Daihatsu Terios J102 2000-2006 Service Repair Manual
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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Model Code: J102 Production Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006 Codes Chassis Codes: J102G (4WD) 👋 Introduction Market Position Market Segment: Compact SUV / Kei SUV crossover, known for its off-road capability and practicality in urban environments. Competitive Analysis Competitors: Suzuki Jimny, Honda CR-V (first generation), Toyota RAV4 (first generation), Mitsubishi Pajero Mini, Nissan X-Trail (early models). Key Features Platform: Body-on-frame construction (unique for its class at the time), providing robust durability and off-road prowess. Drivetrain Advantage: Standard 4WD (select models may have been available in 2WD), differentiating it from many front-wheel-drive based compact SUVs. Target Audience: Individuals seeking a versatile, compact, and capable vehicle for both daily commuting and light off-road adventures. 📋 Manual Details Coverage Areas Primary Coverage: North America, Europe, Asia (specific markets may vary) Page Count Estimated Page Count: 800+ Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete overhaul, diagnostics, timing belt replacement, cooling system, lubrication system, fuel system (injection/carburetion specifics), ignition system, emissions control Transmission: Manual Transmission (MT) and Automatic Transmission (AT) overhaul, diagnostics, fluid replacement, clutch system, torque converter Drivetrain: Four-Wheel Drive (4WD) system operation and service, transfer case, differentials (front and rear), drive shafts, CV joints, propeller shafts Suspension: Front and rear suspension components, shock absorbers, springs, control arms, bushings, wheel alignment procedures Steering: Power steering system, steering column, steering rack, tie rod ends, troubleshooting Brakes: Hydraulic brake system, front and rear disc/drum brakes, ABS (Anti-lock Braking System) components and diagnostics, brake fluid replacement, parking brake Electrical: 12V electrical system, battery, charging system (alternator), starting system (starter motor), lighting system, instrument cluster, power windows, door locks, wiring diagrams for all circuits Bodywork And Chassis: Body panel removal and installation, door mechanisms, interior trim, glass replacement, chassis lubrication points, frame inspection HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant handling, blower motor, heater core, A/C compressor Procedures Included Maintenance: Scheduled maintenance tasks, oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspection/replacement Troubleshooting: Diagnostic procedures for common problems, symptom-based troubleshooting guides, error code interpretation (OBD-II) Repair: Step-by-step repair instructions for all major vehicle systems, including engine rebuilds, transmission overhauls, and component replacements Diagnostics: Detailed diagnostic flowcharts, sensor testing procedures, actuator testing, use of scan tools Specifications: Torque specifications for all fasteners, critical component clearances, fluid capacities, electrical specifications Technical Depth Depth: Comprehensive, covering basic maintenance to full engine and transmission rebuilds. Includes detailed diagrams and troubleshooting charts. 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Print Quality Quality: High-resolution scans, clear text and diagrams, printable pages Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code: 3SZ-VE Engine Type: Inline 4-cylinder, DOHC, 16-valve, VVT-i (Variable Valve Timing with Intelligence) Displacement: 1.3 Liters (1298 cc) Bore X Stroke: 72.0 mm x 80.5 mm Performance Horsepower: 86 hp (64 kW) @ 6000 rpm (approx.) Torque: 115 Nm (85 lb-ft) @ 4000 rpm (approx.) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline (RON 91 or higher recommended) Engine Management Ignition System: Electronic ignition with distributorless ignition system (DIS) or distributor-based (model dependent). Cooling System Coolant Type: Ethylene Glycol based coolant (50/50 mix with distilled water) 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission (5MT) Optional Transmission Type: 4-speed Automatic Transmission (4AT) Features 4Wd System: Full-time 4WD with viscous coupling center differential. Fluid Specifications Manual Transmission Fluid: API GL-4, SAE 75W-90 or 80W-90 (check manual for exact spec) Automatic Transmission Fluid: Dexron III or equivalent 📐 Dimensions Exterior Length: Approx. 