Daihatsu Terios J100 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Codes Chassis Code: J100 Series 👋 Introduction Market Position Segment: Compact SUV / Mini SUV. Positioned as an affordable, capable, and compact all-wheel-drive vehicle, often appealing to those seeking light off-road capability and urban maneuverability. Competitive Analysis Competitors: Competed against vehicles like the Suzuki Vitara/Grand Vitara, Toyota RAV4 (early generations), Honda CR-V (early generations), Mitsubishi Pajero/Montero Sport (smaller variants). Key Features Features: Compact dimensions, available 4WD, robust chassis for its class, relatively simple mechanicals, and good value proposition. 📋 Manual Details Coverage Areas Regions Covered: Global (Specific regional variations may exist but core technical data is universal) Page Count Estimated Page Count: Over 1000 pages (Typical for comprehensive factory service manuals) Manual Type Type: Factory Service and Repair Workshop Manual Language Language: English (Likely based on common availability, Japanese originals may exist) Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Powertrain: Engine mechanicals (including disassembly, assembly, overhaul), fuel system, ignition system, exhaust system, cooling system, lubrication system. Drivetrain: Manual and automatic transmissions, transfer case, differentials (front and rear), drive shafts, CV joints, axles. Chassis: Suspension (front and rear), steering system (power and manual), braking system (hydraulic, ABS components), wheel alignment. Electrical: Engine control unit (ECU), sensors, actuators, lighting system, charging system, starting system, infotainment system wiring, power windows, door locks, safety systems wiring. Body: Body panels, doors, hood, tailgate, interior trim, glass, bumpers, exterior trim, underbody protection. Procedures Included Maintenance: Scheduled maintenance tasks, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, inspections. Diagnostics: Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs), wiring diagrams for diagnostic purposes. Repair: Detailed step-by-step repair procedures for all major mechanical and electrical components, including torque specifications, special tool requirements, and component removal/installation. Rebuilding: Comprehensive engine overhaul procedures, transmission rebuild instructions, differential assembly, and component-specific rebuilding processes. Troubleshooting Specific: Detailed diagnostic trees for common drivability issues, starting problems, charging system faults, and transmission performance problems. Includes identification of faulty components based on symptoms. Technical Depth Depth: Factory-level diagnostic and repair information, suitable for professional technicians and advanced DIY enthusiasts. Includes detailed schematics and exploded views. Diagnostic Tools: While the manual will list OBD-II diagnostic procedures where applicable, it will also heavily rely on visual inspections, basic electrical multimeter testing, and component-specific diagnostic routines not requiring advanced scan tools. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Fully searchable PDF, allowing users to quickly find specific terms, procedures, or part numbers. Print Quality Quality: High-resolution scans ensuring clarity of diagrams, text, and images. Searchable text for efficient navigation. Diagrams Clarity: Schematics and exploded view diagrams are rendered with high detail, essential for correct disassembly and reassembly of components. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Model: G15A (Common for J100 series) Engine Type: Inline 4-cylinder, SOHC, 16-valve, Naturally Aspirated Displacement: 1.5 Liters (1498 cc) Performance Horsepower: Approx. 92-100 PS (68-74 kW) @ 5500-6000 rpm (Varies by market and specific engine tune) Torque: Approx. 130-140 Nm (96-103 lb-ft) @ 3500-4500 rpm (Varies by market and specific engine tune) Fuel System Injection: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline Engine Codes Other Engines: F5A (1.3L), G13B (1.3L), G16A (1.6L), G16B (1.6L DOHC) may also be found in some J100 variants depending on region and model year. 🔧 Transmission Standard Type: 5-speed Manual Transmission Optional Type: 4-speed Automatic Transmission Features Drivetrain Options: Full-time 4WD (often with a viscous coupling center differential) and Rear-Wheel Drive (RWD) variants exist. The manual likely covers both. 📐 Dimensions Exterior Length: Approx. 3,995 mm (157.3 in) Width: Approx. 1,695 mm (66.7 in) Height: Approx. 1,630 - 1,650 mm (64.2 - 65.0 in) (Varies with roof rails) Wheelbase: Approx. 2,430 mm (95.7 in) Ground Clearance: Approx. 195 mm (7.7 in) Weights Curb Weight: Approx. 1100 - 1250 kg (2425 - 2756 lbs) (Varies by drivetrain and options) Gross Vehicle Weight: Varies by configuration, typically around 1500-1600 kg. 🛡️ Safety Features Ratings Crash Test Ratings: No standardized global ratings like Euro NCAP or NHTSA were consistently applied to all J100 models during its production span. Refer to specific market regulations. Active Features ABS: Optional or standard on higher trims in later years/specific markets. The manual will detail its operation and diagnosis. Passive Features Airbags: Driver airbag typically standard. Passenger airbag optional or standard on higher trims depending on market and year. The manual covers airbag system components and SRS logic. Seatbelts: All seating positions equipped with 3-point seatbelts (front and rear outer seats), center rear seat may have a 2-point belt in some configurations. Manual details pre-tensioners if equipped. 💡 Technology Features Infotainment Audio System: Factory fitted AM/FM radio with cassette player or CD player. Speakers typically 2 or 4. Manual details wiring and basic troubleshooting for the audio...
