Daihatsu Copen 2004 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Copen Year: 2004 Codes Chassis Code: L880K 👋 Introduction Market Position Vehicle Segment: Kei car, convertible sports car Target Audience: Enthusiasts, owners seeking...

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Type: Car

Vendor:

Sku: 451644

Tags: 2004 Car Cars Copen Daihatsu

Product variants

Description

🏷️ Basic Information

Identification

Make:

Daihatsu

Model:

Copen

Year:

Codes

Chassis Code:

L880K

👋 Introduction

Market Position

Vehicle Segment:

Kei car, convertible sports car

Target Audience:

Enthusiasts, owners seeking to maintain or repair their vehicle independently.

Competitive Analysis

Key Competitors Era:

Honda Beat, Suzuki Cappuccino, Mazda Autozam AZ-1

Key Features

Vehicle Defining Feature:

Compact, turbocharged convertible sports car with electric retractable hardtop

📋 Manual Details

Coverage Areas

Covered Models:

Daihatsu Copen 2004 (All Styles)

Page Count

Estimated Page Count:

Hundreds of pages

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Service:

Transmission Service:

Brake System:

Wiring Diagrams:

Electrical System:

Suspension:

Steering:

Cooling System:

Fuel Injection Fuel System:

Emission System:

HVAC System:

Engine Control System:

Chassis Body:

Restraint System:

Interior:

Differential Drive:

Axle:

General Maintenance:

Troubleshooting:

Periodic Lubrication:

Wheel Alignment:

Wheel Bearing Replacement:

Fuel Pump Replacement:

Ignition System Diagnosis:

Procedures Included

Repair Procedures:

Step-by-step, detailed

Maintenance Procedures:

Diagnostic Procedures:

Advanced troubleshooting guide

Engine Rebuild:

Yes, detailed procedures for engine overhaul and component replacement.

Transmission Overhaul:

Yes, covering both manual and automatic transmission disassembly and reassembly.

Body Panel Repair:

Yes, including procedures for panel alignment and minor bodywork.

Technical Depth

Depth:

Complete official factory information, comparable to professional technician knowledge

Diagrams Illustrations:

Includes hundreds of diagrams, drawings, and photos for visual guidance.

📊 Manual Specifications

File Format

Format:

Print Quality

Printability:

Fully printable (single pages, chapters, or entire manual)

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

JB-DET

Engine Type:

659cc, Inline-3, DOHC, 12-valve, turbocharged and intercooled

Performance

Horsepower Ps:

64 PS (47 kW; 63 hp) @ 6,400 rpm (Japanese Kei car regulations)

Torque Nm:

100 Nm (74 lb-ft) @ 3,200 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Engine Management

ECU Type:

Factory ECU with specific tuning for turbocharged operation

Engine Type

Engine Orientation:

Transverse

🔧 Transmission

Standard

Transmission Type Standard:

5-speed Manual Transmission

Optional

Transmission Type Optional:

4-speed Automatic Transmission

Features

Differential Type:

Limited Slip Differential (LSD) often available on performance variants or as an option

📐 Dimensions

Exterior

Length:

3,395 mm (133.7 in)

Width:

1,475 mm (58.1 in)

Height:

1,245 mm (49.0 in)

Weights

Curb Weight Kg:

Approx. 820-850 kg (1,808-1,874 lb)

Gross Vehicle Weight Kg:

Refer to specific vehicle VIN and local regulations.

🛡️ Safety Features

Ratings

Crash Test Ratings:

Not extensively tested under global NCAP standards due to its Kei car classification and market focus

Active Features

Braking System:

Front Ventilated Disc Brakes, Rear Solid Disc Brakes

Passive Features

Airbags:

Driver and Passenger Airbags (standard)

Body Structure:

Reinforced chassis and A-pillars for convertible rigidity and safety

💡 Technology Features

Infotainment

Audio System:

Factory fitted single-DIN or double-DIN radio with CD player, often with basic speaker system.

Driver Assistance

Traction Control:

Traction Control System (TCS) available on some higher-spec models.

Connectivity

Connectivity Features:

Limited by era, primarily focused on audio connectivity.

🔧 Maintenance

Service Intervals

Oil Change Interval Km:

Recommended every 7,500 km or 6 months (refer to manual for precise details based on driving conditions)

Fluid Specifications

Engine Oil Type Grade:

Refer to manual for specific viscosity (e.g., 5W-30, 10W-40) and API/ACEA specifications

Coolant Type:

Ethylene Glycol based, Japanese coolant specification (e.g., Toyota Super Long Life Coolant compatible)

Transmission Fluid Type Manual:

API GL-4, SAE 75W-90 (for manual gearbox)

Transmission Fluid Type Automatic:

Dexron II/III or equivalent (for automatic gearbox)

Known Issues

Common Wear Item Turbo:

Turbocharger oil feed and return lines can be prone to clogging or leaks if maintenance is neglected.

Common Wear Item Suspension:

Sway bar links and bushings can wear over time, leading to clunking noises.

Common Wear Item Retractable Roof:

Actuator seals and hydraulic lines for the power roof can develop leaks, requiring careful inspection and maintenance.

Common Wear Item Electronics:

Corrosion on electrical connectors, particularly for the convertible roof system, can cause intermittent faults.

Filter Part Numbers

Oil Filter Example:

e.g., Daihatsu part # 90047-82036 or equivalent aftermarket (e.g., Fram PH3553, Bosch 0986452033)

📚 Vehicle History

Brand Heritage

Daihatsu Specialization:

Known for small, fuel-efficient, and often quirky vehicles, including Kei cars and microcars

Model Evolution

First Generation Introduction:

June 2002

Facelift Year:

Model year 2004 typically refers to the pre-facelift version, with a facelift occurring in 2004 for some markets.

Production

Production Location:

Ikeda, Osaka, Japan

🏆 Awards & Recognition

Recognitions

Kei Car Design Award:

Often praised for its styling and sporty appeal within the Kei car segment.