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DAIHATSU TERIOS 2006-09 Service Repair Manual

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Welcome to the comprehensive service manual for the Terios, Second Generation (J200 Series), covering model years 2006 through 2009. This compact crossover SUV, also known as a Mini SUV or...
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DAIHATSU TERIOS 2006-09 Service Repair Manual
Welcome to the comprehensive service manual for the Terios, Second Generation (J200 Series), covering model years 2006 through 2009. This compact crossover SUV, also known as a Mini SUV or Light Utility Vehicle, is recognized for its compact size, fuel efficiency, affordability, and practical capabilities, including available 4WD for light off-roading. Engineered with a focus on reliability and utility, the Terios, powered by the efficient 1.5-liter 3SZ-VE engine, offers a blend of urban maneuverability and adventurous spirit, making it a versatile choice for various driving needs. This factory service manual provides in-depth, A-Z coverage identical to what authorized service centers utilize. It serves as an indispensable resource for owners, mechanics, and technicians, detailing every aspect of the vehicle from routine maintenance procedures like oil changes and filter replacements to complex repair and rebuild instructions for all major systems. The manual includes extensive troubleshooting guides, diagnostic procedures, and precise technical specifications, ensuring accurate and efficient upkeep and repair of your Terios.
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Terios
Generation:
Second Generation (J200 Series)
Model Years Covered:
2006, 2007, 2008, 2009
👋 Introduction
Market Position
Segment:
Compact Crossover SUV / Mini SUV
Key Selling Points:
Compact size, fuel efficiency, affordability, off-road capability (often with 4WD option), practicality for urban environments and light off-roading.
Competitive Analysis
Key Competitors:
Suzuki Vitara, Mitsubishi Pajero Mini/IO, Toyota RAV4 (earlier generations), Nissan X-Trail (smaller variants), Honda CR-V (earlier generations).
Key Features
Vehicle Type:
Light Utility Vehicle (LUV) / Compact SUV
Drivetrain Options:
Available in 2WD (Rear-Wheel Drive) and 4WD (Full-Time or Part-Time 4WD systems).
📋 Manual Details
Coverage Areas
All Models Included:
Yes
All Engines Included:
Yes
Repair Scope:
A-Z (All Repairs)
Manual Type
Type:
Factory Service Manual / Workshop Manual
Professional Equivalent:
Yes (Same as provided to authorized service centers)
Language
Language:
English
Format
Format:
Digital (Likely PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, cylinder head, block, pistons, connecting rods, crankshaft, valve train, timing system, lubrication system, cooling system, intake and exhaust systems.
Engine Management:
Fuel injection system (EFI), ignition system, emission control systems (EVAP, EGR), engine control unit (ECU) operation and diagnosis, sensors and actuators.
Transmission Drivetrain:
Manual transmission, automatic transmission (AT), transfer case, propeller shafts, drive shafts, differentials (front and rear), hubs and bearings.
Suspension Steering:
Front suspension (MacPherson strut), rear suspension (multi-link or solid axle depending on specific variant), steering gear, power steering system, wheel alignment.
Brakes:
Front disc brakes, rear drum or disc brakes (depending on trim), anti-lock braking system (ABS), parking brake system.
Electrical System:
Battery, charging system (alternator), starting system, lighting (headlights, taillights, interior), gauges and instruments, wiring diagrams, fuses and relays, power windows, door locks, mirrors.
Body Chassis:
Body construction, interior trim, exterior trim, doors, hood, tailgate, bumpers, glass, frame and underbody, corrosion protection.
HVAC:
Heating, ventilation, and air conditioning (HVAC) system components, refrigerant system, climate control operation.
Procedures Included
Maintenance:
Routine maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt replacement, brake inspection, tire rotation.
Troubleshooting:
Diagnostic procedures for common and uncommon problems, symptom-based troubleshooting charts, DTC (Diagnostic Trouble Code) interpretation.
Repair Rebuild:
Detailed step-by-step instructions for component removal, installation, and overhaul (e.g., engine overhaul, transmission rebuild, brake caliper replacement).
Specifications:
Torque specifications for all fasteners, fluid capacities and types, electrical component specifications, dimensional data.
Diagnosis:
On-board diagnostics (OBD-II) procedures, scan tool usage, sensor testing, actuator testing.
Technical Depth
Depth:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds).
Diagnostics Level:
Advanced diagnostic procedures and troubleshooting.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Typically text-searchable PDF for quick information retrieval.
Print Quality
Resolution:
High-resolution scans ensuring clarity of diagrams and text.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
3SZ-VE
Engine Type:
Inline 4-cylinder, DOHC, 16-valve, VVT-i (Variable Valve Timing with intelligence)
Displacement:
1.5 liters (1495 cc)
Bore X Stroke:
72.0 mm x 91.8 mm
Compression Ratio:
10.0:1
Horsepower Net Max:
Approx. 109 PS (107 hp / 80 kW) at 6000 rpm
Torque Net Max:
Approx. 14.4 kgf·m (141 Nm / 104 lb·ft) at 4400 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), Sequential Multi-port Fuel Injection
Fuel Type:
Unleaded gasoline
Recommended Octane:
91 (or higher, check local market specifications)
Engine Codes Other
Other Engine Options:
May include smaller 1.3L engines (e.g., K3-VE) in certain markets, but 1.5L is most common for this generation. Manual covers all variants.
