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DAIHATSU TERIOS 2 Workshop Repair Manual 2006-2011

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The Daihatsu Terios, specifically the second generation (J200 series) produced between 2006 and 2011, is a capable compact SUV renowned for its practicality and robust engineering. Built on a chassis...
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DAIHATSU TERIOS 2 Workshop Repair Manual 2006-2011
The Daihatsu Terios, specifically the second generation (J200 series) produced between 2006 and 2011, is a capable compact SUV renowned for its practicality and robust engineering. Built on a chassis that supports both 2WD and 4WD configurations, this vehicle is powered by a 1.5-liter (1495cc) inline 4-cylinder engine featuring DOHC and VVT-i technology, delivering approximately 109 PS and 140 Nm of torque. Its versatile design, seating five occupants and offering substantial cargo space, makes it suitable for both urban commuting and light off-road adventures. The vehicle's heritage underscores its reputation for reliability and value within its competitive segment, often compared to models like the Toyota RAV4 and Honda CR-V. This comprehensive Workshop Service and Repair Manual provides in-depth guidance for the Daihatsu Terios (J200 series) covering the years 2006 through 2011. The manual details essential maintenance procedures, including scheduled service intervals, fluid specifications, and component replacement for the engine, transmission, brakes, and suspension. It also offers extensive troubleshooting guides, diagnostic procedures for electrical systems, and step-by-step instructions for repair and overhaul of all major vehicle systems. With over 1000 pages of technical information, including wiring diagrams and torque specifications, this manual is an indispensable resource for professional technicians, mechanics, and dedicated DIY enthusiasts aiming to maintain and repair their vehicle effectively.
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Terios
Generation:
Second Generation (J200 series)
Years Covered:
2006, 2007, 2008, 2009, 2010, 2011
Codes
Chassis Codes:
J200G, J210G, J200E, J210E
Engine Codes Common:
3SZ-VE
👋 Introduction
Market Position
Vehicle Segment:
Compact SUV / Crossover
Target Audience Manual:
Professional automotive technicians, DIY enthusiasts, and Daihatsu dealerships.
Competitive Analysis
Key Competitors Vehicle:
Toyota RAV4, Honda CR-V, Suzuki Grand Vitara, Nissan X-Trail, Ford EcoSport (in certain markets).
Key Features
Manual Advantage:
Provides dealership-level technical information, essential for accurate diagnostics and repairs, covering all aspects of the vehicle.
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service and Repair Manual
Primary Language:
English
Format Availability:
Downloadable Digital Format (likely PDF)
Page Count
Estimated Page Count:
1000+ pages (typical for comprehensive workshop manuals)
Format
File Format Detail:
Likely a searchable PDF document, allowing for quick access to information.
Print Quality
Print Quality Description:
High-resolution diagrams and text, ensuring clarity for complex procedures and technical details.
Binding Type
Binding Type Description:
Digital download, no physical binding.
Paper Type
Paper Type Description:
N/A (Digital Format)
📖 Manual Coverage
Systems Covered
Engine Service:
Complete engine overhaul, troubleshooting, diagnostics, timing belt replacement, cooling system, lubrication system, fuel system, emissions control.
Transmission Service:
Manual and automatic transmission repair, clutch service, gearbox overhaul, differential maintenance, fluid specifications and replacement.
Drivetrain Suspension:
Front and rear suspension components, drive shafts, CV joints, wheel bearings, steering system (power steering, rack and pinion).
Brake System:
Disc and drum brake systems, ABS (Anti-lock Braking System) troubleshooting, brake fluid replacement, caliper and master cylinder overhaul.
Electrical System:
Complete wiring diagrams, ECU (Engine Control Unit) diagnostics, starter, alternator, battery service, lighting system, power accessories, sensor testing.
Body And Chassis:
Body panel repair and replacement, interior trim removal and installation, door mechanisms, glass replacement, chassis component inspection and repair.
Procedures Included
Maintenance:
Scheduled maintenance tasks, fluid level checks and top-ups, filter replacements (oil, air, fuel, cabin), spark plug replacement, belt inspection and replacement.
Troubleshooting:
Detailed diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides, fault code interpretation.
Repair Overhaul:
Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation for all major vehicle systems.
Specifications Data:
Torque specifications for all fasteners, clearances, tolerances, diagnostic values, fluid capacities, wiring diagrams, and component identification.
