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Daihatsu Terios J100 1998 All Service Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Generation: J100 Year: 1998 Codes Chassis Code: J100 👋 Introduction Market Position Segment: Compact SUV / Kei SUV Target Audience: Individuals seeking a reliable, compact, and often affordable vehicle for urban commuting and light off-road use. Competitive Analysis Key Competitors: Suzuki Jimny, Mitsubishi Pajero Mini, Honda CR-V (early generations, though larger). Key Features Chassis: Body-on-frame construction, providing robust durability for off-road applications. Drivetrain Options: Available in 2WD (rear-wheel drive) and 4WD (four-wheel drive) configurations, enhancing versatility. Compact Size: Maneuverable and easy to park, especially in urban environments. Utility: Practical for light hauling and recreational activities due to its SUV form factor. 📋 Manual Details Coverage Areas Manual Type: Service and Repair Manual Language: English Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, component inspection, timing belt replacement, piston and ring service, cylinder head procedures, crankshaft and bearing service. Engine Electrical: Ignition system diagnosis and repair, fuel injection system troubleshooting, starting and charging system, sensors and actuators (MAP, TPS, O2, Crankshaft Position), ECU diagnosis. Transmission Manual: Clutch system service, gear shift mechanism, internal transmission component repair, overhaul procedures, fluid specifications and replacement. Transmission Automatic: Torque converter service, hydraulic control system, valve body diagnosis, planetary gear sets, fluid specifications and replacement, shift control. Drivetrain: Front and rear differential service, driveshaft inspection and repair, CV joints and boots, transfer case operation and maintenance (4WD models). Suspension: Front and rear suspension component identification, strut and shock absorber replacement, spring service, ball joint and tie rod end inspection, bushing replacement. Steering: Power steering system diagnosis, pump and rack repair, steering column service, alignment procedures and specifications. Brakes: Front and rear brake system inspection, pad and rotor replacement, caliper and wheel cylinder service, brake fluid flush and bleeding procedures, ABS system diagnosis (if equipped). Cooling System: Radiator service, thermostat replacement, water pump inspection and replacement, coolant type and capacity, fan clutch/electric fan operation. Fuel System: Fuel pump diagnosis and replacement, fuel filter replacement, fuel injectors cleaning and testing, evaporative emission control (EVAP) system. Exhaust System: Muffler and catalytic converter inspection, exhaust manifold service, gasket replacement, hanger and clamp inspection. Body And Interior: Door panel removal, seat adjustment and replacement, dashboard components, exterior trim, bumper service, glass replacement. Electrical System Lighting: Headlight, taillight, and interior lighting bulb replacement, wiring harness diagrams, fuse and relay identification. Heating Ventilation Air Conditioning HVAC: Heater core replacement, blower motor service, AC system refrigerant handling, cabin air filter replacement. Procedures Included Routine Maintenance: Oil and filter changes, fluid checks and top-offs, tire rotation and pressure checks, spark plug replacement, air filter replacement. Troubleshooting: Diagnostic flowcharts for common drivability issues, electrical faults, and mechanical problems. Symptom-based troubleshooting guides. Repair Procedures: Step-by-step instructions for component removal, installation, and adjustment across all major vehicle systems. Diagnostic Codes: OBD-II diagnostic trouble code (DTC) definitions and suggested diagnostic steps. Special Tools: Identification and usage instructions for specialized tools required for specific repair procedures. Technical Depth Depth: Comprehensive coverage suitable for professional mechanics and advanced DIY enthusiasts. Includes detailed torque specifications, clearances, and diagnostic data. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text within the PDF document for quick information retrieval. Printability: Printable pages for on-hand reference during repairs. Resolution: High-resolution images and diagrams for clarity. ⚙️ Engine Specifications Primary Engine Engine Code: H20A Engine Type: Inline 4-cylinder, DOHC, 16-valve Displacement: 1998 cc (2.0 Liters) Performance Horsepower: Approx. 120-130 PS (90-97 kW) at varying RPMs (specific figure depends on market and tune). Torque: Approx. 170-180 Nm (125-133 lb-ft) at varying RPMs. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline Emission Control Catalytic Converter: Equipped with a catalytic converter for emissions compliance. 🔧 Transmission Standard Type: 5-speed Manual Transmission Optional Type: 4-speed Automatic Transmission Features Transfer Case: For 4WD models: Dual-range transfer case with selectable 2WD, 4WD High, and 4WD Low. Fluid Specifications Manual Fluid: API GL-4, SAE 75W-90 (or equivalent, refer to manual for exact specification). Automatic Fluid: Dexron III or equivalent (refer to manual for exact specification). 📐 Dimensions Exterior Length: Approx. 3,735 mm (147.0 in) Width: Approx. 1,690 mm (66.5 in) Height: Approx. 1,655 mm (65.2 in) Wheelbase: Approx. 2,430 mm (95.7 in) Ground Clearance: Approx. 195 mm (7.7 in) Weights Curb Weight: Approx. 1,160 kg - 1,250 kg (2,557 - 2,756 lbs) depending on configuration. 🛡️ Safety Features Ratings Crash Test Results: Specific crash test ratings for the 1998 J100 are not widely publicized or standardized across global agencies like NHTSA or Euro NCAP as contemporary vehicles. Refer to regional safety data if available. Active Features ABS: Anti-lock Braking System (ABS) may be available as an option or standard on higher trim levels. Passive Features Airbags: Driver and front passenger airbags (standard or optional depending on market). Seatbelts: 3-point seatbelts with pretensioners for front occupants....
