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Daihatsu Terios J102 2005 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Year: 2005 Chassis Code: J102 Codes Engine Code: K3-VE 👋 Introduction Market Position Vehicle Segment: Compact SUV / Crossover Competitive Analysis Key Competitors Circa 2005: Honda CR-V, Toyota RAV4, Nissan X-Trail, Suzuki Vitara, Ford EcoSport (depending on market). Key Features Body Style: 5-door SUV Drivetrain Options: Available in Front-Wheel Drive (FWD) and selectable Full-Time Four-Wheel Drive (4WD). Target Audience: Individuals and small families seeking a versatile, compact, and capable vehicle for urban and light off-road use. 📋 Manual Details Coverage Areas Coverage Scope: All Models/Engines/Trims/Transmissions Page Count Estimated Page Count: Approx. 1500-2000 pages (typical for comprehensive workshop manuals) Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format Format: PDF (Downloadable) 📖 Manual Coverage Systems Covered Engine: Engine mechanical, lubrication, cooling, fuel, ignition, emissions control, starting and charging systems. Transmission: Manual and Automatic transmission overhaul, diagnostics, and fluid specifications. Drivetrain: Front-wheel drive, rear-wheel drive, and 4WD system components, including differentials and driveshafts. Suspension: Front and rear suspension components, shock absorbers, springs, control arms, and alignment procedures. Steering: Power steering system, steering column, tie rods, and steering gear diagnostics and repair. Brakes: Front and rear brake systems (disc/drum), ABS, hydraulic components, and bleeding procedures. Electrical: Complete wiring diagrams, lighting systems, power distribution, fuse/relay identification, ECUs, sensors, and actuators. Body: Body panel removal/installation, interior trim, doors, windows, locks, and related mechanisms. HVAC: Heating, Ventilation, and Air Conditioning system diagnosis and repair. Diagnostics: Troubleshooting charts, diagnostic trouble codes (DTCs), and diagnostic procedures for various systems. Procedures Included Maintenance Procedures: Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, belt inspections/replacement. Repair Procedures: Detailed step-by-step instructions for component removal, overhaul, assembly, and installation. Troubleshooting Procedures: Systematic diagnostic guides for identifying and resolving common and complex issues. Overhaul Procedures: Complete disassembly and reassembly instructions for major components like engines and transmissions. Specifications: Torque specifications, clearances, fluid capacities, and critical measurement data. Technical Depth Depth Of Coverage: Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds, including electrical diagnostics. 📊 Manual Specifications File Format File Type: PDF Searchable Text: Yes (typically OCR'd for searchability) Printable: Yes Print Quality Image Resolution: High (suitable for clear viewing of diagrams and text) Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Name: K3-VE Engine Type: Inline 4-cylinder, DOHC, 16-valve Displacement: 1.3 Liters (1298 cc) Bore X Stroke: 72.0 mm x 80.5 mm Compression Ratio: 9.8:1 Performance Horsepower Output: Approx. 85-87 PS (63-64 kW) at 6000 rpm (market dependent) Torque Output: Approx. 120-125 Nm (89-92 lb-ft) at 3200 rpm (market dependent) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline Ignition System: Electronic Ignition (Distributorless - Coil-on-Plug) Other Engine Features Valvetrain: DVVT (Daihatsu Variable Valve Timing) on some variants. 🔧 Transmission Standard Standard Transmission Type: 5-speed Manual Transmission Optional Optional Transmission Type: 4-speed Automatic Transmission Features Transmission Fluid Type: Refer to manual (typically Dexron III/Mercon for automatic, Gear Oil GL-4 for manual). 4Wd System: Viscous coupling type 4WD system with centre differential lock (on some models). 📐 Dimensions Exterior Length: Approx. 3,995 mm (157.3 in) Width: Approx. 1,695 mm (66.7 in) Height: Approx. 1,700 mm (66.9 in) Wheelbase: Approx. 2,430 mm (95.7 in) Ground Clearance: Approx. 195 mm (7.7 in) Weights Curb Weight: Approx. 1060-1180 kg (2337-2601 lbs) depending on configuration. Gross Vehicle Weight Rating: Refer to vehicle placard or manual. Cargo Cargo Volume: Variable with rear seats folded. Approx. 300-400 liters behind rear seats (market dependent). 🛡️ Safety Features Ratings Crash Test Ratings: Varies by market and specific test (e.g., JNCAP, Euro NCAP). Manual will detail specific vehicle structural information relevant to safety. Active Features Antilock Braking System: Available as an option or standard on higher trims (ABS). Electronic Brake Force Distribution: Often paired with ABS. Passive Features Airbags: Driver and front passenger airbags (standard/optional depending on market/trim). Seatbelts: 3-point seatbelts with pretensioners for front occupants. Child Seat Anchors: ISOFIX/LATCH mounting points available on rear seats. 💡 Technology Features Infotainment Audio System: Basic AM/FM radio with CD player, potentially with auxiliary input on later models. Speaker configuration varies by trim. Driver Assistance Parking Assistance: Rear parking sensors may be available on some higher-spec models, but generally not a standard feature. Connectivity Connectivity Options: Limited. Typically no Bluetooth or USB connectivity in this era, though aftermarket options exist. Powertrain Control Engine Control Unit: ECU controls fuel injection, ignition timing, and emissions systems. Manual details diagnostic procedures and pinouts. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 5,000-10,000 km (3,000-6,000 miles) or 6-12 months, whichever comes first (refer to manual for precise interval based on driving conditions). Air Filter Replacement: Every 20,000-40,000 km (12,000-24,000 miles) or as needed based on inspection. Spark Plug Replacement: Refer to manual for specific type (e.g., standard,...