3,900 mm (153.5 in) Width: Approx. 1,600 mm (63.0 in) Height: Approx. 1,700 mm (66.9 in) Wheelbase: Approx. 2,430 mm (95.7 in) Weights Curb Weight: Approx. 1,150 - 1,250 kg (2,535 - 2,756 lbs) Cargo Cargo Volume: Variable, with foldable rear seats. Wheels Tires Wheel Size: 15-inch or 16-inch alloy or steel wheels Tire Size: 205/70R15 or 215/65R16 (typical) Bolt Pattern: 5x114.3 mm (5x4.5 inches) 🛡️ Safety Features Ratings Crash Test Ratings: Varies by market and testing organization. Early models may not have extensive official ratings by modern standards. Refer to specific market safety reports. Active Features ABS: Available on some higher trim levels or as an option. Passive Features Airbags: Driver and front passenger airbags (standard or optional depending on trim/market). Seatbelts: 3-point seatbelts with pre-tensioners for front occupants. 💡 Technology Features Infotainment Audio System: Basic AM/FM radio with CD player, often with 4 or 6 speakers. Aftermarket upgrades are common. Driver Assistance Traction Control: Not commonly equipped on this generation. Stability Control: Not commonly equipped on this generation. Connectivity Usb Aux: Typically not equipped. Aftermarket solutions needed for modern device connectivity. Instrument Cluster Gauges: Analog speedometer, tachometer (on some models),...
Four-Wheel Drive (4WD) system operation and service, transfer case, differentials (front and rear), drive shafts, CV joints, propeller shafts
Suspension:
Front and rear suspension components, shock absorbers, springs, control arms, bushings, wheel alignment procedures
Steering:
Power steering system, steering column, steering rack, tie rod ends, troubleshooting
Brakes:
Hydraulic brake system, front and rear disc/drum brakes, ABS (Anti-lock Braking System) components and diagnostics, brake fluid replacement, parking brake
Electrical:
12V electrical system, battery, charging system (alternator), starting system (starter motor), lighting system, instrument cluster, power windows, door locks, wiring diagrams for all circuits
Bodywork And Chassis:
Body panel removal and installation, door mechanisms, interior trim, glass replacement, chassis lubrication points, frame inspection
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant handling, blower motor, heater core, A/C compressor
Procedures Included
Maintenance:
Scheduled maintenance tasks, oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspection/replacement
Troubleshooting:
Diagnostic procedures for common problems, symptom-based troubleshooting guides, error code interpretation (OBD-II)
Repair:
Step-by-step repair instructions for all major vehicle systems, including engine rebuilds, transmission overhauls, and component replacements
Diagnostics:
Detailed diagnostic flowcharts, sensor testing procedures, actuator testing, use of scan tools
Specifications:
Torque specifications for all fasteners, critical component clearances, fluid capacities, electrical specifications
Technical Depth
Depth:
Comprehensive, covering basic maintenance to full engine and transmission rebuilds. Includes detailed diagrams and troubleshooting charts.
📊 Manual Specifications
File Format
File Type:
Portable Document Format (PDF)
Print Quality
Quality:
High-resolution scans, clear text and diagrams, printable pages
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code:
3SZ-VE
Engine Type:
Inline 4-cylinder, DOHC, 16-valve, VVT-i (Variable Valve Timing with Intelligence)
Displacement:
1.3 Liters (1298 cc)
Bore X Stroke:
72.0 mm x 80.5 mm
Performance
Horsepower:
86 hp (64 kW) @ 6000 rpm (approx.)
Torque:
115 Nm (85 lb-ft) @ 4000 rpm (approx.)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (RON 91 or higher recommended)
Engine Management
Ignition System:
Electronic ignition with distributorless ignition system (DIS) or distributor-based (model dependent).
Cooling System
Coolant Type:
Ethylene Glycol based coolant (50/50 mix with distilled water)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transmission (5MT)
Optional
Transmission Type:
4-speed Automatic Transmission (4AT)
Features
4Wd System:
Full-time 4WD with viscous coupling center differential.
