Daihatsu Hijet 1998-2010 All Service Manual Repair
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🏷️ Basic Information Identification Make: Daihatsu Model: Hijet Codes Chassis Codes: S200, S210, S220, S230 series 👋 Introduction Market Position Vehicle Segment: Kei truck/microvan (Utility vehicle, commercial vehicle) Competitive Analysis Competitors: Suzuki Carry, Honda Acty, Subaru Sambar (in markets where Hijet was directly sold and these models were prevalent) Key Features Vehicle Purpose: Designed for practicality, cargo hauling, and urban/small-scale commercial use. Known for its compact size and maneuverability. Manual Value Proposition Diy Repair Benefit: Enables owners to perform high-quality repairs independently, saving money and ensuring vehicle longevity. Technical Knowledge Access: Provides in-depth understanding of vehicle intricacies for better maintenance and troubleshooting, even for those with limited technical background. 📋 Manual Details Coverage Areas Applicable Years: 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Page Count Estimated Page Count: High (comprehensive workshop manual typically exceeds 500 pages, specific count not provided in product info) Manual Type Type: All Service Repair Manual (Workshop Manual) Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Service: Engine removal/installation, cylinder head, pistons, crankshaft, camshaft, lubrication system, cooling system, fuel injection, emission system, engine control system Transmission Service: Manual and Automatic transmission overhaul, clutch system, drivetrain components Brake System: Brake component inspection and replacement (pads, rotors, calipers), hydraulic system bleeding, parking brake system Electrical System: Wiring diagrams, component testing, battery, charging system, ignition system, lighting, accessories Suspension Steering: Front and rear suspension components, steering gear, power steering system Chassis Body: Frame and body construction, doors, windows, interior trim, exterior panels Restraint System: Airbag system inspection, seat belt mechanisms Axle Drivetrain: Front and rear axle components, drive shafts, CV joints Fuel System: Fuel tank, fuel pump, fuel filter, fuel lines, fuel injectors, fuel pressure regulator. Emission System: Catalytic converter, EGR system, oxygen sensors, and emission control computer interactions. Engine Control System: Detailed diagrams and troubleshooting for the ECU, sensors (MAP, TPS, ECT, knock sensor, etc.), and actuators. Cooling System: Radiator, fan, thermostat, water pump, heater core, coolant hoses, and temperature sensors. Lubrication System: Oil pan, oil pump, oil filter, oil passages, and oil pressure. Procedures Included Maintenance: General maintenance procedures, periodic lubrication, fluid changes, filter replacements Troubleshooting: Diagnostic procedures for common issues, symptom-based troubleshooting guides Repair Overhaul: Detailed step-by-step instructions for component disassembly, repair, and reassembly Refurbish Renovate: Guidance on restoring worn or damaged components Diagnostics: Includes diagnostic trouble codes (DTCs) where applicable and systematic diagnostic flows. Wiring Diagrams: Complete electrical wiring diagrams for all major systems, color-coded and component-identified. Torque Specifications: Essential torque specifications for all critical fasteners during assembly and disassembly. Wheel Alignment: Specifications and procedures for front and rear wheel alignment. Tire Specifications: Recommended tire sizes and inflation pressures. Wheel Bolt Pattern: Standard wheel bolt pattern for the Hijet models covered. Technical Depth Depth: Comprehensive: Covers everything from routine maintenance and fluid checks to complete engine and transmission rebuilds, including electrical system diagnostics and body repair. Diagnostics Tools: Information on any specialized tools or diagnostic equipment needed. 📊 Manual Specifications File Format Compatibility: Compatible with all versions of Windows and Mac OS. Required Software: Adobe PDF Reader and WinZip. Searchability: PDF format generally allows for text searching, greatly enhancing the ability to find specific information quickly. Print Quality Printability: Printable pages for on-site workshop use. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code Examples: EF-VE, EF-SE, KF-VE (These are common Daihatsu 3-cylinder engines; specific codes for Hijet 1998-2010 may vary and require manual confirmation) Performance Displacement Range: Approximately 660cc (standard for Kei class vehicles) Power Output Range: Typically 45-64 hp, depending on engine and aspiration (natural aspiration or turbocharging). Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Engine Management ECU Systems: Covers various engine control unit (ECU) systems and diagnostic procedures. 🔧 Transmission Standard Transmission Type Availability: Available with Manual (e.g., 5-speed) and Automatic transmissions (e.g., 3-speed or 4-speed automatic, depending on market and year). Optional Drive Layout: Rear-Wheel Drive (RWD) and All-Wheel Drive (4WD) options available. Features Clutch System: Details on clutch operation, adjustment, and replacement for manual transmissions. 📐 Dimensions Exterior Kei Class Restrictions: Adheres to Kei vehicle regulations (length, width, engine displacement) prevalent in Japan and other markets. Weights Gross Vehicle Weight Rating: GVWR varies by configuration, but typically around 1,500-2,000 kg. Curb Weight: Curb weight typically ranges from 750-950 kg. 🛡️ Safety Features Ratings Crash Test Data: While specific formal crash test ratings might be limited due to its commercial/utility focus and market variations, the manual covers safety-related components like seat belts and potentially airbags. Active Features Braking System: Front disc brakes and rear drum brakes are common, with ABS often optional or standard on later models. Passive Features Occupant Protection: Seat belts, potentially driver-side airbag (market dependent). 💡 Technology Features Infotainment Features Availability: Basic infotainment systems...
