Daihatsu Copen 2002-2012 Workshop Service Manual Repair
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🏷️ Basic Information Identification Make: Daihatsu Model: Copen Model Generation: First Generation (L880K) Model Years Covered: 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012 👋 Introduction Market Position Vehicle Segment: Kei car convertible, micro sports car Niche Appeal: Unique offering in the automotive market, known for its compact size, sporty design, and retractable hardtop. Competitive Analysis Competitors: Limited direct competitors due to its specific segment. Mazda MX-5 Miata (MX-5) as a spiritual competitor in the small, affordable sports car category. Key Features Convertible Top: Electrically operated retractable hardtop, providing coupe-like security and convertible freedom. Design: Distinctive and playful styling, compact dimensions, and agile handling. Value Proposition Diy Support: Empowers owners to perform maintenance and repairs, saving on labor costs and fostering a deeper connection with their vehicle. Professional Tool: Serves as a vital resource for professional mechanics and dealership service departments. 📋 Manual Details Coverage Areas Primary Coverage: Workshop Service and Repair Secondary Coverage: Routine Maintenance, Troubleshooting, Overhaul Procedures, Wiring Diagrams Page Count Estimated Page Count: Hundreds of pages (specific count not provided, but indicative of comprehensive factory manual) Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English Format Delivery Method: Instant Download 📖 Manual Coverage Systems Covered Engine: Detailed information on engine mechanicals, cooling system, lubrication system, fuel system, ignition system, emissions control. Transmission: Coverage for manual and automatic transmission systems, including operation, maintenance, and repair procedures. Drivetrain: Information on driveshafts, differentials, and related components. Suspension And Steering: Details on front and rear suspension systems, shock absorbers, springs, steering rack, power steering. Brakes: Comprehensive coverage of the braking system, including hydraulic components, ABS, brake pad/disc replacement, and bleeding procedures. Electrical System: Extensive wiring diagrams, component locations, diagnostic procedures for lighting, starting/charging systems, power distribution, and body electronics. Body And Chassis: Information on body panels, doors, convertible roof mechanism, interior trim, chassis components, and corrosion protection. Comfort And Convenience: Details on HVAC system, power windows, power locks, audio systems, and other interior features. Procedures Included Maintenance: Periodic maintenance charts, fluid level checks, filter replacements, spark plug replacement, belt inspections/replacement. Diagnostics: Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs) if applicable, systematic problem-solving steps. Repair: Step-by-step repair instructions for virtually all vehicle systems, from minor adjustments to major component overhauls. Overhaul: Detailed procedures for complete engine rebuilds, transmission overhauls, and other complex component refurbishments. Specifications And Tolerances: Critical torque values, clearances, and measurement specifications for all mechanical components. Technical Depth Depth: Comprehensive, suitable for professional technicians, with sufficient detail for advanced DIY mechanics. Scope: Covers factory-level repair procedures, diagnostics, and specifications. 📊 Manual Specifications File Format Format: PDF Readability: Searchable text, allowing for quick information retrieval. Print Quality Printable: Yes, full printable functionality. Zoom Capability: Yes, zoom IN/OUT functionality for detailed viewing of diagrams and text. Binding Type Binding: Digital (PDF download) Paper Type Paper Type Analogy: N/A (digital format) Compatibility Operating Systems: Compatible with all versions of Windows & Mac Requirements Software Requirements: Adobe PDF Reader & WinRAR ⚙️ Engine Specifications Primary Engine Engine Code: JB-DET Engine Type: 659cc (0.7L) Inline 3-cylinder, turbocharged, intercooled, DOHC, 12-valve Bore X Stroke: 64.0 mm x 68.3 mm Compression Ratio: 8.5:1 Horsepower Ps: 64 PS (47 kW; 63 hp) at 6400 rpm (SAE Net) Torque Nm: 10.5 kg⋅m (103 N⋅m; 76 lb⋅ft) at 3200 rpm (SAE Net) Performance Redline: Approx. 