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-90 or 80W-90 (check manual for exact spec)
Automatic Transmission Fluid:
Dexron III or equivalent
📐 Dimensions
Exterior
Length:
Approx. 3,900 mm (153.5 in)
Width:
Approx. 1,600 mm (63.0 in)
Height:
Approx. 1,700 mm (66.9 in)
Wheelbase:
Approx. 2,430 mm (95.7 in)
Weights
Curb Weight:
Approx. 1,150 - 1,250 kg (2,535 - 2,756 lbs)
Cargo
Cargo Volume:
Variable, with foldable rear seats.
Wheels Tires
Wheel Size:
15-inch or 16-inch alloy or steel wheels
Tire Size:
205/70R15 or 215/65R16 (typical)
Bolt Pattern:
5x114.3 mm (5x4.5 inches)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Varies by market and testing organization. Early models may not have extensive official ratings by modern standards. Refer to specific market safety reports.
Active Features
ABS:
Available on some higher trim levels or as an option.
Passive Features
Airbags:
Driver and front passenger airbags (standard or optional depending on trim/market).
Seatbelts:
3-point seatbelts with pre-tensioners for front occupants.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with CD player, often with 4 or 6 speakers. Aftermarket upgrades are common.
Driver Assistance
Traction Control:
Not commonly equipped on this generation.
Stability Control:
Not commonly equipped on this generation.
Connectivity
Usb Aux:
Typically not equipped. Aftermarket solutions needed for modern device connectivity.
Instrument Cluster
Gauges:
Analog speedometer, tachometer (on some models), fuel gauge, temperature gauge, warning lights.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, whichever comes first.
Air Filter Replacement:
Every 15,000 - 30,000 miles (24,000 - 48,000 km).
Spark Plug Replacement:
Every 30,000 - 60,000 miles (48,000 - 96,000 km), depending on plug type (standard vs. iridium).
Timing Belt Replacement:
Recommended every 60,000 - 90,000 miles (96,000 - 144,000 km) or 5-7 years due to the interference engine design.
Fluid Specifications
Engine Oil Capacity:
Approx. 3.5 - 3.8 Liters (3.7 - 4.0 US Quarts) with filter change. Consult manual for exact capacity.
Engine Oil Type:
API SN/SP, SAE 5W-30 or 5W-40 recommended (check manual for climate-specific recommendations).
Coolant Capacity:
Approx. 5.0 - 5.5 Liters (5.3 - 5.8 US Quarts)
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Engine Timing Belt:
The 3SZ-VE engine is an interference engine; failure to replace the timing belt per schedule can lead to catastrophic engine damage. Belt tensioner and idler pulley wear can also occur.
Cooling System:
Overheating can occur if the cooling system is not maintained, leading to potential head gasket issues. Radiator cap and thermostat replacement may be needed.
Transmission Clutches:
Automatic transmission clutches can wear over time, especially with aggressive driving or towing. Regular fluid changes are crucial.
4Wd System:
Transfer case and differential seals can leak. Regular inspection and maintenance of the 4WD system is recommended.
Suspension Bushings:
Rubber suspension bushings can degrade over time, leading to clunks, rattles, and poor handling. Replacement of worn bushings is a common repair.
Exhaust System:
Corrosion and rust can affect exhaust components, particularly in areas with road salt.
📚 Vehicle History
Brand Heritage
Daihatsu Legacy:
Daihatsu, a subsidiary of Toyota, has a long history of producing reliable and compact vehicles, often specializing in Kei cars and small SUVs.
Model Evolution
Generation 1:
The J100/J102 series represents the first generation of the Daihatsu Terios, introduced in 1997 globally and updated with the J102 facelift and new engine around 2000.
Facelift:
The 2000-2006 models are part of the refreshed first generation, featuring updated styling and the introduction of the more powerful 3SZ-VE engine.
Production
Manufacturing Location:
Primarily manufactured in Japan by Daihatsu Motor Co., Ltd.
Global Availability:
Sold in various markets worldwide, often under different names or with badge engineering (e.g., Toyota Cami).
🏆 Awards & Recognition
Recognitions
Market Perception:
The Terios is recognized for its value, capability for its size, and robust build quality, often praised in markets where it was popular as a budget-friendly compact SUV.
Ratings
Reliability:
Generally considered reliable, particularly the mechanical components, when properly maintained. However, specific wear items like bushings and exhaust can be subject to age-related issues.
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