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2008 Daihatsu Boon (2nd gen) Service and Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Boon Generation Generation Designation: 2nd Generation Generation Years: 2004-2010 Codes Chassis Code: M300 Series 👋 Introduction Market Position Segment: Subcompact car, city car Target Audience: First-time car buyers, urban commuters, budget-conscious consumers Competitive Analysis Key Competitors: Toyota Yaris, Honda Fit, Suzuki Swift, Nissan March (Micra), Mazda Demio (2) Key Features Of Manual Authenticity: Exact same manual used by dealership technicians Usability: Easy-to-use PDF format, no need to flip through multiple books, print-on-demand Content Detail: Complete step-by-step instructions, diagrams, illustrations, wiring schematics, and specifications Durability Of Manual: Protects original manual from grease and tears by printing only necessary pages 📋 Manual Details Coverage Areas Covered Models: All Daihatsu Boon (2nd gen) models Coverage Scope: All repairs A-Z Page Count Estimated Page Count: Extensive (specific number not provided, but implied to be comprehensive) Manual Type Type: Factory Service and Repair Manual Language Language: English Format Digital Format: PDF File Compatibility: Windows Vista (32/64-bit), XP, ME, 98, NT, 2000, macOS 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, internal components, pistons, rings, bearings, crankshaft, camshaft, cylinder head, valves, timing system Engine Control: Engine control module (ECM) diagnostics, sensor operation, fuel injection system, ignition system, emission control systems Fuel System: Fuel pump, fuel injectors, fuel filter, fuel tank, fuel pressure regulation, fuel service specifications Emission Control: Exhaust gas recirculation (EGR), catalytic converter, evaporative emission control (EVAP) system, oxygen sensors, compliance with emissions standards Intake Exhaust Cooling: Intake manifold, throttle body, exhaust system, radiator, cooling fan, thermostat, water pump, coolant specifications Lubrication: Oil pump, oil filter, oil passages, oil specifications, oil change procedures Ignition Starting Charging: Spark plugs, ignition coils, starter motor, alternator, battery, charging system diagnostics, specifications Automatic Transmission: Automatic transmission overhaul, fluid specifications, torque converter, shift solenoids, transmission control module (TCM) diagnostics Manual Transmission: Manual transmission overhaul, clutch assembly, gear sets, shift linkage, transmission fluid specifications Drivetrain: Transfer case, propeller shaft, drive shafts, CV joints, differential (front and rear), axle shafts, gear ratios Suspension Steering: Front and rear suspension components (struts, shocks, control arms, bushings), steering column, power steering system, rack and pinion, steering fluid specifications Brakes: Brake system diagnostics, disc brakes (pads, rotors), drum brakes, anti-lock braking system (ABS), brake fluid specifications, hydraulic system repair Parking Brake: Parking brake mechanism, cable adjustment, brake shoe adjustment (if applicable) Wheels Tires: Tire pressure monitoring system (TPMS), wheel bearing replacement, tire size specifications, wheel bolt pattern Climate Control: Air conditioning system service, refrigerant types, compressor, evaporator, condenser, heater core, cabin air filter replacement Restraint Systems: Supplemental Restraint System (SRS), airbags, seat belt pre-tensioners, SRS module diagnostics and replacement Immobilizer Security: Engine immobilizer system diagnostics, key programming Cruise Control: Cruise control system operation, diagnostics, actuator testing Wipers Washers: Wiper motor, wiper linkage, washer pump, washer fluid reservoir, wiper blade replacement Doors Locks: Door lock mechanisms, power door locks, remote keyless entry system, door hinge lubrication, door panel removal Lighting Signals: Headlights, taillights, turn signals, interior lighting, bulb replacement, wiring schematics for lighting Instrument Panel Gauges: Instrument cluster removal and installation, gauge diagnostics, warning lights explanation, meter lighting Audio Visual: Radio/infotainment system service, speaker replacement, antenna system Body Exterior: Engine hood, doors, bumpers, body panel alignment, trim removal and installation, exterior mirror replacement Body Interior: Seat removal and installation, interior trim panels, headliner, floor coverings, dashboard removal Electrical System: Complete electrical system overview, battery, alternator, starter, fuses, relays, lighting circuits, power windows, power seats Multiplex Can Communication: CAN bus system diagnostics, multiplex communication network troubleshooting, module communication Procedures Included Maintenance Procedures: Oil and filter changes, fluid checks and top-offs, tire rotations, brake inspections, tune-up procedures Diagnostic Procedures: Troubleshooting guides for common symptoms, fault code retrieval and interpretation, diagnostic tool usage Repair Procedures: Step-by-step instructions for component removal, installation, and adjustment across all vehicle systems Wiring Schematics: Detailed wiring diagrams for all electrical systems, including component locations and connector pinouts Specifications: Torque specifications for fasteners, fluid capacities, performance data, dimensional data Technical Depth Depth Of Coverage: Vehicle specific, technician-level detail Diagnostic Capability: Advanced diagnostics, including troubleshooting electrical faults, engine performance issues, and transmission problems Rebuild Procedures: Complete rebuild instructions for major components like engines and transmissions 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable due to PDF format, facilitating quick information retrieval Print Quality Printability: All pages are printable Zoom Capability: Images can be blown up for enlarged viewing and printing Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Quality: N/A (Digital PDF format, allows for printing on desired paper) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 3-cylinder / Inline 4-cylinder petrol engines Displacement: Commonly 1.0L (K3-VE) and 1.3L (1KR-FE) for early 2nd gen, later models may have updated engine codes or variants Performance Horsepower Range: Approximately 65-90 PS (48-66 kW) depending on engine and market Torque Range: Approximately 90-120 Nm depending on...
