Daihatsu Terios J100 Service & Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Model Code: J100 Generation Generation: First Generation (J100) Production Years: 1997-2006 👋 Introduction Market Position Segment: Compact SUV, often marketed as a...

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Description

🏷️ Basic Information

Identification

Make:

Daihatsu

Model:

Terios

Model Code:

Generation

Generation:

First Generation (J100)

Production Years:

1997-2006

👋 Introduction

Market Position

Segment:

Compact SUV, often marketed as a small, capable off-roader.

Target Audience:

Individuals seeking an affordable, durable, and versatile vehicle for urban and light off-road use, often budget-conscious owners.

Competitive Analysis

Competitors:

Suzuki Vitara, Toyota RAV4 (early models), Honda CR-V (early models), Mitsubishi Pajero Mini.

Key Features

Durability:

Known for its robust construction and reliable mechanicals.

Off Road Capability:

Part-time or full-time 4WD systems available, good ground clearance for its class.

Compact Size:

Easy to maneuver and park in urban environments.

📋 Manual Details

Coverage Areas

Coverage Scope:

All workshop procedures, maintenance, repair, diagnostics.

Page Count

Estimated Page Count:

Detailed sections suggest a comprehensive manual, likely exceeding 1000 pages, common for full workshop manuals.

Manual Type

Type:

Service & Repair Manual

Language

Language:

English

Format

Format:

PDF Download

Compatibility

Operating Systems:

All Versions of Windows & Mac

Requirements

Software Requirements:

Adobe PDF Reader

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul procedures, component testing, timing, compression.

Emission Control:

Diagnosis and repair of emissions-related systems, catalytic converter, O2 sensors.

Efi System:

Fuel injection system components, sensors, actuators, control unit diagnosis, fuel pressure.

Lubrication System:

Oil pump, oil filter, oil passages, oil pressure specifications.

Cooling System:

Radiator, water pump, thermostat, coolant specifications, pressure testing.

Ignition System:

Spark plugs, ignition coils, ignition timing, distributor (if applicable), sensor testing.

Starting System:

Starter motor, solenoid, battery testing, charging system interaction.

Charging System:

Alternator, voltage regulator, battery diagnosis, output testing.

Clutch:

Clutch disc, pressure plate, release bearing, hydraulic system, adjustment, bleeding.

Manual Transmission:

Gearbox overhaul, component identification, fluid specifications, shift mechanism.

Automatic Transmission:

ATF specifications, fluid change procedures, torque converter, shift control.

Transmission And Transfer:

Transfer case operation, lubrication, 4WD system components, engagement/disengagement.

Propeller Shaft:

U-joints, driveshaft balance, removal and installation.

Front And Rear Differential:

Differential fluid type, backlash, gear inspection, seal replacement.

Front Axle And Suspension:

CV joints, control arms, ball joints, strut replacement, alignment specifications.

Rear Axle And Suspension:

Shock absorbers, coil springs, trailing arms, alignment specifications.

Brake Including ABS:

Brake pad replacement, rotor resurfacing/replacement, caliper service, ABS sensor diagnosis, hydraulic system.

Steering:

Steering rack, power steering pump, fluid, tie rods, steering column.

Body:

Body panel repair, door mechanisms, glass replacement, interior trim removal.

Body Electrical:

Lighting systems, power windows, central locking, wiper motors, horn.

Harness And Wiring Diagram:

Detailed electrical schematics for all vehicle systems, troubleshooting by circuit.

Procedures Included

Maintenance:

Scheduled maintenance (oil changes, filter replacements, fluid checks), inspections.

Troubleshooting:

Diagnostic charts for common symptoms, fault finding procedures.

Repair:

Step-by-step instructions for component removal, repair, and reinstallation.

Installation:

Instructions for fitting new or replacement parts.

Technical Depth

Depth:

Comprehensive, covering basic DIY maintenance to complex engine and transmission rebuilds, including electrical diagnostics.

📊 Manual Specifications

File Format

Format Details:

PDF, allowing for easy searching, zooming, and printing of specific pages.

Print Quality

Quality:

Digital, with clear diagrams and text, comparable to original factory publications.