🔧 Transmission
Standard
Type Std:
5-speed Manual Transmission (MT)
Optional
Type Opt:
4-speed Automatic Transmission (AT)
Features
4Wd System:
Often features a selectable 4WD system (e.g., Full-time or Part-time with center differential lock/viscous coupling)
Fluid Specifications
Atf Type:
Dexron III or equivalent automatic transmission fluid (check specific owner's manual or shop manual for exact spec).
Mtf Type:
API GL-4 gear oil, SAE 75W-90 (check specific owner's manual or shop manual for exact spec).
📐 Dimensions
Exterior
Length:
Approx. 4,055 - 4,175 mm (159.6 - 164.4 inches)
Width:
Approx. 1,690 - 1,715 mm (66.5 - 67.5 inches)
Height:
Approx. 1,700 - 1,740 mm (66.9 - 68.5 inches)
Wheelbase:
Approx. 2,580 mm (101.6 inches)
Ground Clearance:
Approx. 190 mm (7.5 inches)
Weights
Curb Weight:
Approx. 1,200 - 1,350 kg (2,645 - 2,976 lbs)
Gross Vehicle Weight Rating:
Approx. 1,700 - 1,800 kg (3,748 - 3,968 lbs)
Cargo
Cargo Volume Seats Up:
Approx. 301 liters (10.6 cu ft)
Cargo Volume Seats Down:
Approx. 751 liters (26.5 cu ft) (with rear seats folded)
🛡️ Safety Features
Ratings
NHTSA Ratings:
Varies by market and testing agency. Generally aimed for good safety performance for its class, but specific ratings require checking local databases for the 2006-2009 models.
Active Features
ABS:
Available (Anti-lock Braking System)
E Brake Type:
Mechanical parking brake, usually foot-operated or hand lever.
Passive Features
Airbags:
Front airbags for driver and passenger. Side airbags and curtain airbags may be optional on higher trims.
Seatbelts:
3-point seat belts with pre-tensioners and force limiters for front occupants. 3-point seat belts for rear occupants.
Child Seat Anchors:
ISOFIX/LATCH child seat anchorage points.
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM radio with CD player. Higher trims may offer MP3 compatibility or enhanced speaker systems.
Navigation:
Navigation systems were not standard and would have been optional or aftermarket additions.
Driver Assistance
Cruise Control:
Available on higher trim levels.
Parking Sensors:
Optional on some models.
Connectivity
Aux Input:
May be present on some audio units for connecting external devices.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-10,000 km (3,000-6,000 miles) or 6-12 months, whichever comes first (refer to manual for specific recommendation based on driving conditions).
Air Filter Replacement:
Every 20,000-30,000 km (12,000-18,000 miles) or as needed based on dusty conditions.
Spark Plug Replacement:
Around 80,000-100,000 km (50,000-60,000 miles) for standard plugs, or longer for iridium/platinum plugs. Manual will specify exact type and interval.
Coolant Change:
Every 40,000-60,000 km (24,000-36,000 miles) or 2-3 years.
Fluid Specifications
Engine Oil Spec:
SAE 5W-30 or 10W-30 API SN/SP or ILSAC GF-5/GF-6 (confirm with manual for exact specification and viscosity based on climate).
Engine Oil Capacity:
Approx. 3.7 - 4.1 liters (3.9 - 4.3 US quarts) with filter change.
Coolant Type:
Ethylene glycol-based coolant, typically pink or red for Toyota/Daihatsu long-life coolant (e.g., Toyota Super Long Life Coolant).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (check manual for exact specification).
Known Issues
Common Wear Items:
Front struts/shocks, rear suspension bushings, exhaust system components, clutch wear (on manual transmissions), catalytic converter issues in high-mileage vehicles.
Engine Performance Issues:
Occasional issues with carbon buildup on intake valves, potential for oil consumption in higher mileage engines. VVT-i system maintenance is crucial.
Electrical Faults:
While generally reliable, minor electrical gremlins can occur over time, often related to wiring harness integrity or sensor failures. Manual's wiring diagrams are essential.
4Wd System Maintenance:
Regular inspection and maintenance of the 4WD system, including transfer case and differential fluids, is vital for longevity, especially in off-road use.
📚 Vehicle History
Brand Heritage
Daihatsu Specialty:
Daihatsu is a Japanese manufacturer known for producing small, fuel-efficient vehicles, kei cars, and mini SUVs.
Model Evolution
Terios Concept:
The Terios (also known as Toyota Cami/Rush in some markets) was conceived as a compact, affordable, and capable small SUV, blending car-like comfort with off-road pretensions.
Second Gen Launch:
The second generation (J200 series) was introduced in 2006, featuring a larger platform, more modern styling, and improved engines compared to the first generation.
Production
Manufacturing Location:
Primarily manufactured in Japan, with production facilities also located in other countries through licensing agreements or joint ventures.
Model Discontinuation In Some Markets:
Daihatsu withdrew from many Western markets, including Europe and North America, in the early 2010s, although the Terios continued to be sold under Toyota branding in some regions.
🏆 Awards & Recognition
Recognitions
Class Rankings:
The Terios often received positive mentions for its value proposition, practicality, and fuel efficiency within the compact SUV segment in markets where it was sold.
Ratings
Fuel Economy:
Generally considered to have good fuel economy for its class, especially the 1.5L engine and manual transmission variants.
Certifications
Emissions Standards:
Designed to meet prevailing emissions standards for its production years (e.g., Euro IV or equivalent).
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