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DAIHATSU TERIOS J100 Series Service Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Chassis Code: J100 Series Generation: First Generation Codes Engine Code: HC-EJ Engine Configuration: Inline 4-cylinder, SOHC 👋 Introduction Market Position Positioning: The Daihatsu Terios J100 Series (1997-2000) was a compact, body-on-frame SUV designed for light off-roading and versatile urban use. It targeted budget-conscious consumers seeking a capable, no-frills 4x4 vehicle. Competitive Analysis Competitors: Competed with vehicles like the Suzuki Vitara, Kia Sportage (first generation), and potentially smaller trims of the Toyota RAV4. Key Features Features: Compact dimensions, robust body-on-frame construction, available four-wheel drive, affordable price point, good fuel economy for its class. 📋 Manual Details Coverage Areas Years Covered: 1997-2000 Regions Covered: Global (focus on markets where J100 was prevalent) Page Count Estimated Page Count: Approx. 1000+ pages (typical for a comprehensive service manual) Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine: Engine Mechanical, Engine Control System (EFI), Lubrication System, Cooling System, Ignition System, Fuel System, Emission Control Drivetrain: Transmission (Manual & Automatic), Driveline (4WD System), Differentials, Driveshafts, Axles Chassis: Suspension (Front & Rear), Steering System, Brakes (Front & Rear), Wheels & Tires Electrical: Wiring Diagrams, Lighting System, Instrumentation, Audio System, Power Accessories, Starting & Charging System Body: Body Exterior & Interior Trim, Doors, Windows, Seats, Body Repair Procedures Included Maintenance: Routine Maintenance (oil changes, filter replacements, inspections), Scheduled Maintenance Intervals Repair: Engine Rebuild Procedures, Transmission Overhaul, Brake Component Replacement, Suspension Component Replacement, Steering System Repair, Electrical Component Diagnosis & Repair Troubleshooting: Diagnostic Procedures for Common Faults, Symptom-Based Troubleshooting Guides, Diagnostic Trouble Codes (DTCs) and their Meanings Specifications: Torque Specifications, Fluid Types and Capacities, Clearances, Tolerances, Wiring Schematics, Component Locations Technical Depth Depth: Comprehensive: Covers everything from basic maintenance and fluid checks to detailed engine overhaul, transmission rebuilds, and advanced electrical diagnostics. Suitable for professional mechanics and experienced DIY enthusiasts. 📊 Manual Specifications File Format Format: Searchable PDF Print Quality Quality: High-resolution scans with clear text and diagrams, suitable for on-screen viewing and printing. Binding Type Type: N/A (Digital Format) Paper Type Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-cylinder, SOHC (Single Overhead Camshaft) Displacement: 1.3 Liters (1300cc) Bore X Stroke: 76.0 mm x 71.4 mm (approximate) Compression Ratio: 9.5:1 (typical) Performance Horsepower: 82-88 PS (approx. 81-87 bhp) @ 6000 rpm (varies slightly by market and emissions standards) Torque: 105-112 Nm (approx. 77-83 lb-ft) @ 3500-4000 rpm (varies slightly by market) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), Multi-point Injection Fuel Type: Unleaded Gasoline (Octane rating as per owner's manual, typically 91 RON or higher) Engine Internals Valvetrain: SOHC, 16 Valves (4 per cylinder) Timing Drive: Timing Belt 🔧 Transmission Standard Type: 5-speed Manual Transmission Optional Type: 4-speed Automatic Transmission Features Drivetrain Options: Rear-Wheel Drive (RWD) and Selectable Four-Wheel Drive (4WD) with low range transfer case Fluid Specifications Manual Transmission Fluid: API GL-4, SAE 75W-90 (Check manual for exact specification, e.g., Dia-Queen GL-4) Automatic Transmission Fluid: Dexron II/III compatible or Dia-Queen SP-III (Check manual for exact specification) 📐 Dimensions Exterior Length: Approx. 3745 mm (147.4 in) Width: Approx. 1690 mm (66.5 in) Height: Approx. 1670-1700 mm (65.7-66.9 in) (depending on roof rails/options) Wheelbase: Approx. 2430 mm (95.7 in) Weights Curb Weight: Approx. 1050-1200 kg (2315-2646 lbs) (depending on configuration) Gross Vehicle Weight Rating: Approx. 1500-1600 kg (3307-3527 lbs) Wheels Tires Wheel Bolt Pattern: 5x114.3 mm (5x4.5 inches) Standard Tire Size: 205/70R15 (common fitment, check manual for specifics) 🛡️ Safety Features Ratings Crash Test Results: Limited official crash test data available for this specific generation and model from major agencies like NHTSA or Euro NCAP. Likely to be basic by modern standards. Active Features Active Safety: Four-wheel drive system (optional), ABS (Anti-lock Braking System) may be available on higher trims or optional. Passive Features Passive Safety: Seat belts (front and rear), potentially basic airbags for driver and front passenger on later models or higher trims. 💡 Technology Features Infotainment Audio System: Basic AM/FM radio and CD player (or cassette player) with 2-4 speakers. Aftermarket upgrades are common. Driver Assistance Driver Assistance Features: Very limited. Primarily focused on mechanical aspects. No advanced electronic driver-assistance systems (ADAS) like adaptive cruise control or lane keeping assist. Connectivity Connectivity Options: No factory integrated smartphone connectivity or Bluetooth for this era. Aftermarket head unit installations are the primary method for adding these features. 🔧 Maintenance Service Intervals Engine Oil Change: Every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, whichever comes first (refer to manual for precise recommendation). Engine Oil Filter Replacement: At every oil change. Timing Belt Replacement: Recommended every 60,000-100,000 miles (96,000-160,000 km) or 5-7 years, as timing belt failure can cause catastrophic engine damage. Crucial to follow manual. (Example Part Number: 13028-4F100 or similar Daihatsu equivalent) Spark Plug Replacement: Every 30,000-60,000 miles (48,000-96,000 km), depending on type (copper...
