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Daihatsu Copen 2002-2012 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Copen Generation Codes: L880K Model Years Covered: 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012 👋 Introduction Market Position Vehicle Segment: Kei car, convertible sports car. Target Audience: Enthusiasts and owners seeking detailed repair and maintenance information. Competitive Analysis Competitors: Other small, sporty convertibles, though the Copen occupies a unique niche. Key Features Manual Advantage: Provides professional-level diagnostic and repair procedures in an accessible digital format. Manual Benefit: Enables DIY repairs, reduces reliance on expensive dealership services, and aids in maintaining vehicle value. 📋 Manual Details Coverage Areas Primary Coverage: Full Service Repair Secondary Coverage: Maintenance, Diagnostics, Wiring Diagrams, Troubleshooting Page Count Estimated Pages: N/A (Digital Download) Manual Type Type: Service and Repair Manual Language Language: English Format File Format: PDF Delivery Method: Instant Download 📖 Manual Coverage Systems Covered Engine: Comprehensive coverage for engine mechanical and electrical systems. Transmission: Manual and automatic transmission service, repair, and diagnostics. Drivetrain: Front-wheel drive system, including axles, CV joints, and differential. Suspension: Front and rear suspension components, including struts, springs, bushings, and alignment. Steering: Power steering system, steering column, and linkage. Brakes: Front and rear brake systems, including ABS, rotors, pads, calipers, and hydraulic lines. Electrical: Complete electrical system diagnostics, wiring diagrams, lighting, ignition, and charging systems. Body And Frame: Body panels, doors, convertible roof mechanism, interior trim, and chassis components. Heating Ventilation And Air Conditioning HVAC: HVAC system components, refrigerant, and diagnostics. Fuel System: Fuel tank, pump, injectors, and fuel pressure regulator. Exhaust System: Exhaust manifold, catalytic converter, mufflers, and pipes. Procedures Included Maintenance: Regular maintenance procedures, fluid changes, filter replacements, and inspections. Troubleshooting: Step-by-step troubleshooting guides for common and complex issues. Repair: Detailed repair procedures for all major vehicle systems. Diagnostics: Diagnostic procedures for engine management, ABS, and other electronic systems. Rebuilds: Engine and transmission rebuild procedures. Wiring Diagrams: Comprehensive and detailed electrical wiring diagrams for all circuits. Technical Depth Depth: Comprehensive, suitable for professional technicians and advanced DIY enthusiasts. 📊 Manual Specifications File Format Compatibility: All versions of Windows and Mac. Required Software: Adobe PDF Reader & WinRAR Print Quality Printability: Full printable pages. Digital Storage: Can be saved to hard drive or burned to CD-ROM. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: JB-DET Engine Type: 659cc, turbocharged, intercooled, DOHC, 16-valve, inline-3 petrol engine. Performance Horsepower: 64 PS (47 kW; 63 bhp) at 6000 rpm (Japanese Domestic Market due to Kei car regulations). Torque: 10.5 kg⋅m (103 N⋅m; 76 lb⋅ft) at 3200 rpm. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI). Fuel Type: Unleaded gasoline. Induction Turbocharger: Yes, Garrett TGV or similar specification turbocharger. Engine Management ECU Type: Engine Control Unit (ECU) with detailed diagnostic parameters. 🔧 Transmission Standard Transmission Type: 4-speed automatic or 5-speed manual. Optional Transmission Options: 5-speed manual transmission, 4-speed automatic transmission. Features Clutch: Hydraulic clutch actuation (manual transmission). 📐 Dimensions Exterior Length: 3,395 mm (133.7 in) Width: 1,475 mm (58.1 in) Height: 1,245 mm (49.0 in) Wheelbase: 2,290 mm (90.2 in) Weights Curb Weight: Approximately 850 kg (1,874 lb). Cargo Trunk Capacity: Minimal; designed for personal transport, not cargo. 🛡️ Safety Features Ratings Crash Test Ratings: Varies by market and testing agency; generally designed to meet JNCAP standards for its era. Active Features ABS: Anti-lock Braking System (ABS) typically optional or standard on higher trims. Traction Control: Traction Control System (TCS) may be available on some models. Passive Features Airbags: Driver and passenger airbags. Rollover Protection: Integrated rollover protection bar behind the seats. 