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DAIHATSU TERIOS Service Repair Manual 97-05

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The Daihatsu Terios is a compact SUV renowned for its blend of affordability, surprising off-road capability, and practical design. Produced between 1997 and 2005, this versatile vehicle, identified by chassis...
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DAIHATSU TERIOS Service Repair Manual 97-05
The Daihatsu Terios is a compact SUV renowned for its blend of affordability, surprising off-road capability, and practical design. Produced between 1997 and 2005, this versatile vehicle, identified by chassis codes such as J100G and J102G, offered both 3-door and 5-door body styles. It was engineered with a body-on-frame construction in earlier models and available with rear-wheel drive or robust four-wheel drive systems, often including low-range gearing, making it a capable choice for light off-roading and general utility. Powered by efficient inline 4-cylinder engines ranging from 1.3L to 1.5L, the Terios provided a balanced performance profile suitable for both urban commuting and more adventurous excursions, cementing its reputation as a reliable and economical compact utility vehicle. This comprehensive Service and Repair Manual in English provides detailed, step-by-step procedures for the maintenance, diagnosis, and repair of the Daihatsu Terios. It covers all major vehicle systems, including the powertrain, drivetrain, suspension, steering, brakes, and electrical systems, along with HVAC and body components. The manual offers in-depth technical specifications, rebuilding instructions, troubleshooting guides, and essential safety information. Its detailed content, including precise torque values and wiring diagrams, is designed to empower owners, mechanics, and technicians to effectively maintain and restore the vehicle, ensuring its longevity and optimal performance.
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Terios
Generation:
First Generation (J100/J122/J131)
Years Covered:
1997-2005
Codes
Chassis Codes:
J100G, J102G, J122G, J131G
👋 Introduction
Market Position
Vehicle Segment:
Compact SUV / Off-roader
Target Audience:
Individuals seeking an affordable, capable, and compact utility vehicle for light off-roading and urban driving
Competitive Analysis
Key Competitors:
Suzuki Vitara, Mitsubishi Pajero Mini, Toyota RAV4 (early models), Honda CR-V (early models)
Competitive Advantage:
Compact size, genuine four-wheel drive capability, reliability, fuel efficiency for its class, affordability
Key Features
Body Style:
3-door and 5-door SUV
Drivetrain Options:
Rear-wheel drive (RWD) and Selectable/Full-time four-wheel drive (4WD)
Off Road Capability:
Body-on-frame construction (early models), independent front suspension, solid rear axle (often), low-range gearing (on some 4WD models) providing respectable off-road prowess for its size
📋 Manual Details
Coverage Areas
Manual Type:
Service and Repair Manual
Language:
English
Format:
PDF
Page Count:
Hundreds (specific count not provided, but implies comprehensive)
Documentation Style:
Detailed, step-by-step procedures
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, cooling system, lubrication system, exhaust system, emission control systems
Drivetrain:
Manual transmission, automatic transmission, transfer case, differentials, driveshafts, CV joints, wheel hubs
Suspension And Steering:
Front suspension, rear suspension, steering gear, power steering system, wheel alignment
Brakes:
Front and rear brake systems (disc/drum), parking brake, ABS (if equipped)
Electrical System:
Battery, charging system, starting system, lighting, instruments and gauges, wipers and washers, horn, power accessories, wiring diagrams
Body And Chassis:
Body construction, exterior panels, doors, windows, interior trim, seats, chassis components, structural integrity
HVAC:
Heating, ventilation, and air conditioning systems
Diagnostic Troubleshooting:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting charts
Procedures Included
Maintenance:
Routine maintenance checks, oil changes, fluid level checks, filter replacements, spark plug replacement, brake pad replacement
Repair:
Engine rebuild procedures, transmission overhaul, brake caliper service, suspension component replacement, electrical component diagnosis and repair, body panel repair
Rebuilding:
Detailed instructions for rebuilding major components like engines, transmissions, and differentials
Refurbishment:
Guidance on restoring worn or damaged components and systems
Restoration:
Advice on bringing the vehicle back to original specifications
Troubleshooting:
Systematic approaches to diagnosing and resolving mechanical and electrical issues
Technical Depth
Diagnostic Capabilities:
Advanced diagnostic procedures, including interpretation of sensor data and fault codes
Rebuilding Specifications:
Precision specifications for component clearances, torque values, and assembly sequences
Wiring Diagrams:
Comprehensive and detailed electrical wiring schematics for all systems
Special Tools:
Identification of required special tools and equipment for specific repair procedures
Torque Specifications:
Precise torque values for all fasteners across all vehicle systems
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Likely text-searchable, enabling quick navigation to specific topics
Printability:
Designed to be printable for workshop use
Image Quality:
High-resolution images, diagrams, and illustrations
Print Quality
Illustration Detail:
Detailed, clear diagrams for component identification and assembly
Text Clarity:
Legible text for easy reading of procedures and specifications
Binding Type
Digital Format:
N/A (Digital PDF)
Paper Type
Digital Format:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Codes:
G13BB, G13A, G15A, 3SZ-VE (later models within the range, though less common in early '97)
Engine Type:
Inline 4-cylinder, SOHC/DOHC, naturally aspirated
Displacement:
1.3L (1298cc), 1.5L (1498cc), 1.3L (1298cc - 3SZ-VE)
Performance
Horsepower:
Approx. 70-85 HP (for 1.3L), Approx. 90-97 HP (for 1.5L), Approx. 86 HP (for 3SZ-VE)
Torque:
Approx. 100-115 Nm (for 1.3L), Approx. 120-130 Nm (for 1.5L), Approx. 114 Nm (for 3SZ-VE)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Engine Management
ECU Type:
Engine Control Unit (ECU) based fuel and ignition management
🔧 Transmission
Standard
Transmission Type Std:
5-speed manual transmission
Optional
Transmission Type Opt:
4-speed automatic transmission
Features
Transfer Case:
Selectable 2WD/4WD or Full-time 4WD with low-range gearing on many 4WD models
Gear Ratios:
Specific gear ratios for manual and automatic transmissions are detailed within the manual.