Technical Depth
Diagnostic Capabilities:
Advanced diagnostic procedures, including sensor data interpretation, ECU relearning procedures, and system testing using diagnostic tools.
Rebuild Procedures:
Comprehensive instructions for complete engine, transmission, and differential rebuilds, including component specifications and tolerances.
⚙️ Engine Specifications
Primary Engine
Engine Displacement Cc:
1495cc
Engine Configuration:
Inline 4-cylinder, DOHC, 16-valve with VVT-i (Variable Valve Timing with intelligence)
Performance
Horsepower Ps:
Approx. 109 PS @ 6000 rpm
Torque Nm:
Approx. 140 Nm @ 4000 rpm
Fuel System
Fuel Induction:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Engine Management
ECU Type:
Engine Control Unit (ECU) - specific model number would be detailed in the manual.
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission
Optional
Transmission Type Optional:
4-speed Automatic Transmission
Features
Drivetrain Options:
Available in 2WD (Rear-Wheel Drive) and 4WD (Four-Wheel Drive) configurations.
📐 Dimensions
Exterior
Length Mm:
Approx. 4295 mm
Width Mm:
Approx. 1700 mm
Height Mm:
Approx. 1695 mm
Wheelbase Mm:
Approx. 2685 mm
Weights
Curb Weight Kg:
Approx. 1300-1400 kg (depending on configuration)
Gross Vehicle Weight Rating Kg:
Approx. 1800 kg
Interior
Seating Capacity:
5 Seats
Cargo
Cargo Volume Liters:
Approx. 350-400 liters (rear seats up)
🛡️ Safety Features
Ratings
E Ncap Rating:
Likely 4-star Euro NCAP rating (for models tested in Europe).
Active Features
ABS:
Standard on most trims
Electronic Stability Control:
Optional on some trims/markets
Traction Control System:
Optional on some trims/markets
Passive Features
Airbags:
Front airbags for driver and passenger, side airbags (optional on some trims).
Seatbelts:
3-point seatbelts with pretensioners and load limiters.
Child Seat Anchors:
ISOFIX mounting points
💡 Technology Features
Infotainment
Infotainment System Standard:
Basic AM/FM radio with CD player, and 4 speakers on base models.
Infotainment System Optional:
Optional upgraded audio systems with CD changer, MP3 playback, and sometimes auxiliary input.
Driver Assistance
Driver Assistance Features:
Limited driver assistance features for this era, primarily ABS and optional traction control/stability control.
Connectivity
Connectivity Options:
Auxiliary audio input jack on higher trims. Bluetooth connectivity was rare for this model year.
🔧 Maintenance
Service Intervals
Oil Change Interval Km:
Every 10,000 km or 6 months, whichever comes first (refer to manual for specific conditions).
Air Filter Replacement Km:
Every 20,000 km or as needed based on inspection.
Spark Plug Replacement Km:
Every 40,000 km (for standard plugs) or 80,000-100,000 km (for iridium plugs).
Fluid Specifications
Engine Oil Type:
API SL or SM, ILSAC GF-3 or GF-4, SAE 5W-30 or 10W-30 (refer to manual for exact specification and capacity).
Coolant Type:
Daihatsu Super Long Life Coolant (or equivalent ethylene glycol-based coolant with protection additives).
Transmission Fluid Automatic:
Dexron III or equivalent.
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Common Issues Mention:
Occasional reports of minor electrical gremlins, suspension wear (bushings, ball joints), and clutch wear on manual transmission models with high mileage.
📚 Vehicle History
Brand Heritage
Daihatsu Heritage:
Daihatsu, a subsidiary of Toyota, has a long history of producing small, reliable, and often innovative vehicles, particularly known for kei cars and compact SUVs.
Model Evolution
Terios Generations:
The Terios was first introduced in 1997. The second generation (J200) marked a significant redesign, offering a more modern appearance and improved practicality.
Production
Manufacturing Locations:
Primarily manufactured in Japan and Indonesia. Also sold under other brand names (e.g., Toyota Rush) in certain markets.
🏆 Awards & Recognition
Recognitions
Vehicle Awards:
While specific awards for the 2006-2011 Terios are not widely publicized, it was recognized for its value, reliability, and practicality in the compact SUV segment in various markets.
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