Compact SUV / Mini SUV. Positioned as an affordable, capable, and compact all-wheel-drive vehicle, often appealing to those seeking light off-road capability and urban maneuverability.
Competitive Analysis
Competitors:
Competed against vehicles like the Suzuki Vitara/Grand Vitara, Toyota RAV4 (early generations), Honda CR-V (early generations), Mitsubishi Pajero/Montero Sport (smaller variants).
Key Features
Features:
Compact dimensions, available 4WD, robust chassis for its class, relatively simple mechanicals, and good value proposition.
📋 Manual Details
Coverage Areas
Regions Covered:
Global (Specific regional variations may exist but core technical data is universal)
Page Count
Estimated Page Count:
Over 1000 pages (Typical for comprehensive factory service manuals)
Manual Type
Type:
Factory Service and Repair Workshop Manual
Language
Language:
English (Likely based on common availability, Japanese originals may exist)
Manual and automatic transmissions, transfer case, differentials (front and rear), drive shafts, CV joints, axles.
Chassis:
Suspension (front and rear), steering system (power and manual), braking system (hydraulic, ABS components), wheel alignment.
Electrical:
Engine control unit (ECU), sensors, actuators, lighting system, charging system, starting system, infotainment system wiring, power windows, door locks, safety systems wiring.
Detailed step-by-step repair procedures for all major mechanical and electrical components, including torque specifications, special tool requirements, and component removal/installation.
Detailed diagnostic trees for common drivability issues, starting problems, charging system faults, and transmission performance problems. Includes identification of faulty components based on symptoms.
Technical Depth
Depth:
Factory-level diagnostic and repair information, suitable for professional technicians and advanced DIY enthusiasts. Includes detailed schematics and exploded views.
Diagnostic Tools:
While the manual will list OBD-II diagnostic procedures where applicable, it will also heavily rely on visual inspections, basic electrical multimeter testing, and component-specific diagnostic routines not requiring advanced scan tools.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Fully searchable PDF, allowing users to quickly find specific terms, procedures, or part numbers.
Print Quality
Quality:
High-resolution scans ensuring clarity of diagrams, text, and images. Searchable text for efficient navigation.
Diagrams Clarity:
Schematics and exploded view diagrams are rendered with high detail, essential for correct disassembly and reassembly of components.
Approx. 92-100 PS (68-74 kW) @ 5500-6000 rpm (Varies by market and specific engine tune)
Torque:
Approx. 130-140 Nm (96-103 lb-ft) @ 3500-4500 rpm (Varies by market and specific engine tune)
Fuel System
Injection:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Engine Codes
Other Engines:
F5A (1.3L), G13B (1.3L), G16A (1.6L), G16B (1.6L DOHC) may also be found in some J100 variants depending on region and model year.
🔧 Transmission
Standard
Type:
5-speed Manual Transmission
Optional
Type:
4-speed Automatic Transmission
Features
Drivetrain Options:
Full-time 4WD (often with a viscous coupling center differential) and Rear-Wheel Drive (RWD) variants exist. The manual likely covers both.
📐 Dimensions
Exterior
Length:
Approx. 3,995 mm (157.3 in)
Width:
Approx. 1,695 mm (66.7 in)
Height:
Approx. 1,630 - 1,650 mm (64.2 - 65.0 in) (Varies with roof rails)
Wheelbase:
Approx. 2,430 mm (95.7 in)
Ground Clearance:
Approx. 195 mm (7.7 in)
Weights
Curb Weight:
Approx. 1100 - 1250 kg (2425 - 2756 lbs) (Varies by drivetrain and options)
Gross Vehicle Weight:
Varies by configuration, typically around 1500-1600 kg.