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Daihatsu Terios J100 1998 All Service Repair Manual
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Terios
Generation:
J100
Year:
1998
Codes
Chassis Code:
J100
👋 Introduction
Market Position
Segment:
Compact SUV / Kei SUV
Target Audience:
Individuals seeking a reliable, compact, and often affordable vehicle for urban commuting and light off-road use.
Competitive Analysis
Key Competitors:
Suzuki Jimny, Mitsubishi Pajero Mini, Honda CR-V (early generations, though larger).
Key Features
Chassis:
Body-on-frame construction, providing robust durability for off-road applications.
Drivetrain Options:
Available in 2WD (rear-wheel drive) and 4WD (four-wheel drive) configurations, enhancing versatility.
Compact Size:
Maneuverable and easy to park, especially in urban environments.
Utility:
Practical for light hauling and recreational activities due to its SUV form factor.
📋 Manual Details
Coverage Areas
Manual Type:
Service and Repair Manual
Language:
English
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, component inspection, timing belt replacement, piston and ring service, cylinder head procedures, crankshaft and bearing service.
Engine Electrical:
Ignition system diagnosis and repair, fuel injection system troubleshooting, starting and charging system, sensors and actuators (MAP, TPS, O2, Crankshaft Position), ECU diagnosis.
Transmission Manual:
Clutch system service, gear shift mechanism, internal transmission component repair, overhaul procedures, fluid specifications and replacement.
Transmission Automatic:
Torque converter service, hydraulic control system, valve body diagnosis, planetary gear sets, fluid specifications and replacement, shift control.
Drivetrain:
Front and rear differential service, driveshaft inspection and repair, CV joints and boots, transfer case operation and maintenance (4WD models).
Suspension:
Front and rear suspension component identification, strut and shock absorber replacement, spring service, ball joint and tie rod end inspection, bushing replacement.
Steering:
Power steering system diagnosis, pump and rack repair, steering column service, alignment procedures and specifications.
Brakes:
Front and rear brake system inspection, pad and rotor replacement, caliper and wheel cylinder service, brake fluid flush and bleeding procedures, ABS system diagnosis (if equipped).
Cooling System:
Radiator service, thermostat replacement, water pump inspection and replacement, coolant type and capacity, fan clutch/electric fan operation.
Fuel System:
Fuel pump diagnosis and replacement, fuel filter replacement, fuel injectors cleaning and testing, evaporative emission control (EVAP) system.
Exhaust System:
Muffler and catalytic converter inspection, exhaust manifold service, gasket replacement, hanger and clamp inspection.
Body And Interior:
Door panel removal, seat adjustment and replacement, dashboard components, exterior trim, bumper service, glass replacement.
Electrical System Lighting:
Headlight, taillight, and interior lighting bulb replacement, wiring harness diagrams, fuse and relay identification.
Heating Ventilation Air Conditioning HVAC:
Heater core replacement, blower motor service, AC system refrigerant handling, cabin air filter replacement.
Procedures Included
Routine Maintenance:
Oil and filter changes, fluid checks and top-offs, tire rotation and pressure checks, spark plug replacement, air filter replacement.
Troubleshooting:
Diagnostic flowcharts for common drivability issues, electrical faults, and mechanical problems. Symptom-based troubleshooting guides.
Repair Procedures:
Step-by-step instructions for component removal, installation, and adjustment across all major vehicle systems.
Diagnostic Codes:
OBD-II diagnostic trouble code (DTC) definitions and suggested diagnostic steps.
Special Tools:
Identification and usage instructions for specialized tools required for specific repair procedures.
Technical Depth
Depth:
Comprehensive coverage suitable for professional mechanics and advanced DIY enthusiasts. Includes detailed torque specifications, clearances, and diagnostic data.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text within the PDF document for quick information retrieval.
Printability:
Printable pages for on-hand reference during repairs.
Resolution:
High-resolution images and diagrams for clarity.
⚙️ Engine Specifications
Primary Engine
Engine Code:
H20A
Engine Type:
Inline 4-cylinder, DOHC, 16-valve
Displacement:
1998 cc (2.0 Liters)
Performance
Horsepower:
Approx. 120-130 PS (90-97 kW) at varying RPMs (specific figure depends on market and tune).
