Vehicle Segment:
Kei car segment (Japan), subcompact sports convertible globally.
Target Audience:
Enthusiasts, owners seeking to maintain or restore their vehicle, DIY mechanics.
Key Competitors:
Honda Beat (previous generation), Suzuki Cappuccino (previous generation), later Mazda MX-5 Miata (though larger and different segment).
Unique Selling Proposition:
Compact, stylish, affordable convertible with a turbocharged engine and a unique power retractable hardtop.
Manual Value Proposition:
Provides comprehensive, professional-grade repair information, enabling owners to perform maintenance and repairs efficiently and accurately, saving on labor costs and ensuring longevity.
Years Covered:
2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012
Regions Covered:
Primarily Japan (JDM), but applicable to all markets where this generation was sold or imported
Model Variants Covered:
All variants equipped with the JB-DET engine and relevant transmissions for the specified years.
Estimated Page Count:
Likely over 1000 pages (typical for a comprehensive workshop manual of this scope)
Manual Type:
Workshop Repair Service Manual
Language:
English (Assumed, based on product description of universal compatibility and widespread use)
Format:
Digital Downloadable PDF
Powertrain:
Engine Mechanical (block, head, pistons, crankshaft), Engine Lubrication, Engine Cooling, Engine Control System (ECU, sensors, actuators), Fuel System (injectors, pump, lines), Exhaust System
Drivetrain:
Clutch System, Manual Transaxle (gearbox), Automatic Transaxle, Front Axle, Rear Axle, Driveshafts, CV Joints
Suspension Steering Brakes:
Front Suspension (struts, control arms), Rear Suspension (multi-link), Road Wheels & Tires, Brake System (discs, calipers, lines), Parking Brake System, Brake Control Systems (ABS), Power Steering System, Steering System (rack and pinion)
Body Restraints:
Body Structure, Lock & Security System, Glasses, Window System & Mirrors, Roof Mechanism (power retractable hardtop), Exterior & Interior Trim, Instrument Panel, Seats, Seat Belts, Supplemental Restraint System (SRS/Airbags)
Electrical Climate:
Wiring Diagrams, Starting & Charging System (alternator, starter), Lighting System (headlights, taillights), Driver Information System (gauges, warning lights), Wiper, Washer & Horn, Body Control System (ECU functions), LAN System, Audio Visual, Navigation & Telephone System, Auto Cruise Control System, Power Supply, Ground & Circuit Elements, Air Conditioner System
Repair Maintenance:
Detailed step-by-step repair and maintenance procedures for all covered systems, including diagnostics, disassembly, assembly, adjustment, and replacement.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting guides for common and uncommon issues.
Technical Data:
Specifications, torque values, clearances, fluid capacities, component identification, and electrical resistance/voltage values.
Maintenance Schedules:
Recommended maintenance intervals for routine services (oil changes, filter replacements, etc.).
Depth Of Coverage:
Comprehensive from basic maintenance to advanced diagnostics and major component rebuilds. Suitable for professional technicians and experienced DIY enthusiasts.
Engine Type:
Inline 3-cylinder, DOHC, 12-valve, turbocharged, intercooled petrol.
Displacement:
659 cc (0.7 L)
Horsepower:
64 PS (47 kW; 63 hp) @ 6400 rpm (JDM regulated output)
Torque:
10.5 kg⋅m (103 N⋅m; 76 lb⋅ft) @ 3200 rpm
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (Octane rating as per market/manufacturer recommendation, typically 95 RON or higher for optimal performance)
ECU Type:
Electronic Control Unit (specific model varies by year/market, but generally Denso or Hitachi based)
Transmission Type Standard:
5-speed Manual Transaxle
Transmission Type Optional:
4-speed Automatic Transaxle
Drive Layout:
Front-engine, Front-wheel drive (FF)
Clutch Type:
Dry, single-plate, diaphragm spring clutch (for manual transmission)
Crash Test Ratings:
Specific official crash test ratings (e.g., NHTSA, Euro NCAP) are limited due to its JDM focus and niche market. Generally designed to meet Japanese safety standards of the era.
Active Safety Features:
Optional ABS (Anti-lock Braking System), Power Assisted Brakes.
Passive Safety Features:
Front airbags (driver and passenger), Seatbelts with pre-tensioners, Reinforced chassis structure for convertible safety.
Infotainment Features:
Basic AM/FM radio, CD player, and optional navigation systems were available. Speaker quality and screen size were typical for the era.
Driver Assistance Systems:
Limited by modern standards. Primarily ABS (optional) and power steering. No advanced driver-assistance systems (ADAS) like adaptive cruise control or lane keeping assist.
Connectivity Options:
Early Bluetooth phone integration might have been optional on later models. Primarily focused on basic audio and driver controls.
Oil Change Interval:
Typically every 5,000-10,000 km or 6-12 months, depending on driving conditions (refer to manual for exact specification).
Spark Plug Replacement:
Refer to manual; generally around 40,000-60,000 km for standard plugs, or 80,000-100,000 km for long-life iridium plugs (if fitted).
Engine Oil Type:
Refer to manual for viscosity (e.g., 5W-30 or 0W-20 depending on climate) and API/ACEA specifications. Typically a synthetic or semi-synthetic blend is recommended for turbocharged engines.
Coolant Type:
Ethylene Glycol-based antifreeze, mixed with distilled water (typically 50/50 ratio). Use of Toyota Super Long Life Coolant (SLLC) or equivalent is recommended.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (check manual for specific recommendation).
Transmission Fluid Manual:
API GL-4 gear oil, viscosity typically 75W-90.
Transmission Fluid Automatic:
Dexron II/III or equivalent ATF (Automatic Transmission Fluid). Check manual for exact specification.
Common Wear Items:
Turbocharger seals (oil leaks), suspension bushings, brake components, convertible roof mechanism wear and seals.
Engine Specific Concerns:
Oil consumption due to turbocharger wear, potential for carbon buildup in turbocharged engines if not maintained properly.
Daihatsu Specialization:
Daihatsu, a subsidiary of Toyota, has a long history of producing small, fuel-efficient vehicles, often excelling in the Kei car segment.
Copen Concept:
The Copen was developed as a stylish and fun 'sporty Kei car' focusing on open-top driving enjoyment. It evolved from concepts shown in previous Tokyo Motor Shows.
Production Period:
First generation produced from 2002 to 2012.
Manufacturing Location:
Japan
