbags.

Body:

Body structure, chassis components, frame repair (if applicable), rust prevention and repair.

Exterior Interior:

Body panels, trim pieces, seat removal and installation, dashboard components, carpet, headliner.

Windshield Windowglass Mirror:

Windshield replacement, side window and rear window removal/installation, mirror assembly repair/replacement.

Door Lock Theft Deterrent:

Door lock mechanisms, central locking system, keyless entry, immobilizer system, alarm system components and diagnosis.

Sunroof Convertible:

Electric convertible roof mechanism, hydraulic system, seals, operation and troubleshooting, sunroof/T-bar roof components (if applicable).

Lighting:

Headlights, taillights, turn signals, interior lighting, fog lights, bulb types and replacement, wiring diagrams for lighting circuits.

Wiper Washer:

Wiper motor, wiper arms, wiper blades, washer pump, washer fluid reservoir, washer nozzles, operation and repair.

Meter:

Instrument cluster (speedometer, tachometer, fuel gauge, temperature gauge), warning lights, odometer, diagnostic procedures for faulty gauges.

Audio Visual System:

Radio/CD player, speaker system, antenna, wiring harnesses for audio components.

Maintenance:

Scheduled maintenance checks (oil changes, filter replacements, fluid checks), brake system checks, suspension component inspection, belt inspection and replacement.

Troubleshooting:

Diagnostic charts and flowcharts for various symptoms (e.g., engine misfires, starting problems, brake noise, electrical faults), DTC interpretation.

Repair:

Step-by-step instructions for component removal, installation, and adjustment across all covered systems.

Diagnostics:

Detailed diagnostic procedures for engine, transmission, braking, electrical, and comfort systems, including use of diagnostic scan tools.

Rebuilds:

Comprehensive instructions for engine and transmission rebuilds, including component specifications and tolerances.

Depth:

Comprehensive factory-level coverage, suitable for professional technicians and advanced DIY enthusiasts. Includes detailed torque specifications, clearances, and diagnostic parameters.

📊 Manual Specifications

File Format:

PDF

Print Quality:

High resolution, suitable for clear printing.

Binding Type:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

Operating Systems:

Windows and Mac compatible.

Print Options:

Printable.

⚙️ Engine Specifications

Engine:

0.66L (659cc) Turbocharged Inline-3 (JB-DET)

Horsepower:

Approximately 64 PS (47 kW; 63 hp) at 6000 rpm (Japanese domestic market regulations).

Torque:

Approximately 10.5 kg⋅m (103 N⋅m; 76 lb⋅ft) at 3200 rpm.

Fuel Delivery:

Electronic Fuel Injection (EFI) with a turbocharger and intercooler.

Fuel Type:

Unleaded Gasoline

🔧 Transmission

Transmission:

5-speed Manual Transmission

Transmission:

4-speed Automatic Transmission

Drive Type:

Front-Wheel Drive (FWD)

📐 Dimensions

Length:

3,395 mm (133.7 in)

Width:

1,475 mm (58.1 in)

Height:

1,295 mm (51.0 in)

Wheelbase:

2,225 mm (87.6 in)

Curb Weight:

Approximately 800-830 kg (1760-1830 lbs) depending on transmission and options.

🛡️ Safety Features

Crash Test Ratings:

As a Kei car, specific international crash ratings (like NHTSA/Euro NCAP) are less common for the JDM version. However, it was equipped with standard safety features for its era.

Active Safety:

ABS (Anti-lock Braking System), often optional or standard depending on trim level. Disc brakes front and rear.

Passive Safety:

Driver and passenger airbags (standard or optional depending on market/trim), seatbelt pre-tensioners.

💡 Technology Features

Audio System:

Factory fitted radio/CD player with speakers. Aftermarket upgrades are common.

Driver Aids:

Basic driver aids for its time, primarily focusing on braking systems (ABS) and chassis dynamics.

Connectivity Features:

Limited in the 2002 model. Primarily focused on basic audio and power accessories. Bluetooth or USB connectivity would be aftermarket additions.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000-10,000 km (3,000-6,000 miles) or 6-12 months, whichever comes first, depending on driving conditions.

Spark Plug Replacement:

Recommended every 40,000-60,000 km (25,000-37,000 miles) for standard spark plugs, or longer for iridium/platinum plugs.

Timing Belt Replacement:

The JB-DET engine uses a timing chain, not a belt, so replacement is generally not a scheduled maintenance item unless worn.

Engine Oil Type:

API SJ/SL/SM, SAE 5W-30 or 10W-30 (check manual for exact specification, often synthetic blend or full synthetic recommended for turbocharged engines).

Engine Oil Capacity:

Approximately 3.2 - 3.5 liters (3.4 - 3.7 US qt) with filter.

Coolant Type:

Ethylene glycol-based coolant, typically a 50/50 mix of antifreeze and distilled water (e.g., Toyota Super Long Life Coolant equivalent).

Transmission Fluid Type Manual:

API GL-4, SAE 75W-90 Gear Oil.

Transmission Fluid Type Automatic:

Dexron III or equivalent ATF (Automatic Transmission Fluid).

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Power Steering Fluid Type:

Dexron III or equivalent ATF or specific power steering fluid (refer to manual).

Common Problems:

Turbocharger wastegate actuator issues (can lead to boost loss), oil consumption in high-mileage engines, convertible roof mechanism wear and leaks, front suspension bushings and ball joint wear, ignition coil failures.

📚 Vehicle History

Brand History:

Daihatsu, a subsidiary of Toyota, has a long history of producing small, fuel-efficient vehicles, particularly in the Kei car segment in Japan.

Model Lineage:

The first generation Copen (L880K) was introduced in 2002, following Daihatsu's history with small sports cars like the Leeza Spider and the more direct precursor, the Suzuki-engineered Copen concept that debuted in 1999.

Production Period:

First Generation: 2002-2012.

🏆 Awards & Recognition

Automotive Awards:

The Copen has received recognition in Japan for its design and innovative features, often cited for its unique appeal in the Kei car segment. Specific international awards are less documented.