1997 Daihatsu Terios (1st gen) Service and Repair Manual
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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Year: 1997 Generation: 1st Generation (J100 Series) Codes Chassis Codes: J100G, J102G, J122G Engine Codes: HC-EJ (1.3L), K3-VE (1.3L, later models, may be covered) 👋 Introduction Market Position Segment: Compact SUV / Mini SUV. Target Audience: Individuals seeking an affordable, capable, and compact off-road-oriented vehicle. Competitive Analysis Key Competitors: Suzuki Vitara, Toyota RAV4 (early models), Honda CR-V (early models), Isuzu Vehi-Cross (niche). Key Features Offroad Capability: Part-time or full-time 4WD system (depending on market/trim), short wheelbase, good ground clearance. Compact Size: Easy maneuverability in urban environments and on tight trails. Fuel Efficiency: Generally good fuel economy for its class. Utility: Practical for light towing, hauling, and recreational activities. 📋 Manual Details Coverage Areas Coverage: All Models & All Repairs A-Z Page Count Page Count: Detailed page count not specified, but implies comprehensive coverage. Manual Type Type: Service and Repair Manual Language Language: English Format Format: Not explicitly stated as print or digital, but described as the 'exact same manual used by technicians at the dealerships'. 📖 Manual Coverage Systems Covered Engine Service: Engine overhaul, timing belt replacement, cooling system, lubrication system, fuel system, ignition system, emissions control. Transmission Service: Manual and automatic transmission service, clutch, driveline components (driveshafts, differentials). Brake System: Disc and drum brake service, parking brake, hydraulic system. Suspension Steering: Front and rear suspension components, shock absorbers, springs, steering gear, power steering system. Electrical System: Battery, charging system (alternator), starting system, lighting, instrument cluster, gauges, wiring diagrams, fuses, relays. Body And Chassis: Body panel repair, interior trim, doors, windows, mirrors, chassis lubrication, structural components. HVAC System: Air conditioning, heating, ventilation system diagnostics and repair. Fuel And Exhaust: Fuel tank, fuel pump, injectors, catalytic converter, muffler, exhaust piping. Procedures Included Maintenance Procedures: Routine maintenance, oil changes, filter replacements, fluid checks, tune-ups. Troubleshooting Diagnostics: Diagnostic charts, common fault finding, symptom-based troubleshooting. Repair Procedures: Step-by-step repair instructions for all major vehicle systems. Rebuild Procedures: Engine and transmission rebuild specifications and procedures. Calibration Adjustment: Wheel alignment specifications, steering angle adjustments. Wiring Diagrams: Detailed electrical system wiring diagrams for all circuits. Technical Depth Depth: Vehicle-specific, comprehensive from basic maintenance to complete engine and transmission overhauls. Designed for dealership technicians. 📊 Manual Specifications File Format Format: Likely printed format, as per dealer technician usage. If digital, typically PDF. Print Quality Quality: High quality, professional printing suitable for workshop environments. Binding Type Binding: Likely spiral-bound or hardbound for durability and ease of use in a workshop. Paper Type Paper: Durable, high-grade paper designed to withstand workshop conditions. ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-cylinder, SOHC Displacement: 1296 cc (1.3 Liters) Engine Code: HC-EJ Bore X Stroke: 70.0 mm x 81.5 mm Compression Ratio: 9.5:1 Power Output: Approx. 70-75 PS (51-55 kW) at 6000 rpm (varies by market and tuning) Torque Output: Approx. 100-105 Nm (74-77 lb-ft) at 3500-4000 rpm (varies by market and tuning) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline Octane Rating: 91 RON minimum recommended. Cooling System Cooling Type: Water-cooled, pressurized. Lubrication System Oil Type: API SG or higher, SAE 10W-30 recommended for most conditions. Refer to manual for specific climate recommendations. Oil Capacity: Approx. 3.2 - 3.5 liters (3.4 - 3.7 US quarts) with filter change. Consult manual for exact capacity. 🔧 Transmission Standard Type: 5-speed Manual Transmission Optional Type: 4-speed Automatic Transmission Features Drivetrain: Part-time 4WD (with optional full-time 4WD system on some models/markets). Transfer Case: Two-speed transfer case (high/low range) on 4WD models. Fluid Specifications Manual Fluid: API GL-4 SAE 75W-90 or SAE 80W-90 gear oil. Automatic Fluid: Dexron II or Dexron III compatible ATF (Automatic Transmission Fluid). 📐 Dimensions Exterior Length: Approx. 3,735 mm (147.0 inches) Width: Approx. 1,600 mm (63.0 inches) Height: Approx. 1,690 - 1,705 mm (66.5 - 67.1 inches) Wheelbase: Approx. 2,340 mm (92.1 inches) Ground Clearance: Approx. 195 mm (7.7 inches) Weights Curb Weight: Approx. 1,080 - 1,150 kg (2,381 - 2,535 lbs) depending on configuration. Gross Vehicle Weight Rating: Varies by market and model, consult specific vehicle documentation. Cargo Cargo Volume: Configurable seating allows for versatile cargo space. Exact volume figures vary. 🛡️ Safety Features Ratings Crash Test Data: Specific official crash test ratings for this model year and region may be limited. Refer to regional safety authorities if available. Active Features ABS: Anti-lock Braking System (ABS) available on some models/trims, particularly later in the generation. 4Wd System: The 4WD system enhances traction and stability in various conditions. Passive Features Airbags: Driver airbag standard. Passenger airbag availability may vary by market. Seat Belts: Front and rear seat belts. Pre-tensioners on front seat belts may be present. Chassis Design: Body-on-frame construction (common for the era and class) provides a robust structure. 💡 Technology Features Infotainment Audio System: Typically a basic AM/FM radio with cassette player or CD player, depending on...