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DAIHATSU TERIOS J100 Series Service Repair Manual
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Terios
Chassis Code:
J100 Series
Generation:
First Generation
Codes
Engine Code:
HC-EJ
Engine Configuration:
Inline 4-cylinder, SOHC
👋 Introduction
Market Position
Positioning:
The Daihatsu Terios J100 Series (1997-2000) was a compact, body-on-frame SUV designed for light off-roading and versatile urban use. It targeted budget-conscious consumers seeking a capable, no-frills 4x4 vehicle.
Competitive Analysis
Competitors:
Competed with vehicles like the Suzuki Vitara, Kia Sportage (first generation), and potentially smaller trims of the Toyota RAV4.
Key Features
Features:
Compact dimensions, robust body-on-frame construction, available four-wheel drive, affordable price point, good fuel economy for its class.
📋 Manual Details
Coverage Areas
Years Covered:
1997-2000
Regions Covered:
Global (focus on markets where J100 was prevalent)
Page Count
Estimated Page Count:
Approx. 1000+ pages (typical for a comprehensive service manual)
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Engine Mechanical, Engine Control System (EFI), Lubrication System, Cooling System, Ignition System, Fuel System, Emission Control
Drivetrain:
Transmission (Manual & Automatic), Driveline (4WD System), Differentials, Driveshafts, Axles
Chassis:
Suspension (Front & Rear), Steering System, Brakes (Front & Rear), Wheels & Tires
Electrical:
Wiring Diagrams, Lighting System, Instrumentation, Audio System, Power Accessories, Starting & Charging System
Body:
Body Exterior & Interior Trim, Doors, Windows, Seats, Body Repair
Procedures Included
Maintenance:
Routine Maintenance (oil changes, filter replacements, inspections), Scheduled Maintenance Intervals
Repair:
Engine Rebuild Procedures, Transmission Overhaul, Brake Component Replacement, Suspension Component Replacement, Steering System Repair, Electrical Component Diagnosis & Repair
Troubleshooting:
Diagnostic Procedures for Common Faults, Symptom-Based Troubleshooting Guides, Diagnostic Trouble Codes (DTCs) and their Meanings
Specifications:
Torque Specifications, Fluid Types and Capacities, Clearances, Tolerances, Wiring Schematics, Component Locations
Technical Depth
Depth:
Comprehensive: Covers everything from basic maintenance and fluid checks to detailed engine overhaul, transmission rebuilds, and advanced electrical diagnostics. Suitable for professional mechanics and experienced DIY enthusiasts.
📊 Manual Specifications
File Format
Format:
Searchable PDF
Print Quality
Quality:
High-resolution scans with clear text and diagrams, suitable for on-screen viewing and printing.