💡 Technology Features Infotainment Audio System: Factory fitted radio/CD player with standard speaker setup. Gauge Cluster: Includes tachometer, speedometer, fuel gauge, and temperature gauge; often with digital odometer. Driver Assistance Parking Sensors: Generally not equipped as standard, but aftermarket options may exist. Connectivity Usb Aux Input: Not typically factory fitted; requires aftermarket integration. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 7,500 - 10,000 km or 6-12 months, depending on driving conditions. Air Filter Replacement: Recommended every 30,000 km or as needed based on inspection. Spark Plug Replacement: Check and replace as per manual, typically around 100,000 km for iridium plugs. Fluid Specifications Engine Oil Type: API SN or higher, SAE 0W-20 or 5W-30 viscosity (refer to manual for specific recommendation). Coolant Type: Ethylene glycol-based coolant, typically a pink or red long-life type (e.g., Toyota Super Long Life Coolant or equivalent). Transmission Fluid Manual: GL-4 specification gear oil, SAE 75W-90 (check manual for exact spec and capacity). Transmission Fluid Automatic: Dexron III or equivalent ATF (check manual for exact spec and capacity). Brake Fluid Type: DOT 3 or DOT 4 brake fluid. Known Issues Turbocharger: Potential for oil leaks or turbo wear with high mileage; regular checks are advised. Convertible Roof Mechanism: Actuator motor, seals, and hydraulic lines can degrade...
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Daihatsu Copen 2002-2012 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Copen
Generation Codes:
L880K
Model Years Covered:
2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012
👋 Introduction
Market Position
Vehicle Segment:
Kei car, convertible sports car.
Target Audience:
Enthusiasts and owners seeking detailed repair and maintenance information.
Competitive Analysis
Competitors:
Other small, sporty convertibles, though the Copen occupies a unique niche.
Key Features
Manual Advantage:
Provides professional-level diagnostic and repair procedures in an accessible digital format.
Manual Benefit:
Enables DIY repairs, reduces reliance on expensive dealership services, and aids in maintaining vehicle value.
📋 Manual Details
Coverage Areas
Primary Coverage:
Full Service Repair
Secondary Coverage:
Maintenance, Diagnostics, Wiring Diagrams, Troubleshooting
Page Count
Estimated Pages:
N/A (Digital Download)
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
File Format:
PDF
Delivery Method:
Instant Download
📖 Manual Coverage
Systems Covered
Engine:
Comprehensive coverage for engine mechanical and electrical systems.
Transmission:
Manual and automatic transmission service, repair, and diagnostics.
Drivetrain:
Front-wheel drive system, including axles, CV joints, and differential.
Suspension:
Front and rear suspension components, including struts, springs, bushings, and alignment.
Steering:
Power steering system, steering column, and linkage.
Brakes:
Front and rear brake systems, including ABS, rotors, pads, calipers, and hydraulic lines.
Electrical:
Complete electrical system diagnostics, wiring diagrams, lighting, ignition, and charging systems.
Body And Frame:
Body panels, doors, convertible roof mechanism, interior trim, and chassis components.
Heating Ventilation And Air Conditioning HVAC:
HVAC system components, refrigerant, and diagnostics.
Fuel System:
Fuel tank, pump, injectors, and fuel pressure regulator.
Exhaust System:
Exhaust manifold, catalytic converter, mufflers, and pipes.
Procedures Included
Maintenance:
Regular maintenance procedures, fluid changes, filter replacements, and inspections.
Troubleshooting:
Step-by-step troubleshooting guides for common and complex issues.
Repair:
Detailed repair procedures for all major vehicle systems.
Diagnostics:
Diagnostic procedures for engine management, ABS, and other electronic systems.
Rebuilds:
Engine and transmission rebuild procedures.
Wiring Diagrams:
Comprehensive and detailed electrical wiring diagrams for all circuits.
Technical Depth
Depth:
Comprehensive, suitable for professional technicians and advanced DIY enthusiasts.
📊 Manual Specifications
File Format
Compatibility:
All versions of Windows and Mac.