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2008 Daihatsu Boon (2nd gen) Service and Repair Manual
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Boon
Generation
Generation Designation:
2nd Generation
Generation Years:
2004-2010
Codes
Chassis Code:
M300 Series
👋 Introduction
Market Position
Segment:
Subcompact car, city car
Target Audience:
First-time car buyers, urban commuters, budget-conscious consumers
Competitive Analysis
Key Competitors:
Toyota Yaris, Honda Fit, Suzuki Swift, Nissan March (Micra), Mazda Demio (2)
Key Features Of Manual
Authenticity:
Exact same manual used by dealership technicians
Usability:
Easy-to-use PDF format, no need to flip through multiple books, print-on-demand
Content Detail:
Complete step-by-step instructions, diagrams, illustrations, wiring schematics, and specifications
Durability Of Manual:
Protects original manual from grease and tears by printing only necessary pages
📋 Manual Details
Coverage Areas
Covered Models:
All Daihatsu Boon (2nd gen) models
Coverage Scope:
All repairs A-Z
Page Count
Estimated Page Count:
Extensive (specific number not provided, but implied to be comprehensive)
Manual Type
Type:
Factory Service and Repair Manual
Language
Language:
English
Format
Digital Format:
PDF
File Compatibility:
Windows Vista (32/64-bit), XP, ME, 98, NT, 2000, macOS
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete engine overhaul, internal components, pistons, rings, bearings, crankshaft, camshaft, cylinder head, valves, timing system
Engine Control:
Engine control module (ECM) diagnostics, sensor operation, fuel injection system, ignition system, emission control systems
Fuel System:
Fuel pump, fuel injectors, fuel filter, fuel tank, fuel pressure regulation, fuel service specifications
Emission Control:
Exhaust gas recirculation (EGR), catalytic converter, evaporative emission control (EVAP) system, oxygen sensors, compliance with emissions standards
Intake Exhaust Cooling:
Intake manifold, throttle body, exhaust system, radiator, cooling fan, thermostat, water pump, coolant specifications
Lubrication:
Oil pump, oil filter, oil passages, oil specifications, oil change procedures
Ignition Starting Charging:
Spark plugs, ignition coils, starter motor, alternator, battery, charging system diagnostics, specifications
Automatic Transmission:
Automatic transmission overhaul, fluid specifications, torque converter, shift solenoids, transmission control module (TCM) diagnostics
Manual Transmission:
Manual transmission overhaul, clutch assembly, gear sets, shift linkage, transmission fluid specifications
Drivetrain:
Transfer case, propeller shaft, drive shafts, CV joints, differential (front and rear), axle shafts, gear ratios
Suspension Steering:
Front and rear suspension components (struts, shocks, control arms, bushings), steering column, power steering system, rack and pinion, steering fluid specifications
Brakes:
Brake system diagnostics, disc brakes (pads, rotors), drum brakes, anti-lock braking system (ABS), brake fluid specifications, hydraulic system repair
Parking Brake:
Parking brake mechanism, cable adjustment, brake shoe adjustment (if applicable)
Wheels Tires:
Tire pressure monitoring system (TPMS), wheel bearing replacement, tire size specifications, wheel bolt pattern
Climate Control:
Air conditioning system service, refrigerant types, compressor, evaporator, condenser, heater core, cabin air filter replacement
Restraint Systems:
Supplemental Restraint System (SRS), airbags, seat belt pre-tensioners, SRS module diagnostics and replacement
Immobilizer Security:
Engine immobilizer system diagnostics, key programming
Cruise Control:
Cruise control system operation, diagnostics, actuator testing
Wipers Washers:
Wiper motor, wiper linkage, washer pump, washer fluid reservoir, wiper blade replacement
Doors Locks:
Door lock mechanisms, power door locks, remote keyless entry system, door hinge lubrication, door panel removal
Lighting Signals:
Headlights, taillights, turn signals, interior lighting, bulb replacement, wiring schematics for lighting
Instrument Panel Gauges:
Instrument cluster removal and installation, gauge diagnostics, warning lights explanation, meter lighting
Audio Visual:
Radio/infotainment system service, speaker replacement, antenna system
Body Exterior:
Engine hood, doors, bumpers, body panel alignment, trim removal and installation, exterior mirror replacement
Body Interior:
Seat removal and installation, interior trim panels, headliner, floor coverings, dashboard removal
Electrical System:
Complete electrical system overview, battery, alternator, starter, fuses, relays, lighting circuits, power windows, power seats
Multiplex Can Communication:
CAN bus system diagnostics, multiplex communication network troubleshooting, module communication
Procedures Included
Maintenance Procedures:
Oil and filter changes, fluid checks and top-offs, tire rotations, brake inspections, tune-up procedures
Diagnostic Procedures:
