DAIHATSU S85 HIJET Diesel Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Daihatsu Model: Hijet Model Code: S85 Generation: Third Generation (S80 Series) Codes Engine Code Primary: 1.4L Diesel (e.g., DL42) 👋 Introduction Market Position Vehicle Segment: Kei truck/van, light commercial vehicle Competitive Analysis Key Competitors Segment: Suzuki Carry, Mitsubishi Minicab, Subaru Sambar (during its era) Key Features Value Proposition: Compact size, fuel efficiency (diesel), utility, affordability, and reliability for light commercial use. Manual Advantage: Provides DIY enthusiasts and professional mechanics with the necessary technical data to maintain and repair the S85 Hijet effectively, saving on labor costs. 📋 Manual Details Coverage Areas Manual Coverage: All models and sub-models of Daihatsu S85 Hijet equipped with diesel engines Page Count Estimated Page Count: Hundreds of pages (specific count not provided, but described as comprehensive) Manual Type Manual Type: Service Repair Workshop Manual Language Language: English (implied by typical availability and product description) Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Service: Engine mechanicals, lubrication, cooling, fuel system (diesel injection), intake and exhaust, starting and charging Transmission Service: Manual transmission (and potentially automatic if offered on S85 diesel), clutch, driveshafts, differentials Brake System Service: Front and rear brakes (likely drum or disc depending on configuration), hydraulic system, parking brake Suspension Steering Service: Front and rear suspension components, steering gear, power steering (if equipped) Electrical System Service: Wiring diagrams, lighting, instrument cluster, ignition system, charging system, starter motor, fuses, relays Body Chassis Service: Body panels, doors, interior trim, chassis components, frame, exhaust system, fuel tank Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, belt adjustments, spark plug replacement (if applicable, less common on diesel), tire rotation Diagnostic Troubleshooting: Step-by-step procedures for identifying and resolving common and uncommon problems across all vehicle systems Repair Rebuild Procedures: Detailed instructions for engine overhaul, transmission repair, brake caliper replacement, suspension component replacement, and more Electrical Troubleshooting: Using wiring diagrams, testing circuits, diagnosing faults in electrical components Torque Specifications: Precise torque values for critical fasteners across all major components Technical Depth Depth Of Coverage: Comprehensive: Covers everything from basic maintenance to complete engine rebuilds, including detailed diagnostic procedures and specifications. 📊 Manual Specifications File Format File Quality: PDF format, expected to be high resolution and searchable text for ease of use. Print Readability: Designed for easy reading on screen and printing of specific pages for workshop use. Binding Type Binding Type: Digital Download (PDF) Paper Type Paper Type: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 3-cylinder, naturally aspirated diesel Displacement Cc: Approx. 1.4 Liters (e.g., 1377cc for DL42) Bore X Stroke Mm: Specific to engine variant (e.g., 76.0 x 100.0 mm for DL42) Compression Ratio: Typical of naturally aspirated diesel of the era (e.g., around 22:1) Power Output Ps Rpm: Estimated 40-50 PS (specific to variant and market) Torque Kgm Rpm: Estimated 8-10 kgm (specific to variant and market) Fuel System Fuel Type: Diesel Injection System: Indirect Injection (IDI) with rotary or inline injection pump Glow Plugs: Equipped with glow plugs for cold starting Performance Fuel Economy City Highway Kpl: Highly variable, but expected to be efficient for its class (e.g., 15-20+ km/L) 🔧 Transmission Standard Transmission Type: 4-speed or 5-speed manual transmission Optional Transmission Type Optional: Automatic transmission (less common on diesel variants of this generation) Features Drivetrain: Rear-wheel drive (RWD) or 4-wheel drive (4WD) options available Clutch Type: Dry single-plate clutch 📐 Dimensions Exterior Length Mm: Varies by body style (e.g., truck vs. panel van), typically around 3395-3400 mm for Kei class length restrictions. Width Mm: Varies by body style, typically around 1475 mm for Kei class width restrictions. Height Mm: Varies by body style, often around 1880-1900 mm for panel vans. Weights Curb Weight Kg: Approximately 850-1000 kg depending on configuration. Gross Vehicle Weight Rating Kg: Typically around 1700-1800 kg. 