General maintenance procedures, periodic lubrication, fluid changes, filter replacements
Troubleshooting:
Diagnostic procedures for common issues, symptom-based troubleshooting guides
Repair Overhaul:
Detailed step-by-step instructions for component disassembly, repair, and reassembly
Refurbish Renovate:
Guidance on restoring worn or damaged components
Diagnostics:
Includes diagnostic trouble codes (DTCs) where applicable and systematic diagnostic flows.
Wiring Diagrams:
Complete electrical wiring diagrams for all major systems, color-coded and component-identified.
Torque Specifications:
Essential torque specifications for all critical fasteners during assembly and disassembly.
Wheel Alignment:
Specifications and procedures for front and rear wheel alignment.
Tire Specifications:
Recommended tire sizes and inflation pressures.
Wheel Bolt Pattern:
Standard wheel bolt pattern for the Hijet models covered.
Technical Depth
Depth:
Comprehensive: Covers everything from routine maintenance and fluid checks to complete engine and transmission rebuilds, including electrical system diagnostics and body repair.
Diagnostics Tools:
Information on any specialized tools or diagnostic equipment needed.
📊 Manual Specifications
File Format
Compatibility:
Compatible with all versions of Windows and Mac OS.
Required Software:
Adobe PDF Reader and WinZip.
Searchability:
PDF format generally allows for text searching, greatly enhancing the ability to find specific information quickly.
Print Quality
Printability:
Printable pages for on-site workshop use.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code Examples:
EF-VE, EF-SE, KF-VE (These are common Daihatsu 3-cylinder engines; specific codes for Hijet 1998-2010 may vary and require manual confirmation)
Performance
Displacement Range:
Approximately 660cc (standard for Kei class vehicles)
Power Output Range:
Typically 45-64 hp, depending on engine and aspiration (natural aspiration or turbocharging).
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Engine Management
ECU Systems:
Covers various engine control unit (ECU) systems and diagnostic procedures.
🔧 Transmission
Standard
Transmission Type Availability:
Available with Manual (e.g., 5-speed) and Automatic transmissions (e.g., 3-speed or 4-speed automatic, depending on market and year).
Optional
Drive Layout:
Rear-Wheel Drive (RWD) and All-Wheel Drive (4WD) options available.
Features
Clutch System:
Details on clutch operation, adjustment, and replacement for manual transmissions.
📐 Dimensions
Exterior
Kei Class Restrictions:
Adheres to Kei vehicle regulations (length, width, engine displacement) prevalent in Japan and other markets.
Weights
Gross Vehicle Weight Rating:
GVWR varies by configuration, but typically around 1,500-2,000 kg.
Curb Weight:
Curb weight typically ranges from 750-950 kg.
🛡️ Safety Features
Ratings
Crash Test Data:
While specific formal crash test ratings might be limited due to its commercial/utility focus and market variations, the manual covers safety-related components like seat belts and potentially airbags.
Active Features
Braking System:
Front disc brakes and rear drum brakes are common, with ABS often optional or standard on later models.
Basic infotainment systems typically include AM/FM radio and CD player. Features vary significantly by trim level and market. Manual covers system components and troubleshooting.
Driver Assistance
Availability:
Limited driver assistance features typical for this era and vehicle type. Manual covers any available systems.
Connectivity
Features:
Minimal connectivity features; primarily focuses on vehicle operation rather than advanced infotainment or communication integration.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000-10,000 km or 6-12 months, depending on oil type and driving conditions. Manual will specify.
Spark Plug Replacement:
Refer to manual for specific intervals, often around 20,000-40,000 km, depending on plug type (standard, platinum, iridium).
Timing Belt Replacement:
Crucial maintenance item for many engines; intervals vary greatly but can be 60,000-100,000 km. Manual will specify if belt-driven.
Fluid Specifications
Engine Oil Viscosity:
Commonly 5W-30 or 10W-30 API SN or higher. Manual will confirm specific grade and API classification.
Coolant Type:
Ethylene glycol-based coolant, often pre-mixed or requiring a specific concentration. Manual will specify type and capacity.
Transmission Fluid Type:
Manual transmission oil (GL-4 specification) or Automatic Transmission Fluid (ATF) specific to Daihatsu models. Manual is critical for correct ATF type.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid. Manual will specify.
Known Issues
Common Wear Items:
Ignition coils, spark plugs, exhaust system components, clutch wear (manual transmission), suspension bushings, and fuel injectors can be common wear items over time.
Water Pump Failure:
Water pump failure can occur, often indicated by coolant leaks or overheating. Manual covers replacement procedures.
Wiring Harness Issues:
Corrosion or damage to wiring harnesses, especially in environments with high humidity or salt exposure, can lead to intermittent electrical faults.
📚 Vehicle History
Brand Heritage
Daihatsu Specialization:
Daihatsu is a manufacturer historically known for its compact and small car expertise, particularly the Kei class vehicles.
Model Evolution
Hijet Generations:
The Hijet has a long lineage, with the S200 series representing a significant generation of this platform.
Production
Manufacturing Locations:
Primarily manufactured by Daihatsu Motor Co., Ltd. in Japan, with potential global assembly plants depending on market distribution.
🏆 Awards & Recognition
Recognitions
Market Recognition:
The Daihatsu Hijet is widely recognized for its reliability, durability, and cost-effectiveness as a light commercial vehicle.
Ratings
Ownership Satisfaction:
Owners often report high satisfaction due to low running costs and functional simplicity.
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