Specific official crash test ratings for this model year and region may be limited. Refer to regional safety authorities if available.
Active Features
ABS:
Anti-lock Braking System (ABS) available on some models/trims, particularly later in the generation.
4Wd System:
The 4WD system enhances traction and stability in various conditions.
Passive Features
Airbags:
Driver airbag standard. Passenger airbag availability may vary by market.
Seat Belts:
Front and rear seat belts. Pre-tensioners on front seat belts may be present.
Chassis Design:
Body-on-frame construction (common for the era and class) provides a robust structure.
💡 Technology Features
Infotainment
Audio System:
Typically a basic AM/FM radio with cassette player or CD player, depending on trim level and market. Aftermarket upgrades are common.
Speakers:
Standard 2 or 4 speaker configuration.
Driver Assistance
Cruise Control:
Optional on higher trim levels or specific markets.
Parking Assistance:
No factory parking sensors or backup cameras on this generation.
Connectivity
Connectivity Options:
No Bluetooth or USB connectivity available from the factory. Auxiliary input might be present on later models or via aftermarket additions.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 - 10,000 km (3,000 - 6,000 miles) or 6-12 months, whichever comes first. Consult manual for precise recommendation based on driving conditions.
Air Filter Replacement:
Every 20,000 - 30,000 km (12,000 - 18,000 miles). Inspect more frequently.
Fuel Filter Replacement:
Every 40,000 - 60,000 km (25,000 - 37,000 miles), especially for in-tank filters.
Spark Plug Replacement:
Every 40,000 - 60,000 km (25,000 - 37,000 miles) with standard copper plugs. Platinum or iridium plugs may have longer intervals.
Timing Belt Replacement:
Crucial: Every 80,000 - 100,000 km (50,000 - 60,000 miles) or 4-5 years, as it is an interference engine. Failure will cause catastrophic engine damage.
Fluid Specifications
Coolant Type:
Ethylene glycol-based coolant, typically a green or blue color. Mix 50/50 with distilled water. Refer to manual for specific Daihatsu/Toyota recommendation.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid:
ATF Dexron II or III compatible, or specific power steering fluid as per manual.
Known Issues
Timing Belt:
As mentioned, crucial to replace on schedule due to interference design. Lack of maintenance leads to engine failure.
Rust Corrosion:
As with many vehicles of this age, particularly in rust-prone climates, check chassis, body panels, and suspension components for rust.
Suspension Wear:
Bushings and ball joints can wear over time, leading to clunks and poor handling.
Exhaust System:
Corrosion can affect exhaust pipes, mufflers, and catalytic converters.
Electrical Connectors:
Corrosion or degradation of electrical connectors can cause intermittent issues.
📚 Vehicle History
Brand Heritage
Daihatsu Focus:
Daihatsu, a subsidiary of Toyota, has a long history of producing small, efficient, and reliable vehicles.
Model Evolution
Terios Introduction:
The first-generation Terios was introduced in 1997, designed to fill the niche of a compact, capable SUV.
Platform:
Based on Daihatsu's proprietary platform, featuring a ladder frame chassis.
Production
Manufacturing Location:
Primarily manufactured in Japan.
Production Years:
1st Generation: 1997-2006.
Global Presence:
Sold in numerous markets worldwide, often under different badges (e.g., Toyota Cami in Japan).
🏆 Awards & Recognition
Recognitions
Awards Citations:
While not typically winning major 'Car of the Year' awards, the Daihatsu Terios was recognized for its value, affordability, and capability in the compact SUV segment.
Reliability Perception:
Daihatsu vehicles are generally perceived as reliable, particularly given their Toyota lineage. Proper maintenance, as detailed in this manual, is key to long-term reliability.
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