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Daihatsu Copen Complete Workshop Service Repair Manual 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012

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🏷️ Basic Information Identification Make: Daihatsu Model: Copen Generation Codes: L880 Chassis Codes: L880K Product Name: Daihatsu Copen Complete Workshop Service Repair Manual Applicable Model Years: 2002, 2003, 2004, 2005,...
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Daihatsu Copen Complete Workshop Service Repair Manual 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012Daihatsu Copen Complete Workshop Service Repair Manual 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012Daihatsu Copen Complete Workshop Service Repair Manual 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012Daihatsu Copen Complete Workshop Service Repair Manual 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Copen
Generation Codes:
L880
Chassis Codes:
L880K
Product Name:
Daihatsu Copen Complete Workshop Service Repair Manual
Applicable Model Years:
2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012
👋 Introduction
Market Position
Vehicle Segment:
Kei car convertible sports car
Unique Selling Proposition:
Compact, affordable, open-top sports car with distinctive styling.
Competitive Analysis
Key Competitors Of Era:
While niche, direct competitors were limited. Primarily positioned against other small, fun-to-drive vehicles, and aspirational sports cars.
Key Features
Convertible Mechanism:
Power-operated retractable hardtop, a significant feature for its class and era.
Styling:
Retro-inspired design with a focus on 'cute yet sporty' aesthetics.
Manual Benefit:
Empowers owners to perform maintenance and repairs, saving significant costs.
📋 Manual Details
Coverage Areas
Coverage Scope:
All Models, Engines, Trim Levels, and Transmission Types
Page Count
Estimated Page Count:
Extensive (exact number not specified, but described as 'complete' and 'A-Z')
Manual Type
Type:
Complete Workshop Service Repair Manual
Language
Language:
English (implied by marketing and typical manual language)
Format
Format:
Downloadable Digital File
Delivery Method:
Instant Email Delivery
📖 Manual Coverage
Systems Covered
Engine Service And Repair:
Detailed procedures for engine assembly, disassembly, troubleshooting, and overhaul.
Transmission Service And Repair:
Covers both automatic and manual transmission systems, including fluid changes, component repair, and troubleshooting.
Drivetrain Service And Repair:
Includes differentials, drive axles, and related components.
Suspension And Steering Service And Repair:
Detailed information on suspension components (struts, shocks, springs, bushings), steering rack, power steering system.
Braking System Service And Repair:
Covers disc and drum brakes, ABS systems, hydraulic lines, and parking brake.
Cooling System Service And Repair:
Radiator, water pump, thermostat, cooling fans, and coolant specifications.
Fuel System Service And Repair:
Fuel pump, injectors, fuel lines, fuel filter, and tank service.
Exhaust System Service And Repair:
Catalytic converter, mufflers, pipes, and exhaust manifold repairs.
Electrical System Service And Repair:
Includes battery, alternator, starter, lighting systems, wiring diagrams, and fuses.
Climate Control Service And Repair:
Air conditioning system, heater core, blower motor, and controls.
Body And Chassis Service And Repair:
Body panels, doors, convertible top mechanism, frame, and interior trim.
Safety Systems Service And Repair:
Airbags, seatbelts, and related safety components.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, tire rotation.
Troubleshooting Guides:
Diagnostic procedures for common and uncommon faults across all systems.
Repair And Overhaul:
Step-by-step instructions for component replacement, repair, and complete engine/transmission rebuilds.
Technical Specifications:
Torque specifications, tolerances, and measurement data for all components.
Wiring Diagrams:
Comprehensive electrical schematics for all vehicle systems.
Diagnostic Procedures:
Guidance on using diagnostic tools and interpreting fault codes.
Convertible Top Operation And Maintenance:
Specific instructions for the Copen's electric retractable hardtop mechanism.
Technical Depth
Depth:
Comprehensive, from basic maintenance to advanced diagnostics and full rebuilds.
Visual Aids:
Includes step-by-step instructions with pictures, enhancing ease of understanding.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Likely text-searchable PDF for quick information retrieval.
Print Quality
Printability:
Printable on demand, allowing users to print specific sections or the entire manual.
