Daihatsu Terios 1997-2005 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Generation Code: J100/J122 Years Covered: 1997-2005 👋 Introduction Market Position Market Position: The Daihatsu Terios (J100/J122) was positioned as a compact, affordable, and rugged mini SUV or 'kei SUV' in many markets, offering genuine four-wheel-drive capability in a small package. It competed with vehicles like the Suzuki Vitara, Honda CR-V (early models), and similar subcompact SUVs. Competitive Analysis Competitive Analysis: Its key selling points were its compact size, excellent maneuverability, surprisingly capable off-road performance for its class due to available 4WD, and its fuel efficiency relative to larger SUVs. The manual covers the intricacies of this unique subcompact SUV. Key Features Key Features: Authentic 4WD system, ladder-frame construction (early models), compact dimensions, affordable price point, simple and robust mechanicals. Construction: Early models (J100) utilized a separate body-on-frame construction, offering robust durability and excellent off-road articulation. Later models (J122) adopted a unibody construction for improved ride comfort and weight reduction, while retaining a compact SUV profile. 📋 Manual Details Coverage Areas Coverage Areas: North America, Europe, Asia (specific regions may vary based on original manual distribution) Page Count Page Count: Estimated 800-1200 pages (typical for comprehensive factory service manuals) Manual Type Manual Type: Factory Service Repair Workshop Manual Language Language: English Format Format: Downloadable PDF Searchable Text: Yes, the PDF format includes searchable text, allowing users to quickly find specific topics, component names, or procedures. Printable: Yes, the PDF is designed to be printable, allowing users to create physical copies of sections or the entire manual for workshop use. 📖 Manual Coverage Systems Covered Systems Covered: Engine mechanical, engine electrical, fuel system, ignition system, cooling system, lubrication system, exhaust system, transmission (manual & automatic), drivetrain, suspension, steering, brakes (ABS, drum, disc), body electrical, HVAC, interior trim, exterior body panels, chassis, wheels & tires, diagnostic trouble codes (DTCs) Body Electrical: Headlights, taillights, interior lighting, power windows (if equipped), door locks, wipers, horn, hazard lights, fuses, relays, dashboard indicators, and associated wiring harnesses. Includes troubleshooting for electrical faults. Chassis And Frame: Detailed information on frame inspection, rust prevention, and repair procedures, particularly relevant for early ladder-frame models. Suspension and steering component torque specs and alignment procedures are included. Wheels And Tires: Tire pressure recommendations, wheel balancing, tire rotation, lug nut torque specifications, and wheel bearing service. Brake System: Disc brake pad and rotor replacement, drum brake shoe adjustment and replacement, caliper and wheel cylinder servicing, brake line and hose inspection and replacement, bleeding the brake system. Procedures Included Procedures Included: Routine maintenance, scheduled services, diagnostics, troubleshooting, component removal and installation, adjustments, torque specifications, fluid capacities and types, electrical schematics, wiring diagrams, engine overhaul procedures, transmission rebuild, brake system repair, suspension component replacement, body panel repair, HVAC system service, emissions control system repair Diagnostic Trouble Codes: Provides procedures for reading and interpreting diagnostic trouble codes (DTCs) via the OBD-II port (depending on market and model year). Lists common DTCs and their potential causes. HVAC Service: Refrigerant handling, component testing (compressor, condenser, evaporator), blower motor replacement, dashboard disassembly for heater core or evaporator service, and diagnostic procedures for common HVAC failures. Engine Tuning: Idle speed adjustment, ignition timing checks and adjustments (where applicable), fuel mixture adjustments (if not fully computer controlled). Body And Trim: Removal and installation of bumpers, fenders, doors, hood, tailgate, interior panels, seats, and related trim pieces. Includes methods for dealing with minor dent repair and panel alignment. Technical Depth Technical Depth: Comprehensive; covers everything from basic fluid changes and filter replacements to in-depth engine and transmission rebuilds, advanced electrical diagnostics, and bodywork. Wiring Diagrams: Detailed, color-coded wiring diagrams for all major systems, crucial for accurate electrical diagnosis and repair. Engine Rebuild: Detailed steps for engine disassembly, inspection of engine components (pistons, rings, crankshaft, camshafts, cylinder head), reassembly with correct torque specifications, valve adjustment, and break-in procedures. Diagnostics: Step-by-step diagnostic flowcharts for common symptoms (e.g., hard starting, poor performance, no-start conditions), component testing procedures, and multimeter usage for electrical troubleshooting. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution scans, ensuring clarity of diagrams and text. Designed for on-screen viewing and printing. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Primary Engine 1 Details: Engine Code: HC-EJ; Type: Inline 4-cylinder, SOHC, 16-valve; Displacement: 1298 cc (1.3 L); Bore x Stroke: 70.0 mm x 80.5 mm; Compression Ratio: 9.5:1; Fuel Delivery: Multi-point Fuel Injection (MPI) Primary Engine 2 Details: Engine Code: K3-VE; Type: Inline 4-cylinder, DOHC, 16-valve (VVT-i on later models); Displacement: 1298 cc (1.3 L); Bore x Stroke: 72.0 mm x 79.7 mm; Compression Ratio: 10.0:1; Fuel Delivery: Multi-point Fuel Injection (MPI) Performance Horsepower Hc Ej: Approx. 83-85 PS (82-84 hp) @ 6000 rpm Torque Hc Ej: Approx. 110-115 Nm (81-85 lb-ft) @ 3500-4000 rpm Horsepower K3 Ve: Approx....
The Daihatsu Terios (J100/J122) was positioned as a compact, affordable, and rugged mini SUV or 'kei SUV' in many markets, offering genuine four-wheel-drive capability in a small package. It competed with vehicles like the Suzuki Vitara, Honda CR-V (early models), and similar subcompact SUVs.
Competitive Analysis
Competitive Analysis:
Its key selling points were its compact size, excellent maneuverability, surprisingly capable off-road performance for its class due to available 4WD, and its fuel efficiency relative to larger SUVs. The manual covers the intricacies of this unique subcompact SUV.
Key Features
Key Features:
Authentic 4WD system, ladder-frame construction (early models), compact dimensions, affordable price point, simple and robust mechanicals.
Construction:
Early models (J100) utilized a separate body-on-frame construction, offering robust durability and excellent off-road articulation. Later models (J122) adopted a unibody construction for improved ride comfort and weight reduction, while retaining a compact SUV profile.
📋 Manual Details
Coverage Areas
Coverage Areas:
North America, Europe, Asia (specific regions may vary based on original manual distribution)
Page Count
Page Count:
Estimated 800-1200 pages (typical for comprehensive factory service manuals)
Manual Type
Manual Type:
Factory Service Repair Workshop Manual
Language
Language:
English
Format
Format:
Downloadable PDF
Searchable Text:
Yes, the PDF format includes searchable text, allowing users to quickly find specific topics, component names, or procedures.
Printable:
Yes, the PDF is designed to be printable, allowing users to create physical copies of sections or the entire manual for workshop use.
Headlights, taillights, interior lighting, power windows (if equipped), door locks, wipers, horn, hazard lights, fuses, relays, dashboard indicators, and associated wiring harnesses. Includes troubleshooting for electrical faults.
Chassis And Frame:
Detailed information on frame inspection, rust prevention, and repair procedures, particularly relevant for early ladder-frame models. Suspension and steering component torque specs and alignment procedures are included.
Disc brake pad and rotor replacement, drum brake shoe adjustment and replacement, caliper and wheel cylinder servicing, brake line and hose inspection and replacement, bleeding the brake system.
Procedures Included
Procedures Included:
Routine maintenance, scheduled services, diagnostics, troubleshooting, component removal and installation, adjustments, torque specifications, fluid capacities and types, electrical schematics, wiring diagrams, engine overhaul procedures, transmission rebuild, brake system repair, suspension component replacement, body panel repair, HVAC system service, emissions control system repair
Diagnostic Trouble Codes:
Provides procedures for reading and interpreting diagnostic trouble codes (DTCs) via the OBD-II port (depending on market and model year). Lists common DTCs and their potential causes.