7,000 rpm (refer to manual for precise value) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline Recommended Octane: 91 AKI or higher (refer to manual for exact recommendation) Engine Management ECU: Engine Control Unit (ECU) with diagnostic capabilities. 🔧 Transmission Standard Type: 5-speed Manual Transmission Optional Type: 4-speed Automatic Transmission Features Clutch Type: Hydraulically operated, dry single plate clutch (for manual transmission) Transmission Fluid Type Manual: API GL-4, SAE 75W-90 (manual, consult manual for exact spec) Transmission Fluid Type Auto: Dexron III or equivalent (automatic, consult manual for exact spec) 📐 Dimensions Exterior Length: Approx. 3,395 mm (133.7 in) Width: Approx. 1,475 mm (58.1 in) Height: Approx. 1,245 mm (49.0 in) (roof up) Wheelbase: Approx. 2,280 mm (89.8 in) Ground Clearance: Approx. 140 mm (5.5 in) Weights Curb Weight: Approx. 830-850 kg (1830-1874 lb), depending on transmission and equipment Gross Vehicle Weight Rating: Not readily available, consult manual for specific payload. Interior Seating Capacity: 2-seater convertible Cargo Trunk Volume: Very limited, typically less than 100 liters with roof stowed. 🛡️ Safety Features Ratings Crash Test Results: As a Kei car, it undergoes different safety standards than larger vehicles. Specific independent crash test ratings are limited; refer to JNCAP for Japanese market data. Active Features ABS: Anti-lock Braking System (ABS) available on some models/trims. Traction Control: Traction Control System (TCS) may be available on higher trims. Passive Features Airbags: Driver and front passenger airbags. Rollover Protection: Reinforced A-pillars and roll bar integrated behind the...
Unique offering in the automotive market, known for its compact size, sporty design, and retractable hardtop.
Competitive Analysis
Competitors:
Limited direct competitors due to its specific segment. Mazda MX-5 Miata (MX-5) as a spiritual competitor in the small, affordable sports car category.
Key Features
Convertible Top:
Electrically operated retractable hardtop, providing coupe-like security and convertible freedom.
Design:
Distinctive and playful styling, compact dimensions, and agile handling.
Value Proposition
Diy Support:
Empowers owners to perform maintenance and repairs, saving on labor costs and fostering a deeper connection with their vehicle.
Professional Tool:
Serves as a vital resource for professional mechanics and dealership service departments.
Hundreds of pages (specific count not provided, but indicative of comprehensive factory manual)
Manual Type
Type:
Workshop Service Manual / Repair Manual
Language
Language:
English
Format
Delivery Method:
Instant Download
📖 Manual Coverage
Systems Covered
Engine:
Detailed information on engine mechanicals, cooling system, lubrication system, fuel system, ignition system, emissions control.
Transmission:
Coverage for manual and automatic transmission systems, including operation, maintenance, and repair procedures.
Drivetrain:
Information on driveshafts, differentials, and related components.
Suspension And Steering:
Details on front and rear suspension systems, shock absorbers, springs, steering rack, power steering.
Brakes:
Comprehensive coverage of the braking system, including hydraulic components, ABS, brake pad/disc replacement, and bleeding procedures.
Electrical System:
Extensive wiring diagrams, component locations, diagnostic procedures for lighting, starting/charging systems, power distribution, and body electronics.
Body And Chassis:
Information on body panels, doors, convertible roof mechanism, interior trim, chassis components, and corrosion protection.
Comfort And Convenience:
Details on HVAC system, power windows, power locks, audio systems, and other interior features.
Approx. 7,000 rpm (refer to manual for precise value)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline
Recommended Octane:
91 AKI or higher (refer to manual for exact recommendation)
Engine Management
ECU:
Engine Control Unit (ECU) with diagnostic capabilities.
