🏷️ Basic Information

Make:

Daihatsu

Model:

Copen

Year:

2009

Chassis Code:

L880

👋 Introduction

Market Position:

The Daihatsu Copen 2009 is a compact, two-seater convertible sports car known for its distinctive styling, nimble handling, and turbocharged performance. It occupies a niche market segment, appealing to enthusiasts seeking a fun and stylish personal mobility vehicle.

Competitive Analysis:

While direct competitors are few, the Copen competes against other small roadsters and sporty compact cars that prioritize driving enjoyment and unique design over practicality. Its key differentiators include its retractable hardtop and its compact, urban-friendly dimensions.

Key Features:

Retractable electric hardtop, turbocharged engine, compact size, sporty handling, unique styling, front-wheel drive.

📋 Manual Details

Coverage Areas:

Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, Bodywork, Interior, Climate Control, Diagnostic Procedures, Troubleshooting, Maintenance Schedules

Page Count:

Estimated 1500+ pages (typical for a comprehensive service manual of this nature)

Manual Type:

Full Service Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Systems Covered:

Engine Mechanical (1.3L JB-DET Turbocharged), Engine Control System (ECU, sensors, actuators), Fuel System (injection, pumps, lines), Exhaust System, Cooling System, Lubrication System, Ignition System, Transmission (4-speed Automatic, 5-speed Manual), Clutch System, Drivetrain (Front-Wheel Drive, Differential), Suspension (Front MacPherson Strut, Rear Torsion Beam), Steering System (Power Assisted Rack and Pinion), Brake System (Front Ventilated Disc, Rear Disc), ABS System, Electrical System (wiring diagrams, components, fuses, relays), Lighting System, Body Electrical (power windows, locks, mirrors), Interior Systems (seats, airbags), Climate Control System (HVAC), Convertible Roof Mechanism, Diagnostic Trouble Codes (DTCs), Torque Specifications

Engine Mechanical:

Detailed procedures for cylinder head removal/installation, piston and connecting rod removal/installation, crankshaft removal/installation, valve timing adjustment, oil pump removal/installation, lubrication system component servicing.

Engine Control System:

Diagnosis and repair of Engine Control Unit (ECU), sensors (e.g., MAP, TPS, O2, crank, cam), actuators (e.g., injectors, ignition coils), emission control systems, and troubleshooting procedures for drivability issues.

Fuel System:

Service and diagnosis of fuel pump, fuel filter, fuel injectors, fuel pressure regulator, fuel lines, and evaporative emission control (EVAP) system.

Cooling System:

Radiator, thermostat, water pump, cooling fan, heater core, and coolant hose replacement and testing. Includes bleed procedures.

Transmission:

Detailed overhaul procedures for both automatic and manual transmissions. Includes gearset inspection, synchronizer replacement, clutch assembly servicing (manual), torque converter inspection (automatic), valve body diagnosis and repair, and transmission fluid replacement procedures.

Drivetrain:

Front axle components, differential inspection and servicing, drive shaft and CV joint replacement, wheel bearing replacement.

Suspension:

Front strut assembly replacement, rear shock absorber replacement, control arm bushings, ball joint inspection and replacement, spring replacement, and wheel alignment specifications.

Steering:

Power steering pump, steering rack, tie rod ends, steering column components, and steering angle sensor diagnostics. Includes fluid level checks and bleed procedures.

Brake System:

Front and rear brake pad and rotor replacement, caliper servicing, brake line inspection and replacement, master cylinder overhaul, brake booster testing, and ABS control module diagnosis.

Electrical System:

Comprehensive wiring diagrams for all circuits, fuse and relay identification and testing, component testing (e.g., alternators, starter motors, ignition switches), battery maintenance, charging system diagnosis, and troubleshooting of electrical faults.

Bodywork:

Door panel removal, mirror replacement, bumper cover removal/installation, headlight/taillight replacement, convertible top operation system diagnosis and repair, including hydraulic and electric components.

Interior:

Seat removal and replacement, dashboard trim panel removal, instrument cluster service, airbag system diagnostic and precautions, seat belt inspection and replacement.

