Daihatsu Boon 2004-2010 Workshop Service Manual for Repair

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🏷️ Basic Information Identification Make: Daihatsu Model: Boon Model Generation: First Generation Chassis Code: M300 Production Years Covered: 2004-2010 👋 Introduction Market Position Vehicle Segment: Subcompact hatchback, popular in urban environments and for its fuel efficiency. Competitive Analysis Competitors: Competes with vehicles like the Toyota Yaris (Vitz), Honda Fit (Jazz), and Suzuki Swift. Key Features Design Philosophy: Focus on compact dimensions, practical interior packaging, and economical operation. Value Proposition Manual Value: Provides essential information for DIY enthusiasts and professional mechanics to maintain and repair the Daihatsu Boon effectively. 📋 Manual Details Coverage Areas Coverage Type: Comprehensive Workshop Service and Repair Page Count Total Pages: 2622 Manual Type Type: Workshop Service Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine: All engine variants, including disassembly, assembly, troubleshooting, and diagnostics. Transmission: Manual and Automatic transmission service, repair, and adjustment procedures. Drivetrain: Front-wheel drive (FWD) and All-wheel drive (AWD) systems, including differentials and driveshafts. Suspension: Front and rear suspension components, alignment, and related adjustments. Steering: Power steering system, steering column, and wheel assembly. Brakes: Hydraulic brake system, ABS, disc and drum brake service, and parking brake. Electrical System: Full electrical system diagnostics, wiring diagrams, component testing, and repair. Cooling System: Radiator, water pump, thermostat, hoses, and fan assembly service. Fuel System: Fuel tank, fuel pump, injectors, and emissions control systems. Exhaust System: Exhaust manifold, catalytic converter, muffler, and pipe repair/replacement. Body And Chassis: Body panel removal/installation, door mechanisms, glass replacement, and chassis component service. HVAC: Heating, Ventilation, and Air Conditioning system servicing and repair. Interior: Seating, dashboard, trim panels, and interior component service. Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, and general upkeep. Troubleshooting: Comprehensive diagnostic charts and procedures for identifying and resolving common and uncommon faults. Repair: Detailed step-by-step repair instructions for all vehicle systems...

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Mots clés: 2004 2005 2006 2007 2008 2009 2010 Boon Car Cars Daihatsu

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Daihatsu

Model:

Model Generation:

First Generation

Chassis Code:

Production Years Covered:

2004-2010

👋 Introduction

Market Position

Vehicle Segment:

Subcompact hatchback, popular in urban environments and for its fuel efficiency.

Competitive Analysis

Competitors:

Competes with vehicles like the Toyota Yaris (Vitz), Honda Fit (Jazz), and Suzuki Swift.

Key Features

Design Philosophy:

Focus on compact dimensions, practical interior packaging, and economical operation.

Value Proposition

Manual Value:

Provides essential information for DIY enthusiasts and professional mechanics to maintain and repair the Daihatsu Boon effectively.

📋 Manual Details

Coverage Areas

Coverage Type:

Comprehensive Workshop Service and Repair

Page Count

Total Pages:

Manual Type

Type:

Workshop Service Manual

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine:

All engine variants, including disassembly, assembly, troubleshooting, and diagnostics.

Transmission:

Manual and Automatic transmission service, repair, and adjustment procedures.

Drivetrain:

Front-wheel drive (FWD) and All-wheel drive (AWD) systems, including differentials and driveshafts.

Suspension:

Front and rear suspension components, alignment, and related adjustments.

Steering:

Power steering system, steering column, and wheel assembly.

Brakes:

Hydraulic brake system, ABS, disc and drum brake service, and parking brake.

Electrical System:

Full electrical system diagnostics, wiring diagrams, component testing, and repair.

Cooling System:

Radiator, water pump, thermostat, hoses, and fan assembly service.

Fuel System:

Fuel tank, fuel pump, injectors, and emissions control systems.

Exhaust System:

Exhaust manifold, catalytic converter, muffler, and pipe repair/replacement.

Body And Chassis:

Body panel removal/installation, door mechanisms, glass replacement, and chassis component service.

HVAC:

Heating, Ventilation, and Air Conditioning system servicing and repair.

Interior:

Seating, dashboard, trim panels, and interior component service.

Procedures Included

Maintenance:

Scheduled maintenance, fluid changes, filter replacements, and general upkeep.

Troubleshooting:

Comprehensive diagnostic charts and procedures for identifying and resolving common and uncommon faults.

Repair:

Detailed step-by-step repair instructions for all vehicle systems and components.

Removal And Installation:

Explicit instructions for the removal and installation of all major and minor components.

Disassembly And Assembly:

In-depth procedures for the disassembly and reassembly of mechanical and electrical units.

Adjustment:

Precise instructions for adjustments to various systems, including brakes, clutch, and engine components.

