Daihatsu Copen 2002-2012 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Daihatsu Model: Copen Model Code: L880K (primary chassis for the covered years) Generation: 1st Generation Codes Engine Code Primary: JB-DET (for many models) Chassis Code: L880K 👋 Introduction Market Position Target Audience: Car owners with basic mechanical skills and independent auto service professionals. Value Proposition: Empowers owners to perform maintenance and repairs, saving money on labor costs and enabling better informed discussions with technicians. Competitive Analysis Competitor Manuals: This manual is specific to the Daihatsu Copen and not generic, offering dealership-level accuracy. Key Features Accuracy: Vehicle-specific, written by the manufacturer or equivalent, ensuring accuracy and completeness. Clarity: Clear, concise text combined with detailed illustrations and diagrams. Completeness: Covers all major topics with no missing or corrupt parts/pages. 📋 Manual Details Coverage Areas Primary Coverage Years: 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012 Secondary Coverage Notes: While the product description lists up to 2012, the primary chassis code (L880K) was primarily produced until 2012. Minor updates or facelifts within this period are covered. Page Count Estimated Page Count: Extensive (Specific count not provided, but described as 'full service and repair instruction', implying comprehensive content) Manual Type Type: Service Repair Workshop Manual Language Language: English Format File Format: PDF Digital Delivery: Speed Download 📖 Manual Coverage Systems Covered Engine Mechanical: Full engine overhaul, timing belt/chain, pistons, rings, crankshaft, camshafts, cylinder head, valves, lubrication system, cooling system. Engine Electrical: Ignition system, starting system, charging system, sensors, ECU diagnosis, wiring schematics. Emission Control: Catalytic converter, EGR system, EVAP system, emission sensors. Fuel System: Fuel pump, injectors, fuel lines, fuel pressure regulator, throttle body, fuel tank. Clutch System: Clutch disc, pressure plate, release bearing, clutch hydraulics (master and slave cylinders). Manual Transaxle: Gearbox overhaul, shift mechanism, bearings, seals, fluid specifications. Automatic Transaxle: Transmission operation, control systems, fluid, torque converter (if applicable to specific models within the range). Driveshaft And Axle: CV joints, driveshafts, differential (if integrated with transaxle). Suspension System: Front and rear suspension components, springs, shock absorbers, control arms, bushings, wheel alignment specifications. Steering System: Power steering system (hydraulic or electric), steering rack, tie rod ends, steering column. Restraint System: Airbag system components, seat belts, SRS module diagnosis. Brake System: Brake calipers, pads, rotors, brake lines, ABS system, parking brake. Body Interior Exterior: Body panel removal/installation, door mechanisms, convertible top operation and repair, interior trim, seating. Body Electrical: Lighting system, power windows, mirrors, central locking, dashboard instruments, audio system. HVAC: Heating, ventilation, and air conditioning system components, refrigerant handling, cabin filter. Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, tune-ups. Troubleshooting: Diagnostic procedures, symptom-based troubleshooting, error code interpretation. Repair: Step-by-step repair instructions for all major mechanical and electrical components. Diagnostics: Includes wiring diagrams and component testing procedures for electrical systems. Rebuilding: Comprehensive instructions for rebuilding major assemblies like the engine and transmission. Technical Depth Depth: Comprehensive, covering basic maintenance to advanced diagnostics and complete overhaul procedures, mirroring dealer technician resources. Instruction Style: Step-by-step instructions with diagrams, illustrations, and schematics. 📊 Manual Specifications File Format Readability: High-quality PDF, viewable on PC, Mac, phones, and e-readers. Print Quality Printability: All pages are printable, allowing users to take specific pages into the workshop. Binding Type Binding: N/A (Digital format) Paper Type Paper Type: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 3-cylinder turbocharged (commonly JB-DET) Displacement: 659cc (0.7L) Performance Horsepower Est: 64 PS (47 kW; 63 hp) at 6000 rpm (JDM regulations for Kei car class). Some export models might have slightly different tuning. Torque Est: 103 Nm (76 lb-ft) at 3,200 rpm (for JB-DET) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline Cooling System Cooling Type: Liquid-cooled 🔧 Transmission Standard Transmission Type Std: 4-speed Automatic or 5-speed Manual Transaxle Optional Transmission Type Opt: Manual Transaxle (depending on market and trim) Features Drive Layout: Front-wheel drive (FWD) Fluid Specifications Automatic Transmission Fluid: Refer to manual for specific Dexron or equivalent type (e.g., Dexron III or equivalent for this era). Manual Transmission Fluid: Refer to manual for specific gear oil API GL-4 or GL-5, viscosity grade (e.g., 75W-90). 📐 Dimensions Exterior Length: Approx. 3,395 mm (Kei car regulations) Width: Approx. 1,475 mm (Kei car regulations) Height: Approx. 1,245 mm Wheelbase: Approx. 2,430 mm Weights Curb Weight: Approx. 770-800 kg 🛡️ Safety Features Ratings Jnc Ap Crash Safety: Refer to JNCAP or equivalent regional safety ratings for the specific model year and market. Active Features ABS: Available on many models. Passive Features Airbags: Driver and passenger airbags common. Seat Belts: Three-point seat belts 💡 Technology Features Infotainment Audio System: Factory fitted radio/CD player, potential for aftermarket upgrades. Driver Assistance Traction Control: May be available on certain trim levels or optional. Connectivity Bluetooth: Unlikely to be standard on early models; aftermarket solutions are common. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 5,000...