🛡️ Safety Features Ratings Crash Test Data: Limited public data for this specific era and segment, focus is on basic safety features. Active Features Braking System: Front disc brakes, Rear drum brakes (common configuration) Passive Features Seatbelts: Standard seatbelts (likely 2-point in older models, 3-point in later variants) Body Construction: Reinforced chassis and body structure for its class. 💡 Technology Features Infotainment Infotainment Features: Basic AM/FM radio, cassette player or optional CD player (depending on trim and market). Driver Assistance Driver Assistance Features: Minimal; focus on basic functionality rather than electronic aids. Connectivity Connectivity Features: None; designed for utilitarian purposes, not connectivity. 🔧 Maintenance Service Intervals Engine Oil Change Interval Km Months: Typically 5,000-7,500 km or 6 months (refer to manual for exact spec). Oil Filter Replacement Interval: Replace with every oil change. Air Filter Replacement Interval Km: Every 15,000-20,000 km, or more frequently in dusty conditions. Fuel Filter Replacement Interval Km: Every 20,000-30,000 km (critical for diesel systems). Coolant Change Interval Km Years: Every 30,000-40,000 km or 2 years. Fluid Specifications Engine...
Suzuki Carry, Mitsubishi Minicab, Subaru Sambar (during its era)
Key Features
Value Proposition:
Compact size, fuel efficiency (diesel), utility, affordability, and reliability for light commercial use.
Manual Advantage:
Provides DIY enthusiasts and professional mechanics with the necessary technical data to maintain and repair the S85 Hijet effectively, saving on labor costs.
📋 Manual Details
Coverage Areas
Manual Coverage:
All models and sub-models of Daihatsu S85 Hijet equipped with diesel engines
Page Count
Estimated Page Count:
Hundreds of pages (specific count not provided, but described as comprehensive)
Manual Type
Manual Type:
Service Repair Workshop Manual
Language
Language:
English (implied by typical availability and product description)
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Service:
Engine mechanicals, lubrication, cooling, fuel system (diesel injection), intake and exhaust, starting and charging
Transmission Service:
Manual transmission (and potentially automatic if offered on S85 diesel), clutch, driveshafts, differentials
Brake System Service:
Front and rear brakes (likely drum or disc depending on configuration), hydraulic system, parking brake
Suspension Steering Service:
Front and rear suspension components, steering gear, power steering (if equipped)
Body panels, doors, interior trim, chassis components, frame, exhaust system, fuel tank
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, belt adjustments, spark plug replacement (if applicable, less common on diesel), tire rotation
Diagnostic Troubleshooting:
Step-by-step procedures for identifying and resolving common and uncommon problems across all vehicle systems
Repair Rebuild Procedures:
Detailed instructions for engine overhaul, transmission repair, brake caliper replacement, suspension component replacement, and more
Electrical Troubleshooting:
Using wiring diagrams, testing circuits, diagnosing faults in electrical components
Torque Specifications:
Precise torque values for critical fasteners across all major components
Technical Depth
Depth Of Coverage:
Comprehensive: Covers everything from basic maintenance to complete engine rebuilds, including detailed diagnostic procedures and specifications.
📊 Manual Specifications
File Format
File Quality:
PDF format, expected to be high resolution and searchable text for ease of use.
Print Readability:
Designed for easy reading on screen and printing of specific pages for workshop use.
