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Daihatsu Terios 2 J200 2006-2014 Service Repair Manual

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The Daihatsu Terios, specifically the second generation (J200 chassis code) produced from 2006 to 2014, is a compact SUV renowned for its maneuverability, practical interior, and value-conscious appeal. As a...
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Daihatsu Terios 2 J200 2006-2014 Service Repair Manual
The Daihatsu Terios, specifically the second generation (J200 chassis code) produced from 2006 to 2014, is a compact SUV renowned for its maneuverability, practical interior, and value-conscious appeal. As a subsidiary of Toyota, Daihatsu vehicles are recognized for their engineering quality and reliability, and the Terios exemplifies this with its robust construction and user-friendly design. This model offers a versatile driving experience suitable for urban environments and light off-road excursions, often equipped with available All-Wheel Drive, making it a capable and affordable choice in its segment. This comprehensive workshop service and repair manual provides essential technical information for the Daihatsu Terios (J200) covering the model years 2006 through 2014. It details a wide array of systems, including the engine, transmission, drivetrain, suspension, steering, brakes, electrical components, and HVAC. The manual includes procedures for routine maintenance, repair and overhaul, diagnostics, troubleshooting, and technical specifications, complete with electrical wiring diagrams. Its purpose is to empower owners and technicians with the knowledge needed for accurate maintenance and effective repair, ensuring the longevity and optimal performance of the vehicle.
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Terios
Generation:
2
Chassis Code:
J200
Model Years Covered:
2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014
👋 Introduction
Market Position
Vehicle Segment:
Compact SUV / Crossover
Target Audience:
Value-conscious consumers seeking a reliable, versatile, and compact SUV
Competitive Analysis
Key Competitors:
Toyota RAV4, Honda CR-V, Nissan X-Trail, Mitsubishi Outlander, Suzuki Vitara
Key Features
Vehicle Strengths:
Compact size, good maneuverability, available AWD, practical interior, affordability
Manual Value Proposition:
Empowers owners and technicians with comprehensive technical data for accurate diagnosis, maintenance, and repair, reducing reliance on expensive dealership services
📋 Manual Details
Coverage Areas
General Coverage:
Comprehensive service, maintenance, and repair information
Specific Systems Focus:
Engine, transmission, drivetrain, suspension, steering, brakes, electrical system, body, chassis, HVAC, emissions
Page Count
Estimated Page Count:
Over 2000 pages (typical for a comprehensive service manual of this era)
Manual Type
Manual Category:
Workshop Service and Repair Manual
Language
Primary Language:
English
Format
Delivery Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical, engine control system (ECU), fuel injection, ignition, cooling, lubrication, exhaust, emissions control
Transmission Drivetrain:
Manual transmission, automatic transmission (if applicable), transfer case, differentials, drive shafts, axles, AWD system (if equipped)
Suspension Steering:
Front suspension, rear suspension, steering system, power steering, wheel alignment
Brake System:
Front brakes, rear brakes, parking brake, ABS (Anti-lock Braking System), EBD (Electronic Brake-force Distribution)
Electrical System:
Battery, charging system, starting system, lighting, instrumentation, power windows, locks, mirrors, wipers, horn, ECU diagnostics
Body Chassis:
Body structure, interior trim, exterior panels, doors, glass, seat belts, airbags, frame and chassis components
HVAC Emissions:
Heating, Ventilation, Air Conditioning (HVAC) system, emission control systems, evaporative emission control (EVAP)
Procedures Included
Routine Maintenance:
Oil and filter change, air filter replacement, spark plug replacement, fluid checks and changes, tire rotation
Repair And Overhaul:
Engine component replacement, transmission overhaul, brake pad/rotor replacement, suspension component replacement, electrical component repair
Diagnostics Troubleshooting:
Symptom-based troubleshooting guides, diagnostic trouble codes (DTCs), electrical circuit diagrams, component testing procedures
Technical Specifications:
Torque specifications, clearances, fluid capacities, electrical specifications, component dimensions
Wiring Diagrams:
Complete electrical wiring diagrams for all systems
Technical Depth
Depth Of Coverage:
Detailed, from basic fluid changes to complete engine and transmission rebuilds, including advanced diagnostics
📊 Manual Specifications
File Format
PDF Quality:
High-resolution, searchable PDF for easy navigation and printing
Searchability:
Full text search functionality within the PDF
Print Quality
Printability:
Printable pages for physical reference in workshop environments
Binding Type
Digital Binding:
N/A (Digital PDF format)
Paper Type
Digital Paper Type:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Code Common:
3SZ-VE (typically)
Engine Type:
Inline 4-cylinder, DOHC, 16-valve, VVT-i (Variable Valve Timing - intelligent)
Displacement:
1.5 Liters (1495 cc)
Bore X Stroke:
72.0 mm x 91.8 mm (typical for 3SZ-VE)
Compression Ratio:
10.0:1 (typical for 3SZ-VE)
Performance
Horsepower Max:
Approximately 107 hp @ 6000 rpm (for 1.5L 3SZ-VE)
Torque Max:
Approximately 140 Nm (103 lb-ft) @ 4400 rpm (for 1.5L 3SZ-VE)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) / Multi-Point Fuel Injection (MPFI)
Fuel Type:
Unleaded Gasoline
Fuel Tank Capacity:
Approximately 50 Liters (13.2 US gallons)
Engine Management
ECU Type:
Denso ECU (specific model varies by market and year)
🔧 Transmission
Standard
Transmission Type Std:
5-speed Manual Transmission
Optional
Transmission Type Opt:
4-speed Automatic Transmission
Features
Drivetrain Options:
Front-Wheel Drive (FWD), All-Wheel Drive (AWD) with viscous coupling center differential
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-90 (check manual for specific part number and capacity)
Automatic Transmission Fluid:
Dexron III or equivalent (check manual for specific part number and capacity)
📐 Dimensions
Exterior
Length:
Approx. 4055 mm (159.6 in)
Width:
Approx. 1690 mm (66.5 in)
Height:
Approx. 1705 mm (67.1 in) (with roof rails)
Wheelbase:
Approx. 2430 mm (95.7 in)
Ground Clearance:
Approx. 190 mm (7.5 in)
Interior
Seating Capacity:
5 passengers
Cargo
Cargo Volume Rear Seats Up:
Approx. 300 Liters (10.6 cu ft)
Cargo Volume Rear Seats Folded:
Approx. 750 Liters (26.5 cu ft) to window line
Weights
Curb Weight:
Approx. 1200-1300 kg (2645-2866 lbs), depending on configuration
Gross Vehicle Weight Rating Gvwr:
Varies by model and market (refer to vehicle plate)
Wheels Tires
Wheel Size Standard:
16-inch alloy or steel wheels
Tire Size Standard:
215/65R16 (common)
Wheel Bolt Pattern:
5x114.3 mm (5x4.5 inch)
Center Bore:
60.1 mm
🛡️ Safety Features
Ratings
NHTSA Crash Test Ratings:
Varies by year and market. Typically achieved good ratings in frontal and side impacts for its class and era.