Troubleshooting guides for common symptoms, fault code retrieval and interpretation, diagnostic tool usage
Repair Procedures:
Step-by-step instructions for component removal, installation, and adjustment across all vehicle systems
Wiring Schematics:
Detailed wiring diagrams for all electrical systems, including component locations and connector pinouts
Specifications:
Torque specifications for fasteners, fluid capacities, performance data, dimensional data
Technical Depth
Depth Of Coverage:
Vehicle specific, technician-level detail
Diagnostic Capability:
Advanced diagnostics, including troubleshooting electrical faults, engine performance issues, and transmission problems
Rebuild Procedures:
Complete rebuild instructions for major components like engines and transmissions
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable due to PDF format, facilitating quick information retrieval
Print Quality
Printability:
All pages are printable
Zoom Capability:
Images can be blown up for enlarged viewing and printing
Binding Type
Binding:
N/A (Digital PDF format)
Paper Type
Paper Quality:
N/A (Digital PDF format, allows for printing on desired paper)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 3-cylinder / Inline 4-cylinder petrol engines
Displacement:
Commonly 1.0L (K3-VE) and 1.3L (1KR-FE) for early 2nd gen, later models may have updated engine codes or variants
Performance
Horsepower Range:
Approximately 65-90 PS (48-66 kW) depending on engine and market
Torque Range:
Approximately 90-120 Nm depending on engine and market
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline
🔧 Transmission
Standard
Transmission Type Standard:
Continuously Variable Transmission (CVT) or 4-speed Automatic Transmission
Optional
Transmission Type Optional:
5-speed Manual Transmission
Features
Transmission Features:
Front-wheel drive (FWD) or optional All-wheel drive (AWD)
📐 Dimensions
Exterior
Length:
Approximately 3620 mm
Width:
Approximately 1665 mm
Height:
Approximately 1550 mm
Wheelbase:
Approximately 2430 mm
Weights
Curb Weight:
Approximately 900-1000 kg depending on configuration
🛡️ Safety Features
Ratings
Crash Test Ratings:
Varies by region and testing authority; generally aimed at achieving good ratings in its class.
Active Features
Active Safety:
Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Brake Assist (BA)
Passive Features
Passive Safety:
Driver and front passenger airbags, side airbags (optional), curtain airbags (optional), seat belt pretensioners, energy-absorbing steering column
💡 Technology Features
Infotainment
Infotainment System:
Basic AM/FM/CD audio systems, optional navigation systems available on higher trims or as dealer options.
Driver Assistance
Driver Assistance Features:
ABS, EBD, Brake Assist. Limited availability of more advanced driver-assistance systems in this segment and era.
Connectivity
Connectivity Options:
Auxiliary audio input, Bluetooth connectivity might be available on later models or higher trims.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 - 10,000 km or 6-12 months, depending on driving conditions and oil type (refer to manual for specific intervals)
Air Filter Replacement:
Typically every 20,000 - 30,000 km or annually
Spark Plug Replacement:
Varies by spark plug type; iridium or platinum plugs often have longer intervals (e.g., 60,000 - 100,000 km)
Fluid Specifications
Engine Oil Specification:
API SG, SH, SJ or ACEA A1/B1, A3/B3; viscosity grades like 0W-20, 5W-30, or 10W-40 (refer to manual for exact specification)
Transmission Fluid Automatic:
Dexron III, Dexron VI, or equivalent CVT fluid (refer to manual for exact specification and capacity)
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid
Coolant Specification:
Ethylene glycol-based antifreeze, typically a pink or red long-life coolant (refer to manual for specific type and capacity)
Known Issues
Common Wear Items:
Brake pads and rotors, suspension bushings, exhaust components, battery, tires
Potential Engine Issues:
Minor oil leaks, potential for carbon buildup in older engines, normal wear on timing components
Potential Transmission Issues:
CVT belt wear over high mileage, automatic transmission solenoid issues
📚 Vehicle History
Brand Heritage
Brand Focus:
Daihatsu is a Japanese automobile manufacturer with a long history, specializing in small, fuel-efficient vehicles.
Model Evolution
Generation Overview:
The 2nd generation Boon (also sold as Toyota Passo in many markets) was a significant update, offering improved styling, interior space, and powertrain options. It continued the focus on practicality and affordability.
Production
Manufacturing Location:
Primarily Japan
🏆 Awards & Recognition
Recognitions
Awards And Accolades:
The Daihatsu Boon/Toyota Passo has often been recognized for its fuel efficiency and compact size in its respective markets.
Ratings
Fuel Economy Ratings:
Generally excellent fuel economy, often a strong selling point in the subcompact segment.
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