Maintenance
Fluid Type Manual:
API GL-4, SAE 75W-90 (typically, specific part numbers will be in the manual)
Fluid Type Automatic:
Dexron III or equivalent (typically, specific part numbers will be in the manual)
📐 Dimensions
Exterior
Length:
Approx. 3,710 mm (5-door), Approx. 3,735 mm (3-door with spare tire)
Width:
Approx. 1,590 - 1,600 mm
Height:
Approx. 1,640 - 1,700 mm (depending on roof rails and tire size)
Wheelbase:
Approx. 2,430 mm
Ground Clearance:
Approx. 195 - 200 mm
Weights
Curb Weight:
Approx. 1,000 - 1,150 kg
Gross Vehicle Weight:
Varies by model and configuration, typically around 1,500 kg
🛡️ Safety Features
Ratings
Crash Test Data:
Limited official crash test data available for this generation and market; refer to manual for vehicle-specific safety features.
Active Features
ABS:
Available on certain higher trim levels or optional
Traction Control:
Generally not available on this generation
Passive Features
Airbags:
Driver and passenger airbags typically standard on later models or optional on earlier ones.
Seatbelts:
Three-point seatbelts with pretensioners (front seats), two-point or three-point (rear seats)
Body Structure:
Reinforced safety cell, crumple zones designed to absorb impact energy
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette or CD players, often with basic speaker configurations.
Navigation:
Not typically available on this generation; aftermarket solutions would be required.
Driver Assistance
Cruise Control:
Available on some higher trim levels or as an aftermarket option.
Connectivity
Bluetooth:
Not available from factory; aftermarket installation required.
Usb Ports:
Not available from factory; aftermarket installation required.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000 - 10,000 km or 6-12 months, depending on driving conditions and oil type (refer to manual for exact specification).
Air Filter Replacement:
Recommended every 20,000 - 30,000 km or as needed based on inspection.
Spark Plug Replacement:
Typically 30,000 - 60,000 km for standard plugs, longer for iridium/platinum (refer to manual).
Coolant Change:
Recommended every 40,000 - 60,000 km or every 2-3 years.
Fluid Specifications
Engine Oil Type:
Refer to manual; typically SAE 10W-30 or 10W-40 for gasoline engines.
Coolant Type:
Ethylene glycol-based, Japanese equivalent coolant (e.g., Toyota Super Long Life Coolant).
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for exact specification and change interval).
Known Issues
Common Wear Items:
CV boots, suspension bushings, clutch wear (on manual transmissions), exhaust system rust (depending on climate).
Engine Minor Concerns:
Potential for minor oil leaks from gaskets or seals with age and mileage.
Transmission Quirks:
Occasional stiffness in manual gear changes; automatic transmission may exhibit hesitant shifting with age.
Electrical Issues:
Corrosion on connectors, minor issues with door lock actuators or power windows on higher mileage vehicles.
📚 Vehicle History
Brand Heritage
Daihatsu Legacy:
Daihatsu, a subsidiary of Toyota, has a long history of producing small, reliable, and fuel-efficient vehicles, often specializing in kei cars and compact utility vehicles.
Model Evolution
Terios Introduction:
The Daihatsu Terios was first introduced in 1997 as a compact SUV designed to offer genuine off-road capabilities in a smaller, more manageable package.
Generations:
This manual covers the first generation (J100/J122/J131), which was produced from 1997 to 2006. It was succeeded by the second generation (J200) in 2006.
Rebadging:
In some markets, the first-generation Terios was rebadged as the Toyota Terios, benefiting from Toyota's extensive global sales network.
Production
Manufacturing Location:
Primarily manufactured in Japan, with potential assembly in other countries depending on the market.
🏆 Awards & Recognition
Recognitions
Market Reputation:
Praised for its value proposition, affordability, and surprising off-road capability for its class.
Owner Satisfaction:
Generally good owner satisfaction due to its reliability and low running costs, particularly in markets where it was popular.
Certifications
Emission Standards:
Meets Japanese emission standards for the respective model years.
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