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Daihatsu Terios J102 2005 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Terios
Year:
2005
Chassis Code:
J102
Codes
Engine Code:
K3-VE
👋 Introduction
Market Position
Vehicle Segment:
Compact SUV / Crossover
Competitive Analysis
Key Competitors Circa 2005:
Honda CR-V, Toyota RAV4, Nissan X-Trail, Suzuki Vitara, Ford EcoSport (depending on market).
Key Features
Body Style:
5-door SUV
Drivetrain Options:
Available in Front-Wheel Drive (FWD) and selectable Full-Time Four-Wheel Drive (4WD).
Target Audience:
Individuals and small families seeking a versatile, compact, and capable vehicle for urban and light off-road use.
📋 Manual Details
Coverage Areas
Coverage Scope:
All Models/Engines/Trims/Transmissions
Page Count
Estimated Page Count:
Approx. 1500-2000 pages (typical for comprehensive workshop manuals)
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF (Downloadable)
📖 Manual Coverage
Systems Covered
Engine:
Engine mechanical, lubrication, cooling, fuel, ignition, emissions control, starting and charging systems.
Transmission:
Manual and Automatic transmission overhaul, diagnostics, and fluid specifications.
Drivetrain:
Front-wheel drive, rear-wheel drive, and 4WD system components, including differentials and driveshafts.
Suspension:
Front and rear suspension components, shock absorbers, springs, control arms, and alignment procedures.
Steering:
Power steering system, steering column, tie rods, and steering gear diagnostics and repair.
Brakes:
Front and rear brake systems (disc/drum), ABS, hydraulic components, and bleeding procedures.
Electrical:
Complete wiring diagrams, lighting systems, power distribution, fuse/relay identification, ECUs, sensors, and actuators.
Body:
Body panel removal/installation, interior trim, doors, windows, locks, and related mechanisms.
HVAC:
Heating, Ventilation, and Air Conditioning system diagnosis and repair.
Diagnostics:
Troubleshooting charts, diagnostic trouble codes (DTCs), and diagnostic procedures for various systems.
Procedures Included
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, belt inspections/replacement.
Repair Procedures:
Detailed step-by-step instructions for component removal, overhaul, assembly, and installation.
Troubleshooting Procedures:
Systematic diagnostic guides for identifying and resolving common and complex issues.
Overhaul Procedures:
Complete disassembly and reassembly instructions for major components like engines and transmissions.
Specifications:
Torque specifications, clearances, fluid capacities, and critical measurement data.
Technical Depth
Depth Of Coverage:
Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds, including electrical diagnostics.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Yes (typically OCR'd for searchability)
Printable:
Yes
Print Quality
Image Resolution:
High (suitable for clear viewing of diagrams and text)
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Name:
K3-VE
Engine Type:
Inline 4-cylinder, DOHC, 16-valve
Displacement:
1.3 Liters (1298 cc)
Bore X Stroke:
72.0 mm x 80.5 mm
Compression Ratio:
9.8:1
Performance
Horsepower Output:
Approx. 85-87 PS (63-64 kW) at 6000 rpm (market dependent)
Torque Output:
Approx. 120-125 Nm (89-92 lb-ft) at 3200 rpm (market dependent)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Ignition System:
Electronic Ignition (Distributorless - Coil-on-Plug)
Other Engine Features
Valvetrain:
DVVT (Daihatsu Variable Valve Timing) on some variants.