HVAC Service:
Refrigerant handling, component testing (compressor, condenser, evaporator), blower motor replacement, dashboard disassembly for heater core or evaporator service, and diagnostic procedures for common HVAC failures.
Engine Tuning:
Idle speed adjustment, ignition timing checks and adjustments (where applicable), fuel mixture adjustments (if not fully computer controlled).
Body And Trim:
Removal and installation of bumpers, fenders, doors, hood, tailgate, interior panels, seats, and related trim pieces. Includes methods for dealing with minor dent repair and panel alignment.
Technical Depth
Technical Depth:
Comprehensive; covers everything from basic fluid changes and filter replacements to in-depth engine and transmission rebuilds, advanced electrical diagnostics, and bodywork.
Wiring Diagrams:
Detailed, color-coded wiring diagrams for all major systems, crucial for accurate electrical diagnosis and repair.
Engine Rebuild:
Detailed steps for engine disassembly, inspection of engine components (pistons, rings, crankshaft, camshafts, cylinder head), reassembly with correct torque specifications, valve adjustment, and break-in procedures.
Diagnostics:
Step-by-step diagnostic flowcharts for common symptoms (e.g., hard starting, poor performance, no-start conditions), component testing procedures, and multimeter usage for electrical troubleshooting.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution scans, ensuring clarity of diagrams and text. Designed for on-screen viewing and printing.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Primary Engine 1 Details:
Engine Code: HC-EJ; Type: Inline 4-cylinder, SOHC, 16-valve; Displacement: 1298 cc (1.3 L); Bore x Stroke: 70.0 mm x 80.5 mm; Compression Ratio: 9.5:1; Fuel Delivery: Multi-point Fuel Injection (MPI)
Primary Engine 2 Details:
Engine Code: K3-VE; Type: Inline 4-cylinder, DOHC, 16-valve (VVT-i on later models); Displacement: 1298 cc (1.3 L); Bore x Stroke: 72.0 mm x 79.7 mm; Compression Ratio: 10.0:1; Fuel Delivery: Multi-point Fuel Injection (MPI)
Performance
Horsepower Hc Ej:
Approx. 83-85 PS (82-84 hp) @ 6000 rpm
Torque Hc Ej:
Approx. 110-115 Nm (81-85 lb-ft) @ 3500-4000 rpm
Horsepower K3 Ve:
Approx. 86-95 PS (85-94 hp) @ 6000 rpm (VVT-i variants may be slightly higher)
Torque K3 Ve:
Approx. 115-125 Nm (85-92 lb-ft) @ 3200-4000 rpm
Fuel System
Fuel Type:
Unleaded gasoline
Fuel Pump Type:
Electric, in-tank
Emission Controls:
Includes details on EVAP systems, catalytic converters, O2 sensors, and EGR systems (if applicable) for meeting emission standards. Manual provides testing and adjustment procedures.
🔧 Transmission
Standard
Standard Transmission:
5-speed manual transmission
Optional
Optional Transmission:
4-speed automatic transmission (e.g., with torque converter)
Features
Drivetrain Options:
Either Rear-Wheel Drive (RWD) or Full-Time Four-Wheel Drive (4WD) with a center differential and viscous coupling.
Transmission Fluid Type Manual:
API GL-4 SAE 75W-90 or SAE 80W-90 gear oil
Transmission Fluid Type Automatic:
Dexron III or equivalent automatic transmission fluid (ATF)
📐 Dimensions
Exterior
Length:
Approx. 3,710 - 3,750 mm (146.1 - 147.6 in)
Width:
Approx. 1,600 mm (63.0 in)
Height:
Approx. 1,680 - 1,705 mm (66.1 - 67.1 in)
Wheelbase:
Approx. 2,430 mm (95.7 in)
Ground Clearance:
Approx. 195-200 mm (7.7-7.9 in)
Wheel Bolt Pattern:
4x114.3 mm (4.5 inches)
Wheel Size:
Typically 15 or 16 inches
Tire Size:
Commonly 205/70R15 or 215/65R16 (refer to manual or vehicle placard for exact specifications)
Weights
Curb Weight:
Approx. 1,050 - 1,200 kg (2,315 - 2,645 lbs), depending on drivetrain and options
Gross Vehicle Weight Rating:
Approx. 1,500 - 1,600 kg (3,307 - 3,527 lbs)
Cargo
Cargo Volume Rear Seats Up:
Approx. 212 Liters (7.5 cu ft)
Cargo Volume Rear Seats Folded:
Approx. 896 Liters (31.7 cu ft)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Varies by market and testing agency. Early models may not have extensive official crash test data available from major agencies like NHTSA or Euro NCAP. The manual will detail the vehicle's safety features and construction.