Binding Type
Binding:
Not applicable (digital download)
Paper Type
Paper Quality:
Not applicable (digital download)
Software Requirements
Required Software:
Adobe Reader (free, widely available)
Device Compatibility
Compatible Devices:
All PC & MAC Computers, Tablets, Smartphones
⚙️ Engine Specifications
Primary Engine
Engine Code:
JB-DET
Engine Type:
659cc, 12-valve, DOHC, turbocharged, intercooled inline-3 cylinder
Bore X Stroke:
62.0 mm x 73.7 mm
Compression Ratio:
8.5:1
Performance
Horsepower Ps At Rpm:
64 PS (47 kW) @ 6,400 rpm (Kei car regulations)
Torque Nm At Rpm:
10.5 kg⋅m (103 N⋅m; 76 lb⋅ft) @ 3,200 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline
Cooling System
Cooling Type:
Water-cooled
🔧 Transmission
Standard
Transmission Type:
4-speed automatic or 5-speed manual
Optional
Optional Transmission:
5-speed manual (often preferred for sporty driving)
Features
Drive Layout:
Front-engine, Front-wheel drive (FF)
Fluid Specifications
Automatic Transmission Fluid:
Refer to manual for specific ATF type (e.g., Dexron III equivalent)
Manual Transmission Fluid:
Refer to manual for specific gear oil specification (e.g., GL-4)
📐 Dimensions
Exterior
Length:
Approx. 3,395 mm
Width:
Approx. 1,475 mm
Height:
Approx. 1,245 mm (roof up)
Wheelbase:
Approx. 2,070 mm
Ground Clearance:
Approx. 130 mm
Weights
Curb Weight:
Approx. 820-850 kg (depending on transmission)
Gross Vehicle Weight Rating:
Not typically specified for Kei cars in the same way as larger vehicles.
Towing Capacity:
Not specified/recommended
🛡️ Safety Features
Ratings
Crash Test Ratings:
Ratings vary by market and testing agency; detailed official ratings are scarce for Japanese Kei cars in international markets.
Active Features
Antilock Braking System ABS:
Available on some models/trims
Electronic Brakeforce Distribution Ebd:
Often paired with ABS
Passive Features
Airbags:
Driver and passenger airbags (standard on many models).
Seatbelts:
Three-point seatbelts with pre-tensioners
Rollover Protection:
Integrated roll bar structure within the windshield frame and behind the seats.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/CD player with varying speaker configurations depending on trim.
Gauges And Displays:
Includes tachometer, speedometer, fuel gauge, and coolant temperature gauge. Some models may have additional driver information displays.
Driver Assistance
Power Steering:
Hydraulic power steering system.
Traction Control:
Available on some higher-spec models or as an option.
Connectivity
Factory Options:
Limited by modern standards; focus was on mechanical and basic comfort features.
🔧 Maintenance
Service Intervals
Engine Oil And Filter Change:
Typically every 5,000-10,000 km or 6-12 months (refer to manual for exact recommendation).
Air Filter Replacement:
Every 20,000-40,000 km or as needed based on operating conditions.
Spark Plug Replacement:
Typically every 40,000-60,000 km, depending on spark plug type (e.g., standard vs. iridium).
Timing Belt Replacement:
The JB-DET uses a timing chain, which generally does not require regular replacement unless issues arise.
Fluid Specifications
Engine Oil Capacity:
Approx. 3.7 liters (with filter change)
Engine Oil Viscosity:
Refer to manual for recommended viscosity grade (e.g., 5W-30, 10W-30 depending on climate).
Coolant Capacity:
Approx. 4.5 liters
Coolant Type:
Ethylene glycol based antifreeze, typically pink or red in color.
Known Issues
Turbocharger Wear:
Like all turbocharged engines, oil starvation or contamination can lead to turbo failure. Regular maintenance is crucial.
Convertible Top Mechanism:
Potential for hydraulic leaks or motor failure in the retractable hardtop system; requires regular inspection and lubrication.
Ignition Coils:
Individual coil-on-plug ignition systems can sometimes develop faults, leading to misfires.
Oxygen Sensors:
Can degrade over time, affecting fuel economy and emissions.
📚 Vehicle History
Brand Heritage
Daihatsu Focus:
Daihatsu is Japan's oldest car manufacturer, known for producing small, efficient, and affordable vehicles (Kei cars).
Model Evolution
First Generation Launch:
The L880 generation Copen was launched in 2002 in Japan, succeeding the L880K prototype.
Market Availability:
Primarily sold in Japan, with limited official exports to markets like the UK, Australia, and some parts of Europe.
Production
Production Period:
2002-2012 for the L880 generation covered by this manual.
Production Location:
Japan
🏆 Awards & Recognition
Recognitions
Kei Car Design Awards:
Often lauded for its unique and appealing design within the Kei car segment. Specific awards not readily documented but it was a popular and distinctive model.
Ratings
Customer Satisfaction:
Generally positive among owners who appreciate its niche appeal and driving experience.
Certifications
Japanese Kei Car Compliance:
Meets Japanese Kei car regulations for engine size, dimensions, and power output.
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