Binding Type
Type:
N/A (Digital Format)
Paper Type
Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, SOHC (Single Overhead Camshaft)
Displacement:
1.3 Liters (1300cc)
Bore X Stroke:
76.0 mm x 71.4 mm (approximate)
Compression Ratio:
9.5:1 (typical)
Performance
Horsepower:
82-88 PS (approx. 81-87 bhp) @ 6000 rpm (varies slightly by market and emissions standards)
Torque:
105-112 Nm (approx. 77-83 lb-ft) @ 3500-4000 rpm (varies slightly by market)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), Multi-point Injection
Fuel Type:
Unleaded Gasoline (Octane rating as per owner's manual, typically 91 RON or higher)
Engine Internals
Valvetrain:
SOHC, 16 Valves (4 per cylinder)
Timing Drive:
Timing Belt
🔧 Transmission
Standard
Type:
5-speed Manual Transmission
Optional
Type:
4-speed Automatic Transmission
Features
Drivetrain Options:
Rear-Wheel Drive (RWD) and Selectable Four-Wheel Drive (4WD) with low range transfer case
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-90 (Check manual for exact specification, e.g., Dia-Queen GL-4)
Automatic Transmission Fluid:
Dexron II/III compatible or Dia-Queen SP-III (Check manual for exact specification)
📐 Dimensions
Exterior
Length:
Approx. 3745 mm (147.4 in)
Width:
Approx. 1690 mm (66.5 in)
Height:
Approx. 1670-1700 mm (65.7-66.9 in) (depending on roof rails/options)
Wheelbase:
Approx. 2430 mm (95.7 in)
Weights
Curb Weight:
Approx. 1050-1200 kg (2315-2646 lbs) (depending on configuration)
Gross Vehicle Weight Rating:
Approx. 1500-1600 kg (3307-3527 lbs)
Wheels Tires
Wheel Bolt Pattern:
5x114.3 mm (5x4.5 inches)
Standard Tire Size:
205/70R15 (common fitment, check manual for specifics)
🛡️ Safety Features
Ratings
Crash Test Results:
Limited official crash test data available for this specific generation and model from major agencies like NHTSA or Euro NCAP. Likely to be basic by modern standards.
Active Features
Active Safety:
Four-wheel drive system (optional), ABS (Anti-lock Braking System) may be available on higher trims or optional.
Passive Features
Passive Safety:
Seat belts (front and rear), potentially basic airbags for driver and front passenger on later models or higher trims.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio and CD player (or cassette player) with 2-4 speakers. Aftermarket upgrades are common.
Driver Assistance
Driver Assistance Features:
Very limited. Primarily focused on mechanical aspects. No advanced electronic driver-assistance systems (ADAS) like adaptive cruise control or lane keeping assist.
Connectivity
Connectivity Options:
No factory integrated smartphone connectivity or Bluetooth for this era. Aftermarket head unit installations are the primary method for adding these features.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, whichever comes first (refer to manual for precise recommendation).
Engine Oil Filter Replacement:
At every oil change.
Timing Belt Replacement:
Recommended every 60,000-100,000 miles (96,000-160,000 km) or 5-7 years, as timing belt failure can cause catastrophic engine damage. Crucial to follow manual. (Example Part Number: 13028-4F100 or similar Daihatsu equivalent)
Spark Plug Replacement:
Every 30,000-60,000 miles (48,000-96,000 km), depending on type (copper vs. platinum/iridium).
Fluid Specifications
Engine Oil:
API SG/SH/SJ, SAE 10W-30 or 10W-40 (Check manual for specific viscosity based on climate). Capacity: Approx. 3.4 Liters (3.6 US Quarts) with filter.
Coolant:
Ethylene Glycol-based antifreeze, typically a 50/50 mix with distilled water. Color varies (green or pink). Capacity: Approx. 5.0 Liters (5.3 US Quarts).
Brake Fluid:
DOT 3 or DOT 4 (Check manual for exact type). Use fresh fluid and bleed system thoroughly after replacement.
Power Steering Fluid:
Dexron II/III compatible or specific power steering fluid (Check manual). Capacity: Approx. 0.8 Liters (0.85 US Quarts).
Known Issues
Common Problems:
Timing belt degradation (crucial maintenance item), potential for rust in certain climates, aging rubber components (bushings, hoses), minor electrical gremlins in older vehicles, clutch wear in manual transmissions.
Filters
Oil Filter Part Number Example:
Ryco Z285, Bosch 0986452046, or equivalent (verify with parts catalog)
Air Filter Part Number Example:
Ryco A1150, Bosch 1987429136, or equivalent (verify with parts catalog)
📚 Vehicle History
Brand Heritage
Brand Focus:
Daihatsu has a long history as a compact car specialist, with a focus on affordability, reliability, and efficient engineering, particularly in the Kei car and small SUV segments.
Model Evolution
J100 Launch:
The first-generation Terios (J100) was launched in 1997, aiming to fill the niche for a small, affordable, and genuinely capable off-roadable compact SUV.
J100 Design:
Characterized by its upright stance, relatively short wheelbase, and compact footprint, emphasizing practicality and maneuverability.
Production
Production Years:
1997-2000 for the J100 series
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Specific Awards:
No widely publicized major awards for the J100 generation. It was generally recognized for its value and off-road capability within its niche.
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