Active Features
Active Safety Features:
Four-wheel drive (for enhanced traction), optional ABS (Anti-lock Braking System) on some models/trims.
Passive Features
Passive Safety Features:
Front airbags (driver and passenger), three-point seat belts with pre-tensioners, side-impact door beams, crumple zones.
💡 Technology Features
Infotainment
Infotainment System:
Basic AM/FM radio with CD player or cassette tape player. Manual covers electrical systems for these components, including speaker wiring and unit removal/installation.
Driver Assistance
Driver Assistance Features:
Limited to available ABS on some higher trims. No advanced electronic driver aids like traction control or stability control typically found on later models.
Connectivity
Connectivity Features:
No integrated Bluetooth or USB connectivity on base models. Manual details the basic wiring for accessories and potential aftermarket integration.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, whichever comes first. Refer to manual for exact specification based on driving conditions.
Air Filter Replacement:
Every 15,000 - 30,000 miles (24,000 - 48,000 km) or as needed, depending on environment.
Spark Plug Replacement:
Every 30,000 - 60,000 miles (48,000 - 96,000 km) for standard copper plugs; potentially longer for iridium or platinum plugs if fitted.
Timing Belt Replacement:
For HC-EJ engine (if equipped with belt): Typically 60,000 miles (96,000 km) or 5 years. K3-VE engine is typically chain-driven and doesn't require regular replacement, but the manual will specify checks.
Fluid Specifications
Engine Oil Type Capacity:
API SG/SH/SJ or higher; viscosity 5W-30 or 10W-30 (check manual for climate recommendations). Capacity: Approx. 3.7 Liters (3.9 US quarts) with filter change.
Coolant Type Capacity:
Ethylene glycol-based, 50/50 mix with distilled water. Capacity: Approx. 5.5 - 6.0 Liters (5.8 - 6.3 US quarts).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid
Power Steering Fluid:
ATF Dexron II or III, or specific power steering fluid as recommended by Daihatsu. Capacity: Approx. 0.8-1.0 Liters.
Transfer Case Fluid 4Wd:
API GL-4 SAE 75W-90 or SAE 80W-90 gear oil (check manual for exact specification).
Differential Fluid Front Rear:
API GL-5 SAE 75W-90 or SAE 80W-90 gear oil (check manual for exact specification).
Known Issues
Common Issues:
Potential for minor oil leaks from valve cover or oil pan gaskets, clutch wear (manual transmission), occasional issues with fuel injectors or sensors on higher mileage vehicles. The manual provides diagnostic procedures for these and more.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Daihatsu, a subsidiary of Toyota, has a long history of producing small, efficient, and reliable vehicles, particularly known for its 'kei' cars in Japan and its specialized off-road vehicles like the Rocky.
Model Evolution
Model Evolution J100 J122:
The first generation Terios (J100) was launched in 1997. It was designed as a compact, lightweight, and affordable SUV. Later updates in the early 2000s, leading into the J122 chassis designation, included minor styling tweaks and the introduction of the more advanced K3-VE engine. The manual covers this entire lifespan.
Production
Production Locations:
Primarily manufactured in Japan, with some assembly potentially occurring in other Daihatsu or Toyota facilities worldwide.
🏆 Awards & Recognition
Recognitions
Market Reception:
The Daihatsu Terios gained popularity in markets where affordability, compact size, and go-anywhere capability were prioritized. While not a mainstream global bestseller, it carved out a niche for itself as a practical and economical small SUV.
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