🛡️ Safety Features
Ratings
Crash Test Ratings:
No standardized global ratings like Euro NCAP or NHTSA were consistently applied to all J100 models during its production span. Refer to specific market regulations.
Active Features
ABS:
Optional or standard on higher trims in later years/specific markets. The manual will detail its operation and diagnosis.
Passive Features
Airbags:
Driver airbag typically standard. Passenger airbag optional or standard on higher trims depending on market and year. The manual covers airbag system components and SRS logic.
Seatbelts:
All seating positions equipped with 3-point seatbelts (front and rear outer seats), center rear seat may have a 2-point belt in some configurations. Manual details pre-tensioners if equipped.
💡 Technology Features
Infotainment
Audio System:
Factory fitted AM/FM radio with cassette player or CD player. Speakers typically 2 or 4. Manual details wiring and basic troubleshooting for the audio unit.
Driver Assistance
Features:
Limited by era. Primarily focused on mechanical systems and basic safety features like ABS (optional). No advanced driver-assistance systems (ADAS) like adaptive cruise control or lane keeping assist.
Connectivity
Features:
No integrated Bluetooth or USB connectivity in most J100 models. Aftermarket solutions are common. Manual covers factory wiring for basic accessory power.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Typically every 5,000 - 7,500 km (3,000 - 4,500 miles) or 6 months, whichever comes first, depending on driving conditions. Consult manual for exact intervals.
Engine Air Filter:
Inspect every 10,000 - 15,000 km (6,000 - 9,000 miles), replace as needed or every 30,000 - 45,000 km (18,000 - 27,000 miles).
Spark Plugs:
Replace every 30,000 - 60,000 km (18,000 - 36,000 miles), depending on plug type (standard vs. platinum/iridium). Manual will specify part numbers and intervals.
Fluid Specifications
Engine Oil:
API SG/SH/SJ or higher, SAE 10W-30 or 10W-40 typically recommended. Check dipstick for capacity (approx. 3.7L with filter for G15A).
Coolant:
Ethylene glycol-based, anti-freeze/anti-boil, typically a 50/50 mix with distilled water. Manual specifies type and capacity (approx. 5.0L).
Brake Fluid:
DOT 3 or DOT 4 (refer to reservoir cap or manual for exact specification). Capacity typically around 0.75L.
Transmission Fluid Manual:
API GL-4, SAE 75W-90 or 80W-90 gear oil. Capacity approx. 2.0-2.5L for 5-speed manual.
Transmission Fluid Automatic:
Dexron III or equivalent ATF. Capacity approx. 3.5-4.0L for change, higher for overhaul. Manual will specify exact type and procedure.
Transfer Case Fluid:
API GL-4 or GL-5, SAE 75W-90 or 80W-90 gear oil. Capacity approx. 0.9-1.2L.
Differential Fluid Front Rear:
API GL-5, SAE 80W-90 gear oil. Capacity approx. 1.0-1.3L for each.
Known Issues
Common Problems:
While generally robust, common issues can include: exhaust system corrosion, potential for minor oil leaks from engine seals over time, wear on suspension bushings due to off-road use, occasional electrical gremlins (e.g., dashboard lights, window motors), and the need for regular timing belt replacement (if applicable to the specific engine variant covered).
📚 Vehicle History
Brand Heritage
Daihatsu Specialization:
Daihatsu is renowned for its expertise in small and compact vehicles, particularly with robust and lightweight construction, often specializing in kei cars and compact SUVs.
Model Evolution
Terios Generations:
The J100 series represents the first generation of the Daihatsu Terios, introduced in 1997. It was succeeded by the J200 series in 2006. The J100 was designed as a compact, go-anywhere vehicle.
Production
Production Years:
1997 - 2006 (for the J100 series)
Manufacturing Locations:
Primarily manufactured in Japan by Daihatsu Motor Co., Ltd. Licensing and production also occurred in other regions through partnerships.
🏆 Awards & Recognition
Recognitions
Industry Awards:
No major industry awards typically cited for the J100 generation. Its value was in its practicality, affordability, and capability within its segment rather than accolades.
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