🔧 Transmission
Standard
Type:
5-speed Manual Transmission
Optional
Type:
4-speed Automatic Transmission
Features
Clutch Type:
Hydraulically operated, dry single plate clutch (for manual transmission)
Transmission Fluid Type Manual:
API GL-4, SAE 75W-90 (manual, consult manual for exact spec)
Transmission Fluid Type Auto:
Dexron III or equivalent (automatic, consult manual for exact spec)
📐 Dimensions
Exterior
Length:
Approx. 3,395 mm (133.7 in)
Width:
Approx. 1,475 mm (58.1 in)
Height:
Approx. 1,245 mm (49.0 in) (roof up)
Wheelbase:
Approx. 2,280 mm (89.8 in)
Ground Clearance:
Approx. 140 mm (5.5 in)
Weights
Curb Weight:
Approx. 830-850 kg (1830-1874 lb), depending on transmission and equipment
Gross Vehicle Weight Rating:
Not readily available, consult manual for specific payload.
Interior
Seating Capacity:
2-seater convertible
Cargo
Trunk Volume:
Very limited, typically less than 100 liters with roof stowed.
🛡️ Safety Features
Ratings
Crash Test Results:
As a Kei car, it undergoes different safety standards than larger vehicles. Specific independent crash test ratings are limited; refer to JNCAP for Japanese market data.
Active Features
ABS:
Anti-lock Braking System (ABS) available on some models/trims.
Traction Control:
Traction Control System (TCS) may be available on higher trims.
Passive Features
Airbags:
Driver and front passenger airbags.
Rollover Protection:
Reinforced A-pillars and roll bar integrated behind the seats.
Seatbelts:
Three-point seat belts with pretensioners.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/CD player with standard speaker setup. Higher trims might have upgraded audio.
Navigation:
Rarely equipped from the factory; aftermarket units are common.
Driver Assistance
Parking Sensors:
Not commonly available from the factory; aftermarket options exist.
Connectivity
Bluetooth:
Not a standard feature on most models; typically requires aftermarket installation.
Other
Keyless Entry:
May be available on higher trim levels.
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000-10,000 km or 6-12 months (refer to manual for precise interval based on driving conditions).
Air Filter Replacement:
Every 15,000-30,000 km or 12-24 months.
Spark Plug Replacement:
Refer to manual for specific type and interval (e.g., Iridium plugs may last longer).
Coolant Flush:
Every 2-4 years or 40,000-80,000 km.
Timing Belt:
This engine uses a timing chain, which generally does not require periodic replacement unless issues arise.
Fluid Specifications
Engine Oil Capacity:
Approx. 3.5 liters (3.7 US qt) with filter (consult manual for exact capacity).
Engine Oil Viscosity:
5W-30 or 10W-30 (API SN or higher recommended, consult manual).
Coolant Type:
Ethylene glycol-based antifreeze, typically pink or red (consult manual for specific Daihatsu specification).
Brake Fluid Type:
DOT 3 or DOT 4 (consult manual for exact specification).
Known Issues
Turbocharger Reliability:
Early models or poorly maintained turbochargers can be prone to issues. Regular oil changes are critical.
Convertible Top Mechanism:
The electric convertible roof mechanism can develop issues with motors, seals, or hydraulic lines over time. Proper lubrication and maintenance are important.
Coil On Plug Issues:
While not a widespread major issue, ignition coil failure can occur, leading to misfires.
📚 Vehicle History
Brand Heritage
Daihatsu Focus:
Daihatsu, a subsidiary of Toyota, has a long history of producing small, fuel-efficient vehicles and Kei cars.
Model Evolution
First Generation Launch:
The first generation Daihatsu Copen (codenamed L880K for the Japanese market) was launched in 2002.
Design Inspiration:
Evolved from the Daihatsu MS-01 concept car.
Market Availability:
Primarily popular in Japan, with limited export to other markets.
Production
Production Period:
2002 - 2012 for this generation.
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Keicar Awards:
The Copen has received positive attention within the Kei car segment for its design and performance relative to its class.
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