Binding Type

Binding:

Not applicable (Digital download)

Paper Type

Paper:

Not applicable (Digital download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

Typically H20A or G16A (depending on market and year)

Engine Type:

Inline 4-cylinder, DOHC, 16-valve

Displacement:

1.6L (1590cc) or 2.0L (1998cc)

Performance

Horsepower:

Approx. 90-115 hp (depending on engine variant and tuning)

Torque:

Approx. 130-170 Nm (depending on engine variant and tuning)

Fuel System

Induction:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Petrol

Technical Details

Bore X Stroke:

Refer to manual for specific engine code (e.g., 80.0 mm x 81.5 mm for H20A)

Compression Ratio:

Refer to manual for specific engine code (e.g., 9.5:1 for H20A)

🔧 Transmission

Standard

Transmission Type:

5-speed Manual Transmission

Optional

Transmission Type:

4-speed Automatic Transmission

Features

Drivetrain:

Selectable 4WD or Full-time 4WD with viscous coupling center differential.

Fluid Specifications

Manual Transmission Fluid:

API GL-4, SAE 75W-90 or 80W-90 (refer to manual for exact specification and capacity)

Automatic Transmission Fluid:

Dexron II/III or equivalent (refer to manual for exact specification and capacity)

Transfer Case Fluid:

API GL-4, SAE 75W-90 or 80W-90 (refer to manual for exact specification and capacity)

Differential Fluid:

API GL-5, SAE 80W-90 (refer to manual for exact specification and capacity)

📐 Dimensions

Exterior

Length:

Approx. 3,745 mm

Width:

Approx. 1,600 mm

Height:

Approx. 1,695 mm

Wheelbase:

Approx. 2,430 mm

Ground Clearance:

Approx. 195 mm (unladen)

Weights

Curb Weight:

Approx. 1,150 - 1,250 kg (depending on configuration)

Gross Vehicle Weight Rating:

Refer to vehicle plate or manual

Cargo

Cargo Volume:

Compact, but versatile with folding rear seats. Exact figures vary, refer to owner's manual.

🛡️ Safety Features

Ratings

Crash Test Ratings:

Likely limited or no official NHTSA/Euro NCAP ratings for this specific older generation and model, refer to specific market data if available.

Active Features

Available on some models/trims.

Passive Features

Airbags:

Driver and passenger airbags typically standard on later models.

Seatbelts:

3-point seatbelts with pretensioners.

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM radio with CD player, potentially cassette tape on early models. Aux input or USB generally not standard.

Driver Assistance

Optional feature, enhancing braking stability.

Connectivity

Connectivity Features:

Limited to basic audio connectivity. No advanced smartphone integration or Bluetooth typically found on this generation.

🔧 Maintenance

Service Intervals

Engine Oil And Filter:

Every 5,000-7,500 miles or 6-12 months, whichever comes first (refer to manual for precise intervals based on driving conditions).

Air Filter:

Inspect every 15,000 miles, replace as needed or every 30,000 miles.

Spark Plugs:

Replace every 30,000-50,000 miles (depending on plug type, consult manual).

Transmission Fluid Change:

Manual: Inspect every 30,000 miles, consider replacement. Automatic: Every 30,000-50,000 miles (refer to manual).

Fluid Specifications

Engine Oil Type:

API SL/SM/SN, SAE 10W-30 or 10W-40 (check manual for specific viscosity and API rating, oil capacity ~3.8-4.0 liters).

Coolant Type:

Ethylene glycol-based, typically a red or pink long-life coolant (refer to manual for specific type and capacity).

Known Issues

Common Problems:

CV joint wear, rear differential leaks, minor electrical issues, potential for aging rubber components (suspension bushings, hoses).

Rust Susceptibility:

Can be susceptible to rust in areas with heavy road salt usage, especially on the chassis and exhaust system.

📚 Vehicle History

Brand Heritage

Daihatsu Specialty:

Daihatsu is known for producing small, reliable, and fuel-efficient vehicles, often with a focus on compact SUVs and kei cars.

Model Evolution

J100 Positioning:

The J100 generation established the Terios nameplate as Daihatsu's entry into the compact SUV market, emphasizing practicality and light off-road ability.

J100 Design Philosophy:

Designed with an emphasis on a ladder-frame chassis for durability and off-road capability, unusual for compact SUVs of its era which increasingly moved to unibody construction.

Production

Manufacturing Locations:

Primarily Japan, with significant production also in Indonesia (as Daihatsu Taruna) and licensed production in other countries.