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Daihatsu Copen 2005 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Copen Year: 2005 Generation Generation Code: L880K 👋 Introduction Market Position Niche: Compact Kei sports convertible, appealing to enthusiasts seeking unique styling and...
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Daihatsu Copen 2005 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Copen
Year:
2005
Generation
Generation Code:
L880K
👋 Introduction
Market Position
Niche:
Compact Kei sports convertible, appealing to enthusiasts seeking unique styling and performance.
Competitive Analysis
Competitors 2005:
Primarily niche convertibles, but competed indirectly with sporty compact cars of its era.
Key Features
Convertible Roof:
Electrically operated retractable hardtop.
Design:
Distinctive, sporty, and compact design, reminiscent of classic European roadsters.
📋 Manual Details
Coverage Areas
Primary Coverage:
Full Service Repair
Page Count
Estimated Pages:
Extensive (exact count not specified, but described as comprehensive)
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Digital Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, diagnostics, repair of all engine components.
Engine Electrical:
Ignition system, fuel injection, sensors, actuators, ECU diagnostics.
Transmission:
Manual and Automatic transmission repair, clutch, gearbox diagnostics.
Drivetrain:
Front-wheel drive system, differentials, CV joints, driveshafts.
Suspension:
Front and rear suspension systems, shock absorbers, springs, bushings.
Steering:
Power steering system, steering rack, column, tie rods.
Brakes:
Front and rear brake systems, ABS diagnostics, hydraulics, parking brake.
Electrical System:
Complete electrical schematics, lighting, power windows, central locking, audio system.
Body And Frame:
Body panel repair, convertible roof mechanism, interior trim, chassis diagnostics.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system servicing.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks.
Troubleshooting:
Extensive diagnostic procedures for all systems, including electrical fault finding.
Repair:
Step-by-step repair instructions for all major components and systems.
Rebuilding:
Detailed procedures for rebuilding engine, transmission, and other major assemblies.
Restoration:
Information applicable to refurbishment and restoration projects.
Technical Depth
Depth:
Professional Technician Level with DIY accessibility
Wiring Diagrams:
Comprehensive and detailed wiring schematics for all electrical systems.
Diagnostics:
Advanced diagnostic procedures, including OBD-II information and fault code interpretation.
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Printability:
Full Printable
Binding Type
Binding:
Digital Download (Printable pages)
Paper Type
Media:
Digital (PDF)
Requirements
Software:
Adobe PDF Reader, WinRAR
Compatibility
Operating Systems:
All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Engine Code:
JB-DET
Configuration:
659cc, Inline-3, Turbocharged, Intercooled
Bore X Stroke:
64.0 mm x 68.2 mm (typical for JB-DET)
Compression Ratio:
8.5:1 (typical for JB-DET)
Performance
Horsepower Ps:
64 PS (47 kW; 63 hp) @ 6400 rpm (JDM regulations)
Torque Nm:
10.5 kg⋅m (103 N⋅m; 76 lb⋅ft) @ 3200 rpm (JDM regulations)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), Multi-point
Fuel Type:
Unleaded Petrol (Octane rating typically 91 RON or higher recommended)
Induction
Turbocharger:
TD02 (or similar small turbocharger)
🔧 Transmission
Standard
Type:
5-Speed Manual Transmission
Optional
Type:
4-Speed Automatic Transmission (with torque converter)
Features
Differential:
Limited Slip Differential (LSD) often an option or included with certain trims.
📐 Dimensions
Exterior
Length:
3,395 mm (133.7 in)
Width:
1,475 mm (58.1 in)
Height:
1,245 mm (49.0 in) (roof up)
Wheelbase:
2,230 mm (87.8 in)
Weights
Curb Weight:
Approx. 750-800 kg (depending on transmission and options)
Gross Weight Rating:
Not typically specified for Kei class, but within safe operating limits.
🛡️ Safety Features
Ratings
Jncsa Ratings:
The Copen typically met or exceeded Japanese New Car Assessment Program (JNCAP) safety standards of its era.
Active Features
ABS:
Anti-lock Braking System (ABS) - standard on most models.
Ebd:
Electronic Brakeforce Distribution (EBD) - often paired with ABS.
Passive Features
Airbags:
Driver and Passenger Airbags.
Roll Cage:
Integrated Roll-over Protection structure in the A-pillars and windscreen frame.
💡 Technology Features
Infotainment
Audio System:
Factory fitted AM/FM radio with CD player, often with optional upgraded speakers.
Driver Assistance
Traction Control:
Traction Control System (TCS) available on some models.
Connectivity
OBD:
OBD-II compliant for engine diagnostics.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 5,000-10,000 km or 6-12 months (refer to manual for specific recommendations based on driving conditions).
Air Filter:
Inspect every 10,000 km, replace as needed or every 30,000-40,000 km.
Spark Plugs:
Replace every 40,000-60,000 km, depending on type (standard vs. iridium).
Fluid Specifications
Engine Oil:
API SG/SH/SJ or ILSAC GF-2/GF-3, viscosity 5W-30 or 10W-30 (check manual for exact spec based on climate).
Coolant:
Daihatsu Super Long Life Coolant (or equivalent ethylene glycol-based coolant with appropriate corrosion inhibitors).
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Transmission Fluid Auto:
Dexron III or equivalent ATF.
Known Issues
Turbo Wear:
Turbocharger can be a weak point if not maintained; regular oil changes are crucial.
Convertible Roof Mechanism:
Potential issues with seals, motors, or hydraulic systems for the retractable roof if not properly maintained or if seals degrade.
Ignition Coils:
Individual coil-on-plug ignition systems can sometimes fail, leading to misfires.
📚 Vehicle History
Brand Heritage
Daihatsu Specialty:
Daihatsu has a long history of producing compact, economical, and innovative vehicles, particularly within the Kei car segment.
Model Evolution
First Generation Launch:
First generation Copen (L880K) launched in 2002.
Facelifts Updates:
The 2005 model year represents a point in the L880K's lifecycle, likely incorporating minor updates from earlier iterations.
Production
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Kei Car Awards:
While specific awards for the 2005 model may not be widely publicized outside Japan, the Copen was generally well-regarded for its styling and engineering within the Kei sports car segment.
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