Climate Control:

HVAC system components (blower motor, evaporator, condenser), refrigerant charging procedures, cabin air filter replacement, temperature control panel diagnosis.

Diagnostic Trouble Codes (DTCs):

List of common DTCs, their meaning, and step-by-step troubleshooting procedures for each. Includes OBD-II diagnostic connector location and usage.

Torque Specifications:

Precise torque values for all critical fasteners throughout the vehicle, essential for proper assembly and preventing component damage.

Procedures Included:

Scheduled maintenance, routine inspections, detailed disassembly and reassembly of all major components, engine overhaul, transmission repair, brake system servicing, suspension and steering alignment, electrical troubleshooting, fuel system diagnosis, HVAC system repair, convertible top operation and repair, diagnostic procedures, specific repair steps with torque values, wiring harness repair, component replacement, fluid changes and capacities

Scheduled Maintenance:

Detailed descriptions of all periodic maintenance tasks, including oil and filter changes, fluid level checks and top-ups, tire rotation, brake inspection, and belt condition checks.

Engine Overhaul:

Step-by-step instructions for complete engine disassembly, cleaning, inspection of internal components, reassembly with new seals and gaskets, and critical torquing procedures.

Transmission Repair:

Detailed instructions for removing, disassembling, inspecting, repairing, and reinstalling both the automatic and manual transmissions, including torque converter and clutch replacement.

Electrical Troubleshooting:

Systematic approach to diagnosing electrical faults using wiring diagrams, multimeters, and test procedures. Covers circuits from headlights to the ECU.

Convertible Roof Mechanism:

Specific procedures for diagnosing and repairing issues with the retractable hardtop, including hydraulic systems, motors, sensors, and limit switches.

Diagnostic Procedures:

Methods for diagnosing a wide range of vehicle problems, including drivability issues, starting problems, and performance anomalies, often linked to specific DTCs or symptoms.

Component Replacement:

Clear instructions for replacing individual components such as alternators, starter motors, fuel pumps, radiators, and various sensors.

Wiring Harness Repair:

Guidance on inspecting and repairing damaged wiring harnesses, including connector servicing, wire splicing, and crimping techniques.

Technical Depth:

Comprehensive, suitable for professional technicians and advanced DIY mechanics. Covers everything from basic fluid changes and filter replacements to in-depth engine rebuilds, transmission overhauls, and complex electrical diagnostics. Includes detailed troubleshooting guides and specific repair procedures.

Advanced Diagnostics:

Covers advanced diagnostic techniques using scan tools to monitor live data, perform actuator tests, and interpret complex diagnostic trouble codes for sophisticated fault finding.

Complete Rebuild:

Provides the necessary information for complete engine and transmission rebuilds, including specifications for machining and tolerances for reassembly.

Troubleshooting Guides:

Organized troubleshooting flowcharts and symptom-based diagnostic trees to efficiently identify and resolve common and uncommon problems.

Illustration Quality:

Features detailed illustrations, diagrams, and photographs that clearly depict components and procedures, aiding in accurate identification and execution of repair tasks.

Parts Identification:

Enlarged inset views of critical components and exploded diagrams to facilitate precise identification of parts during disassembly and reassembly.

Electrical Diagrams:

Comprehensive and easy-to-follow wiring diagrams for all electrical systems, allowing for clear tracing of circuits and identification of components.

Numbered Instructions:

Step-by-step numbered instructions ensure a logical and clear process for each repair procedure, minimizing the chance of errors.

Cautions And Warnings:

Incorporates critical notes, cautions, and warnings within each chapter to highlight safety concerns, potential damage, or specific procedural requirements.

Table Of Contents:

A well-organized, numbered table of contents allows for quick and easy navigation to specific sections and repair procedures.

Sub-Step Expansion:

Detailed sub-steps provide further clarity and expand on the primary repair procedure information, ensuring all nuances are covered.

Bold Figure Numbers:

Bolded figure numbers are used to quickly match illustrations with the corresponding steps in the repair procedures.

📊 Manual Specifications

File Format:

PDF

Compatibility:

Compatible with all versions of Windows and Mac operating systems. Requires Adobe PDF Reader and WinRAR for extraction and viewing.