While the product description lists up to 2012, the primary chassis code (L880K) was primarily produced until 2012. Minor updates or facelifts within this period are covered.
Page Count
Estimated Page Count:
Extensive (Specific count not provided, but described as 'full service and repair instruction', implying comprehensive content)
Step-by-step repair instructions for all major mechanical and electrical components.
Diagnostics:
Includes wiring diagrams and component testing procedures for electrical systems.
Rebuilding:
Comprehensive instructions for rebuilding major assemblies like the engine and transmission.
Technical Depth
Depth:
Comprehensive, covering basic maintenance to advanced diagnostics and complete overhaul procedures, mirroring dealer technician resources.
Instruction Style:
Step-by-step instructions with diagrams, illustrations, and schematics.
📊 Manual Specifications
File Format
Readability:
High-quality PDF, viewable on PC, Mac, phones, and e-readers.
Print Quality
Printability:
All pages are printable, allowing users to take specific pages into the workshop.
Binding Type
Binding:
N/A (Digital format)
Paper Type
Paper Type:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 3-cylinder turbocharged (commonly JB-DET)
Displacement:
659cc (0.7L)
Performance
Horsepower Est:
64 PS (47 kW; 63 hp) at 6000 rpm (JDM regulations for Kei car class). Some export models might have slightly different tuning.
Torque Est:
103 Nm (76 lb-ft) at 3,200 rpm (for JB-DET)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Cooling System
Cooling Type:
Liquid-cooled
🔧 Transmission
Standard
Transmission Type Std:
4-speed Automatic or 5-speed Manual Transaxle
Optional
Transmission Type Opt:
Manual Transaxle (depending on market and trim)
Features
Drive Layout:
Front-wheel drive (FWD)
Fluid Specifications
Automatic Transmission Fluid:
Refer to manual for specific Dexron or equivalent type (e.g., Dexron III or equivalent for this era).
Manual Transmission Fluid:
Refer to manual for specific gear oil API GL-4 or GL-5, viscosity grade (e.g., 75W-90).
📐 Dimensions
Exterior
Length:
Approx. 3,395 mm (Kei car regulations)
Width:
Approx. 1,475 mm (Kei car regulations)
Height:
Approx. 1,245 mm
Wheelbase:
Approx. 2,430 mm
Weights
Curb Weight:
Approx. 770-800 kg
🛡️ Safety Features
Ratings
Jnc Ap Crash Safety:
Refer to JNCAP or equivalent regional safety ratings for the specific model year and market.
Active Features
ABS:
Available on many models.
Passive Features
Airbags:
Driver and passenger airbags common.
Seat Belts:
Three-point seat belts
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/CD player, potential for aftermarket upgrades.
Driver Assistance
Traction Control:
May be available on certain trim levels or optional.
Connectivity
Bluetooth:
Unlikely to be standard on early models; aftermarket solutions are common.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000 - 10,000 km or 6-12 months, refer to manual for exact specification based on usage and oil type.
Spark Plug Replacement:
Refer to manual for specific interval and spark plug type (e.g., iridium recommended for longer life).
Timing Belt Replacement:
If applicable (some engines may use chains), refer to manual for mileage or age-based replacement interval (e.g., 100,000 km).
Fluid Specifications
Engine Oil Grade:
Refer to manual for recommended viscosity (e.g., 0W-20, 5W-30, 10W-40 depending on climate and engine condition) and API classification.
Coolant Type:
Ethylene glycol-based coolant, refer to manual for specific color and type (e.g., long-life pink or green).
Known Issues
Convertible Top Actuators:
Potential for wear or failure of hydraulic actuators for the power-retractable hardtop.
Turbocharger Care:
Proper warm-up and cool-down procedures are crucial for turbocharger longevity, especially in spirited driving.
Electronic Components:
As with any vehicle, aging electronic components can lead to various system faults; the manual's diagnostic section is key.
📚 Vehicle History
Brand Heritage
Brand Focus:
Daihatsu, a subsidiary of Toyota, specializes in compact and Kei cars, known for efficiency and value.
Model Evolution
Model Concept:
The Copen is a two-seater convertible sports car, designed as a modern interpretation of the classic mini sports car, with a focus on fun and maneuverability.
Generation 1 Launch:
First generation launched in 2002.
Production
Production Location:
Japan
🏆 Awards & Recognition
Recognitions
Kei Car Segment:
The Copen was a notable entrant in the sporty Kei car segment, receiving accolades for its design and unique offering.
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