IIHS Crash Test Ratings:
Varies by year and market. Check specific year's ratings.
Active Features
ABS:
Standard on most models, often with EBD (Electronic Brakeforce Distribution)
Traction Control System TCS:
Optional on some models, particularly AWD variants
Electronic Stability Control Esc:
Optional on some later models, check specific vehicle
Passive Features
Airbags Standard:
Driver and front passenger airbags
Airbags Optional:
Side airbags, curtain airbags (depending on trim level and market)
Seatbelts:
Three-point seatbelts with pretensioners for front seats, three-point seatbelts for rear seats
Child Seat Anchors:
ISOFIX / LATCH system
💡 Technology Features
Infotainment
Audio System:
Factory fitted AM/FM radio with CD player, some models may have optional MP3 input or auxiliary ports.
Speaker Configuration:
Typically 4 or 6 speakers depending on trim level.
Driver Assistance
Parking Assist:
Optional rear parking sensors available on some trims.
Connectivity
Bluetooth:
Rarely standard on early models, may be an aftermarket addition or found on later facelifts/higher trims.
Usb Ports:
Not standard on this generation; typically aftermarket.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000-10,000 km (3,000-6,000 miles) or 6-12 months, whichever comes first (refer to manual for specific grade and severe vs. normal service)
Oil Filter Replacement:
At every engine oil change
Air Filter Replacement:
Every 20,000-30,000 km (12,000-18,000 miles)
Spark Plug Replacement:
Every 40,000-100,000 km (25,000-60,000 miles) depending on spark plug type (standard vs. iridium/platinum)
Coolant Flush:
Every 40,000-80,000 km (25,000-50,000 miles) or 2-4 years
Brake Fluid Change:
Every 2-3 years
Fluid Specifications
Engine Oil Type:
5W-30 or 5W-40 (API SN/SM/SL or ILSAC GF-5/GF-4) - consult manual for exact viscosity and specification
Engine Oil Capacity:
Approx. 3.8 Liters (4.0 US quarts) with filter (for 1.5L 3SZ-VE)
Coolant Type:
Ethylene Glycol based, Toyota Super Long Life Coolant (SLLC) or equivalent (pre-mixed pink/red)
Power Steering Fluid:
ATF Dexron II or III type (check manual for specific type)
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Common Wear Items:
Suspension components (bushings, ball joints), exhaust system, brake wear items, clutch wear (on manual models)
Potential Electrical Issues:
Wiring harness degradation in certain areas, sensor failures (e.g., O2 sensors) due to age
Engine Specifics:
Timing chain stretch can occur on higher mileage 3SZ-VE engines, leading to rattling noise and potential performance issues. VVT-i system maintenance is important.
Transmission Notes:
Automatic transmission can sometimes exhibit delayed shifting or harsh engagement with age and mileage; regular fluid changes are crucial.
Body Rust:
Can be susceptible to rust in areas with heavy road salt usage, particularly on underbody components and wheel arches.
📚 Vehicle History
Brand Heritage
Daihatsu Focus:
Daihatsu, a subsidiary of Toyota, is known for producing small, fuel-efficient, and reliable vehicles, often catering to specific niche markets.
Model Evolution
Terios First Gen:
The first generation (J100) was introduced in 1997 as a compact, body-on-frame SUV.
Terios Second Gen J200:
The second generation (J200) introduced a monocoque (unibody) construction, transitioning it to a more modern crossover SUV. It offered a more car-like driving experience and improved fuel efficiency. It was also sold as the Toyota Rush in some markets.
Production
Manufacturing Locations:
Primarily manufactured in Japan and Indonesia.
Production Period J200:
2006 - 2017 (with facelifts)
🏆 Awards & Recognition
Recognitions
Industry Awards:
While specific awards for the J200 Terios might be regional, the Daihatsu brand generally receives recognition for reliability and value in the compact car and SUV segments.
Ratings
Consumer Reliability Ratings:
Daihatsu vehicles are generally perceived as reliable, with ownership satisfaction often tied to their affordability and low running costs. Specific ratings vary by surveying body and region.
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