Torque:
Approx. 170-180 Nm (125-133 lb-ft) at varying RPMs.
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Emission Control
Catalytic Converter:
Equipped with a catalytic converter for emissions compliance.
🔧 Transmission
Standard
Type:
5-speed Manual Transmission
Optional
Type:
4-speed Automatic Transmission
Features
Transfer Case:
For 4WD models: Dual-range transfer case with selectable 2WD, 4WD High, and 4WD Low.
Fluid Specifications
Manual Fluid:
API GL-4, SAE 75W-90 (or equivalent, refer to manual for exact specification).
Automatic Fluid:
Dexron III or equivalent (refer to manual for exact specification).
📐 Dimensions
Exterior
Length:
Approx. 3,735 mm (147.0 in)
Width:
Approx. 1,690 mm (66.5 in)
Height:
Approx. 1,655 mm (65.2 in)
Wheelbase:
Approx. 2,430 mm (95.7 in)
Ground Clearance:
Approx. 195 mm (7.7 in)
Weights
Curb Weight:
Approx. 1,160 kg - 1,250 kg (2,557 - 2,756 lbs) depending on configuration.
🛡️ Safety Features
Ratings
Crash Test Results:
Specific crash test ratings for the 1998 J100 are not widely publicized or standardized across global agencies like NHTSA or Euro NCAP as contemporary vehicles. Refer to regional safety data if available.
Active Features
ABS:
Anti-lock Braking System (ABS) may be available as an option or standard on higher trim levels.
Passive Features
Airbags:
Driver and front passenger airbags (standard or optional depending on market).
Seatbelts:
3-point seatbelts with pretensioners for front occupants.
Body Structure
Construction:
Reinforced body structure, integrated into the ladder frame for enhanced rigidity.
💡 Technology Features
Infotainment
Audio System:
Typically featured a basic AM/FM radio with cassette player or CD player. Speaker configuration usually 2 or 4.
Dashboard Layout:
Functional and driver-focused with clear analog gauges for speed, RPM, fuel, and temperature.
Driver Assistance
Cruise Control:
Available on some higher trim levels or optional.
Connectivity
Power Outlets:
Typically featured a 12V power outlet for accessory charging.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, whichever comes first.
Engine Air Filter:
Replace every 15,000 - 30,000 miles (24,000 - 48,000 km) or annually.
Spark Plugs:
Replace every 30,000 - 60,000 miles (48,000 - 96,000 km), depending on plug type (standard vs. platinum/iridium).
Timing Belt:
Crucial replacement: Every 60,000 - 90,000 miles (96,000 - 144,000 km) or 4-5 years due to interference engine design. The manual will detail the exact interval and procedure.
Transmission Fluid Change:
Manual: Inspect annually, change every 30,000 - 60,000 miles (48,000 - 96,000 km). Automatic: Every 30,000 - 50,000 miles (48,000 - 80,000 km).
Fluid Specifications
Engine Oil Type:
API SN/SP, ILSAC GF-5 or higher, SAE 5W-30 or 10W-30 (refer to manual for specific viscosity based on ambient temperature).
Coolant Type:
Ethylene Glycol based coolant, typically a 50/50 mix with distilled water. Use Asian vehicle specific coolant if recommended.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Body Rust:
As with many vehicles of this era, particularly those used in regions with salt on roads, rust can be an issue on the chassis, wheel arches, and door sills.
Suspension Wear:
Ball joints, tie rod ends, and bushings can wear over time, leading to steering looseness and noise, especially on higher mileage vehicles.
Timing Belt Tensioner:
While the belt itself is critical, the tensioner can sometimes fail, necessitating replacement alongside the belt. The manual will guide on inspection.
Exhaust Leaks:
Gaskets and hangers for the exhaust system can degrade and cause leaks, leading to noise and potential performance issues.
Window Regulators:
Power window regulators can become stiff or fail, requiring lubrication or replacement.
📚 Vehicle History
Brand Heritage
Daihatsu Legacy:
Daihatsu, a subsidiary of Toyota, has a long history in producing small, economical, and durable vehicles, particularly in the Kei car and compact SUV segments.
Model Evolution
Terios J100 Introduction:
The J100 generation was introduced globally in 1997 as Daihatsu's compact SUV offering, designed to compete in a growing segment. It succeeded the nature of Daihatsu's rugged kei-class vehicles but in a more substantial package.
Production
Manufacturing Locations:
Primarily manufactured in Japan by Daihatsu Motor Co., Ltd. Also produced or assembled under license in other markets.
Production Years
J100 Production Span:
1997-2006 (with facelifts and updates)
🏆 Awards & Recognition
Recognitions
Market Reputation:
The Daihatsu Terios J100 gained a reputation for its compact size, surprising off-road capability (especially 4WD models), and durability in its segment, often favored for its utilitarian nature and affordability.
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