🔧 Transmission
Standard
Standard Transmission Type:
5-speed Manual Transmission
Optional
Optional Transmission Type:
4-speed Automatic Transmission
Features
Transmission Fluid Type:
Refer to manual (typically Dexron III/Mercon for automatic, Gear Oil GL-4 for manual).
4Wd System:
Viscous coupling type 4WD system with centre differential lock (on some models).
📐 Dimensions
Exterior
Length:
Approx. 3,995 mm (157.3 in)
Width:
Approx. 1,695 mm (66.7 in)
Height:
Approx. 1,700 mm (66.9 in)
Wheelbase:
Approx. 2,430 mm (95.7 in)
Ground Clearance:
Approx. 195 mm (7.7 in)
Weights
Curb Weight:
Approx. 1060-1180 kg (2337-2601 lbs) depending on configuration.
Gross Vehicle Weight Rating:
Refer to vehicle placard or manual.
Cargo
Cargo Volume:
Variable with rear seats folded. Approx. 300-400 liters behind rear seats (market dependent).
🛡️ Safety Features
Ratings
Crash Test Ratings:
Varies by market and specific test (e.g., JNCAP, Euro NCAP). Manual will detail specific vehicle structural information relevant to safety.
Active Features
Antilock Braking System:
Available as an option or standard on higher trims (ABS).
Electronic Brake Force Distribution:
Often paired with ABS.
Passive Features
Airbags:
Driver and front passenger airbags (standard/optional depending on market/trim).
Seatbelts:
3-point seatbelts with pretensioners for front occupants.
Child Seat Anchors:
ISOFIX/LATCH mounting points available on rear seats.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with CD player, potentially with auxiliary input on later models. Speaker configuration varies by trim.
Driver Assistance
Parking Assistance:
Rear parking sensors may be available on some higher-spec models, but generally not a standard feature.
Connectivity
Connectivity Options:
Limited. Typically no Bluetooth or USB connectivity in this era, though aftermarket options exist.
Powertrain Control
Engine Control Unit:
ECU controls fuel injection, ignition timing, and emissions systems. Manual details diagnostic procedures and pinouts.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-10,000 km (3,000-6,000 miles) or 6-12 months, whichever comes first (refer to manual for precise interval based on driving conditions).
Air Filter Replacement:
Every 20,000-40,000 km (12,000-24,000 miles) or as needed based on inspection.
Spark Plug Replacement:
Refer to manual for specific type (e.g., standard, iridium). Intervals can range from 40,000 km to over 100,000 km for iridium plugs.
Fluid Specifications
Engine Oil Type:
API SJ or higher, SAE 10W-30 or 10W-40 recommended (refer to manual for precise viscosity and API classification).
Engine Oil Capacity:
Approx. 3.2 - 3.4 liters with filter change.
Coolant Type:
Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Refer to manual for specific Daihatsu/Toyota coolant specification.
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual).
Known Issues
Common Wear Items:
Suspension components (bushings, ball joints), brake pads and rotors, clutch wear (manual transmission), exhaust system components.
Engine Specific Notes:
K3-VE engine is generally robust, but occasional issues can include oil leaks from valve cover gaskets or crankshaft seals. Timing chain tensioner wear is also a possibility over high mileage.
Transmission Specific Notes:
Automatic transmissions can sometimes experience delayed engagement or harsh shifting if fluid is degraded or the valve body has issues.
📚 Vehicle History
Brand Heritage
Daihatsu Legacy:
Daihatsu, a subsidiary of Toyota, has a long history of producing small, reliable, and affordable vehicles, particularly known for its kei cars and compact SUVs.
Model Evolution
Terios Generations:
The J102 represents the first generation of the Daihatsu Terios, introduced in 1997. The 2005 model is part of the facelifted version of this generation, featuring updated styling and potentially minor mechanical enhancements.
Production
Production Location:
Primarily Japan, with production and assembly in other countries through KD (Knock Down) kits for various markets.
Production Years For J100 Series:
1997 - 2006
🏆 Awards & Recognition
Recognitions
General Vehicle Reputation:
Praised for its affordability, practicality in urban environments, and decent fuel economy for its class. Often noted for its compact size and maneuverability. While not typically winning major 'Car of the Year' awards, it holds a strong reputation for value and reliability within its segment.
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