Binding Type
Binding Type:
Digital Download (PDF)
Paper Type
Paper Type:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 3-cylinder, naturally aspirated diesel
Displacement Cc:
Approx. 1.4 Liters (e.g., 1377cc for DL42)
Bore X Stroke Mm:
Specific to engine variant (e.g., 76.0 x 100.0 mm for DL42)
Compression Ratio:
Typical of naturally aspirated diesel of the era (e.g., around 22:1)
Power Output Ps Rpm:
Estimated 40-50 PS (specific to variant and market)
Torque Kgm Rpm:
Estimated 8-10 kgm (specific to variant and market)
Fuel System
Fuel Type:
Diesel
Injection System:
Indirect Injection (IDI) with rotary or inline injection pump
Glow Plugs:
Equipped with glow plugs for cold starting
Performance
Fuel Economy City Highway Kpl:
Highly variable, but expected to be efficient for its class (e.g., 15-20+ km/L)
🔧 Transmission
Standard
Transmission Type:
4-speed or 5-speed manual transmission
Optional
Transmission Type Optional:
Automatic transmission (less common on diesel variants of this generation)
Features
Drivetrain:
Rear-wheel drive (RWD) or 4-wheel drive (4WD) options available
Clutch Type:
Dry single-plate clutch
📐 Dimensions
Exterior
Length Mm:
Varies by body style (e.g., truck vs. panel van), typically around 3395-3400 mm for Kei class length restrictions.
Width Mm:
Varies by body style, typically around 1475 mm for Kei class width restrictions.
Height Mm:
Varies by body style, often around 1880-1900 mm for panel vans.
Weights
Curb Weight Kg:
Approximately 850-1000 kg depending on configuration.
Gross Vehicle Weight Rating Kg:
Typically around 1700-1800 kg.
🛡️ Safety Features
Ratings
Crash Test Data:
Limited public data for this specific era and segment, focus is on basic safety features.
Active Features
Braking System:
Front disc brakes, Rear drum brakes (common configuration)
Passive Features
Seatbelts:
Standard seatbelts (likely 2-point in older models, 3-point in later variants)
Body Construction:
Reinforced chassis and body structure for its class.
💡 Technology Features
Infotainment
Infotainment Features:
Basic AM/FM radio, cassette player or optional CD player (depending on trim and market).
Driver Assistance
Driver Assistance Features:
Minimal; focus on basic functionality rather than electronic aids.
Connectivity
Connectivity Features:
None; designed for utilitarian purposes, not connectivity.
🔧 Maintenance
Service Intervals
Engine Oil Change Interval Km Months:
Typically 5,000-7,500 km or 6 months (refer to manual for exact spec).
Oil Filter Replacement Interval:
Replace with every oil change.
Air Filter Replacement Interval Km:
Every 15,000-20,000 km, or more frequently in dusty conditions.
Fuel Filter Replacement Interval Km:
Every 20,000-30,000 km (critical for diesel systems).
Coolant Change Interval Km Years:
Every 30,000-40,000 km or 2 years.
Fluid Specifications
Engine Oil Type:
Diesel Engine Oil, API CF or higher, SAE 15W-40 or 10W-30 (check manual for exact viscosity).
Engine Oil Capacity Liters:
Approximately 5.0-5.5 Liters (with filter).
Transmission Fluid Type:
GL-4 Gear Oil, SAE 75W-90 or 80W-90 (check manual for exact specification).
Brake Fluid Type:
DOT 3 or DOT 4 Brake Fluid.
Coolant Type:
Ethylene Glycol based coolant (antifreeze/coolant mixture).
Clogging of fuel filters, issues with glow plug operation in cold weather, potential for injector pump wear over high mileage.
📚 Vehicle History
Brand Heritage
Daihatsu History:
Daihatsu, a subsidiary of Toyota, has a long history of producing small, efficient vehicles, particularly kei cars and commercial vehicles.
Model Evolution
Hijet Evolution:
The Hijet has been in continuous production since the 1960s, evolving through numerous generations to meet changing market demands and regulations.
Production
S85 Production Years:
Late 1980s to early 1990s (approx. 1986-1994), depending on market.
Manufacturing Location:
Primarily Japan
🏆 Awards & Recognition
Recognitions
Segment Awards:
While specific awards for the S85 Hijet might not be widely documented, the Hijet line has historically been recognized for its practicality and value in the light commercial vehicle segment.