Technical Depth

Depth:

From basic maintenance checks to complete engine and transmission overhauls. Includes factory specifications and tolerances.

Illustrations

Diagrams And Photos:

Richly illustrated with detailed pictorial diagrams, exploded views, schematics, and photographs.

Special Tools

Tool References:

References to required special service tools and their usage, often depicted in illustrations.

Safety Precautions

Notes And Warnings:

Includes specific notes, cautions, warnings, and DANGER indicators for safety during repair procedures.

📊 Manual Specifications

File Format

File Format:

Print Quality

Printability:

Fully printable, allowing for high-quality hard copy output of all pages.

Binding Type

Binding:

Digital Download (PDF), user printable.

Paper Type

Paper Quality:

Not applicable (digital format), but designed for clear printing on standard paper.

Compatibility

Operating Systems:

Compatible with Windows, Mac, and Linux operating systems.

Requirements

Software Requirement:

Requires Adobe Reader or a compatible PDF viewer.

⚙️ Engine Specifications

Primary Engine

Engine Options:

Primarily features 1.0L (1KR-FE) and 1.3L (K3-VE) inline-3 and inline-4 gasoline engines, respectively.

Performance

Horsepower Range:

Typically ranging from 65-70 hp for the 1.0L and 90-100 hp for the 1.3L, depending on specific market tuning.

Torque Range:

Approximate torque figures of 85-95 Nm for the 1.0L and 120-135 Nm for the 1.3L.

Fuel System

Injection Type:

Electronic Fuel Injection (EFI).

Engine Management

ECU Details:

Detailed information on Engine Control Unit (ECU) operation, diagnostics, and reprogramming procedures.

Emissions

Emissions Control:

Information on catalytic converters, oxygen sensors, and other emissions control systems.

🔧 Transmission

Standard

Transmission Options:

Commonly equipped with either a 5-speed manual transmission or a Continuously Variable Transmission (CVT).

Optional

Gear Ratios:

Detailed gear ratios for both manual and CVT transmissions are provided for performance analysis and repair.

Features

Transmission Fluid:

Specifications for automatic transmission fluid (ATF) type and capacity, as well as manual gearbox oil.

📐 Dimensions

Exterior

Overall Length:

Approximately 3,615 mm (may vary slightly by specific model year and trim).

Overall Width:

Approximately 1,665 mm.

Overall Height:

Approximately 1,500 mm.

Wheelbase

Wheelbase:

Approximately 2,400 mm.

Weights

Curb Weight:

Typically around 850-950 kg, depending on engine and transmission.

🛡️ Safety Features

Ratings

Crash Test Results:

While specific ratings vary by region, the manual provides safety-related information and component specifications for crashworthiness.

Active Features

Information on the Anti-lock Braking System (ABS) operation, components, and troubleshooting.

Passive Features

Airbags:

Details on airbag systems, SRS (Supplemental Restraint System) components, and related safety precautions.

Seatbelts:

Information pertaining to seatbelt mechanisms and their importance in vehicle safety.

💡 Technology Features

Infotainment

Audio System:

Information on factory audio systems, speaker replacement, and basic troubleshooting.

Driver Assistance

Cruise Control:

Details on the operation and service of the cruise control system, if equipped.

Connectivity

Lighting System:

Comprehensive coverage of headlights, taillights, interior lighting, and electrical circuits.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Refer to the manual for specific engine oil and filter change intervals, typically recommended every 5,000-10,000 km or 6-12 months, depending on driving conditions.

Spark Plug Replacement:

Intervals for spark plug replacement will vary by plug type (standard, platinum, iridium) and are detailed within the manual.

Fluid Specifications

Engine Oil Type:

Typically 0W-20 or 5W-30 API SN or higher, with specific viscosity grades detailed in the manual.

Coolant Type:

Ethylene glycol-based coolant with corrosion inhibitors, typically a pink or red long-life formulation.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid as specified in the manual.

Known Issues

Common Wear Items:

Potential wear items include brake pads, clutch components (on manual transmissions), suspension bushings, and oxygen sensors. The manual details inspection and replacement procedures.

Cvt Considerations:

CVT transmissions may require specific maintenance procedures and fluid types; the manual provides detailed guidance.

📚 Vehicle History

Brand Heritage

Daihatsu Legacy:

Daihatsu, a subsidiary of Toyota, has a long history of producing small, economical, and reliable vehicles.

Model Evolution

Boon Origin:

The Daihatsu Boon (also known as Toyota Passo in some markets) was developed as a compact city car with a focus on interior space and practicality.

Production

Manufacturing Location:

Primarily manufactured in Japan.

🏆 Awards & Recognition

Recognitions

Fuel Efficiency Awards:

While not directly listed, the Boon/Passo series has historically been recognized for its strong fuel economy ratings in its class.

Ratings

Reliability Perception:

Generally perceived as a reliable vehicle due to Toyota's engineering influence and Daihatsu's focus on dependable small cars.