Print Quality:

High-resolution, fully printable. Allows users to print individual pages or the entire document.

Printability:

Full printable. All pages can be printed individually or as a complete document.

Binding Type:

Digital Download (No physical binding)

Delivery Method:

Instant Download. No shipping costs or waiting periods.

Paper Type:

N/A (Digital format)

Storage Options:

Can be saved to a hard drive or burned to CD-ROM for offline access.

⚙️ Engine Specifications

Primary Engine:

1.3L JB-DET Inline-4, Turbocharged and Intercooled, DOHC, 16 Valves

Performance:

Approx. 63 kW (85 hp) @ 6000 rpm, 120 Nm (89 lb-ft) torque @ 3200 rpm (depending on market and specific tuning)

Fuel System:

Electronic Fuel Injection (EFI), Sequential Multi-point Injection

🔧 Transmission

Transmission:

4-speed Automatic

Transmission:

5-speed Manual

Features:

Lock-up torque converter (Automatic), Overdrive gears, Sport mode (Automatic).

📐 Dimensions

Exterior:

Length: 3,395 mm (133.7 in), Width: 1,475 mm (58.1 in), Height: 1,245 mm (49.0 in), Wheelbase: 2,430 mm (95.7 in)

Interior:

Designed for two occupants. Interior space is compact, typical for a small roadster.

Cargo:

Limited trunk space, particularly when the hardtop is retracted. Manual will cover cargo area access and any specific storage solutions.

Weights:

Curb Weight: Approx. 970 kg (2,138 lbs) for automatic, slightly less for manual.

🛡️ Safety Features

Ratings:

Specific independent safety ratings for the 2009 Copen vary by region. Generally, compact cars of this era had moderate safety features.

Active Features:

Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), optional Traction Control System (TCS).

Passive Features:

Front airbags, three-point seat belts with pre-tensioners, reinforced cabin structure for rollover protection, side-impact door beams.

💡 Technology Features

Infotainment:

Typically featured a basic AM/FM radio with CD player, and potentially auxiliary input. Higher trims might have offered upgraded audio systems. Manual will cover head unit removal, speaker replacement, and wiring for audio components.

Driver Assistance:

Limited driver assistance features compared to modern vehicles. Primarily focused on ABS and potentially traction control. The manual will detail the operation and servicing of these systems.

Connectivity:

Basic connectivity through auxiliary input for audio playback. No integrated Bluetooth or USB connectivity typically found in the 2009 model year.

🔧 Maintenance

Service Intervals:

The manual will detail recommended intervals for oil changes (e.g., 5,000-7,500 miles or 6-12 months), filter replacements, spark plugs, transmission fluid changes (e.g., 30,000-60,000 miles), coolant flushes, brake fluid, and timing belt/chain checks. These are generally dictated by mileage or time, whichever comes first.

Fluid Specifications:

Engine Oil: Typically 5W-30 or 0W-20 (synthetic, meeting API SN or equivalent). Transmission Fluid: Automatic Transmission Fluid (ATF) such as Dexron III/VI or equivalent; Manual Transmission Fluid: GL-4 75W-90. Coolant: Pre-mixed ethylene glycol coolant (green or similar color). Brake Fluid: DOT 3 or DOT 4. Power Steering Fluid: Specific hydraulic fluid type as per Daihatsu specifications.

Known Issues:

The manual will address common issues which may include: turbocharger wear, potential for coil pack failure, electrical gremlins in older vehicles, convertible roof mechanism issues (e.g., motor, hydraulic lines), worn suspension components due to spirited driving, and corrosion on older vehicles in certain climates. It will also guide on diagnosing and repairing these.

📚 Vehicle History

Brand Heritage:

Daihatsu, a subsidiary of Toyota, has a long history of producing small, fuel-efficient, and reliable vehicles, often focusing on the kei car segment in Japan but also exporting models globally.

Model Evolution:

The Copen (Code name: K-car project) was first introduced in 2002. The 2009 model represents a facelift or second generation of the original L880K platform, with minor updates to styling, features, and potentially the powertrain for emissions compliance.

Production:

Primarily manufactured in Japan. The Copen was sold in various international markets, including the UK, Australia, and parts of Asia.