Required Software:
Adobe PDF Reader & WinRAR
Print Quality
Printability:
Full printable pages.
Digital Storage:
Can be saved to hard drive or burned to CD-ROM.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
JB-DET
Engine Type:
659cc, turbocharged, intercooled, DOHC, 16-valve, inline-3 petrol engine.
Performance
Horsepower:
64 PS (47 kW; 63 bhp) at 6000 rpm (Japanese Domestic Market due to Kei car regulations).
Torque:
10.5 kg⋅m (103 N⋅m; 76 lb⋅ft) at 3200 rpm.
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI).
Fuel Type:
Unleaded gasoline.
Induction
Turbocharger:
Yes, Garrett TGV or similar specification turbocharger.
Engine Management
ECU Type:
Engine Control Unit (ECU) with detailed diagnostic parameters.
🔧 Transmission
Standard
Transmission Type:
4-speed automatic or 5-speed manual.
Optional
Transmission Options:
5-speed manual transmission, 4-speed automatic transmission.
Features
Clutch:
Hydraulic clutch actuation (manual transmission).
📐 Dimensions
Exterior
Length:
3,395 mm (133.7 in)
Width:
1,475 mm (58.1 in)
Height:
1,245 mm (49.0 in)
Wheelbase:
2,290 mm (90.2 in)
Weights
Curb Weight:
Approximately 850 kg (1,874 lb).
Cargo
Trunk Capacity:
Minimal; designed for personal transport, not cargo.
🛡️ Safety Features
Ratings
Crash Test Ratings:
Varies by market and testing agency; generally designed to meet JNCAP standards for its era.
Active Features
ABS:
Anti-lock Braking System (ABS) typically optional or standard on higher trims.
Traction Control:
Traction Control System (TCS) may be available on some models.
Passive Features
Airbags:
Driver and passenger airbags.
Rollover Protection:
Integrated rollover protection bar behind the seats.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/CD player with standard speaker setup.
Gauge Cluster:
Includes tachometer, speedometer, fuel gauge, and temperature gauge; often with digital odometer.
Driver Assistance
Parking Sensors:
Generally not equipped as standard, but aftermarket options may exist.
Connectivity
Usb Aux Input:
Not typically factory fitted; requires aftermarket integration.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 - 10,000 km or 6-12 months, depending on driving conditions.
Air Filter Replacement:
Recommended every 30,000 km or as needed based on inspection.
Spark Plug Replacement:
Check and replace as per manual, typically around 100,000 km for iridium plugs.
Fluid Specifications
Engine Oil Type:
API SN or higher, SAE 0W-20 or 5W-30 viscosity (refer to manual for specific recommendation).
Coolant Type:
Ethylene glycol-based coolant, typically a pink or red long-life type (e.g., Toyota Super Long Life Coolant or equivalent).
Transmission Fluid Manual:
GL-4 specification gear oil, SAE 75W-90 (check manual for exact spec and capacity).
Transmission Fluid Automatic:
Dexron III or equivalent ATF (check manual for exact spec and capacity).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Turbocharger:
Potential for oil leaks or turbo wear with high mileage; regular checks are advised.
Convertible Roof Mechanism:
Actuator motor, seals, and hydraulic lines can degrade over time; requires careful inspection and maintenance.
Suspension Bushings:
Rubber bushings can wear, leading to clunking noises and compromised handling.
📚 Vehicle History
Brand Heritage
Brand Focus:
Daihatsu is known for producing reliable and practical small cars, with a history of innovative designs.
Model Evolution
Generation 1 Start:
The first generation Copen (L880K) was launched in 2002, succeeding the original Copen (L800K).
Key Innovation:
The signature feature is its retractable hardtop convertible roof, which operates electronically.
Production
Manufacturing Location:
Japan.
Production Period:
2002 - 2012 (for the L880K generation covered by this manual).
🏆 Awards & Recognition
Recognitions
Design Awards:
Praised for its unique styling and compact convertible design, often winning accolades in its category in Japan.
Ratings
User Satisfaction:
Generally high owner satisfaction due to its fun-to-drive nature and distinctive appearance.
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