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Daihatsu Terios J102 2002 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Year: 2002 Chassis Code: J102 👋 Introduction Market Position Market Position: Compact SUV/Off-roader, positioned as an affordable and capable entry into the SUV segment, often appealing to younger buyers or those seeking practical, smaller utility vehicles. Competitive Analysis Competitive Analysis: Competed with other compact SUVs and crossover vehicles of its era, such as the Suzuki Vitara/Grand Vitara, Toyota RAV4 (early generations), Honda CR-V (early generations), and Mitsubishi Pajero/Outlander. The Terios often distinguished itself with its more rugged, body-on-frame (for earlier generations) or unibody construction offering genuine off-road capability in a compact package, along with a more accessible price point. Key Features Key Features: Compact dimensions, available 4WD system, decent ground clearance for its class, fuel-efficient engines (relative to larger SUVs), practical interior space for its size, and a focus on utility and versatility. 📋 Manual Details Coverage Areas Coverage Areas: Complete factory service and repair Page Count Page Count: Hundreds of pages (exact count not specified, implies comprehensive) Manual Type Manual Type: Factory Service Repair Manual Language Language: English (implied by typical factory service manuals for export markets) Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Systems Covered: Engine mechanical, engine fuel system, engine cooling system, engine lubrication system, ignition system, emission control system, exhaust system, transmission (manual and automatic), drivetrain, axles, suspension, steering system, brake system (hydraulic and mechanical), electrical system (wiring diagrams, components), HVAC system, body and chassis, interior trim, exterior panels, diagnostic trouble codes (DTCs). Procedures Included Procedures Included: Routine maintenance, scheduled maintenance, troubleshooting, diagnostics, component removal and installation, repair procedures, overhaul instructions, assembly procedures, torque specifications, fluid capacities and types, electrical component testing, wiring harness repair, body panel alignment, clutch service, brake bleeding, suspension component replacement, engine timing adjustment, fuel injector cleaning, EGR system service. Technical Depth Technical Depth: Comprehensive from basic fluid changes and inspections to complete engine and transmission rebuilds. Includes detailed diagnostic procedures and electrical system schematics. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: Printable (allows printing of entire manual or selected pages) Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Primary Engine: 1.3L DOHC 16V Inline-4 (K3-VE) Engine Code Engine Code: K3-VE Displacement Displacement: 1298 cc (1.3 Liters) Bore X Stroke Bore X Stroke: 72.0 mm x 80.5 mm Compression Ratio Compression Ratio: 9.0:1 (typical) Horsepower Horsepower: 86 hp (63 kW) @ 6000 rpm (typical) Torque Torque: 120 Nm (89 lb-ft) @ 3200 rpm (typical) Valvetrain Valvetrain: DOHC, 16 Valves Fuel System Fuel System: Electronic Fuel Injection (EFI) Induction Induction: Naturally Aspirated Emissions Control Emissions Control: Catalytic Converter, EGR (Exhaust Gas Recirculation) Oil Capacity Oil Capacity: Approx. 3.7 Liters (3.9 US Quarts) with filter change (refer to manual for exact specification) Cooling System Capacity Cooling System Capacity: Approx. 5.0 Liters (5.3 US Quarts) (refer to manual for exact specification) Spark Plugs Spark Plugs: NGK BKR6E-11 or equivalent (refer to manual for precise part number and gap) 🔧 Transmission Standard Transmission Standard Transmission: 5-speed Manual Optional Transmission Optional Transmission: 4-speed Automatic Transmission Fluid Manual Transmission Fluid Manual: API GL-4 SAE 75W-90 (Refer to manual for specific type and capacity) Transmission Fluid Automatic Transmission Fluid Automatic: Dexron III or equivalent (Refer to manual for specific type and capacity) Drive Type Drive Type: Rear-Wheel Drive (RWD) or Four-Wheel Drive (4WD) Transfer Case Transfer Case: Part-time 4WD system with center differential lock (on some 4WD models) 📐 Dimensions Exterior Length Exterior Length: Approx. 3995 mm (157.3 inches) Exterior Width Exterior Width: Approx. 1695 mm (66.7 inches) Exterior Height Exterior Height: Approx. 1705 mm (67.1 inches) (with roof rails) Wheelbase Wheelbase: Approx. 2430 mm (95.7 inches) Ground Clearance Ground Clearance: Approx. 195 mm (7.7 inches) Curb Weight Curb Weight: Approx. 1150-1250 kg (2535-2755 lbs) depending on configuration. Cargo Volume Rear Seats Up Cargo Volume Rear Seats Up: Modest, suitable for daily use, expandable with folding rear seats. Tire Size Tire Size: 205/70R15 (typical, refer to manual or vehicle sticker for exact fitment) Wheel Bolt Pattern Wheel Bolt Pattern: 5x114.3 mm (5x4.5 inches) Wheel Size Wheel Size: 15 x 5.5J (typical) 🛡️ Safety Features Ratings Ratings: Specific crash test ratings for this exact J102 generation from major agencies like NHTSA or Euro NCAP are not widely published for all markets. Generally, compact SUVs of this era offered basic safety features. Active Features Active Features: Anti-lock Braking System (ABS) (often optional or standard on higher trims), Electronic Brake-force Distribution (EBD) (on some models). Passive Features Passive Features: Front airbags for driver and passenger, three-point seatbelts with pretensioners, height-adjustable seatbelts, child seat anchor points (ISOFIX/LATCH - check specific market regulations), collapsible steering column, reinforced body structure. Brake System Brake System: Front: Ventilated Disc; Rear: Drum or Disc (depending on trim and market). ABS is available....
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Daihatsu Terios J102 2002 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Terios
Year:
2002
Chassis Code:
J102
👋 Introduction
Market Position
Market Position:
Compact SUV/Off-roader, positioned as an affordable and capable entry into the SUV segment, often appealing to younger buyers or those seeking practical, smaller utility vehicles.
Competitive Analysis
Competitive Analysis:
Competed with other compact SUVs and crossover vehicles of its era, such as the Suzuki Vitara/Grand Vitara, Toyota RAV4 (early generations), Honda CR-V (early generations), and Mitsubishi Pajero/Outlander. The Terios often distinguished itself with its more rugged, body-on-frame (for earlier generations) or unibody construction offering genuine off-road capability in a compact package, along with a more accessible price point.
Key Features
Key Features:
Compact dimensions, available 4WD system, decent ground clearance for its class, fuel-efficient engines (relative to larger SUVs), practical interior space for its size, and a focus on utility and versatility.
📋 Manual Details
Coverage Areas
Coverage Areas:
Complete factory service and repair
Page Count
Page Count:
Hundreds of pages (exact count not specified, implies comprehensive)
Manual Type
Manual Type:
Factory Service Repair Manual
Language
Language:
English (implied by typical factory service manuals for export markets)
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Systems Covered:
Engine mechanical, engine fuel system, engine cooling system, engine lubrication system, ignition system, emission control system, exhaust system, transmission (manual and automatic), drivetrain, axles, suspension, steering system, brake system (hydraulic and mechanical), electrical system (wiring diagrams, components), HVAC system, body and chassis, interior trim, exterior panels, diagnostic trouble codes (DTCs).
Procedures Included
Procedures Included:
Routine maintenance, scheduled maintenance, troubleshooting, diagnostics, component removal and installation, repair procedures, overhaul instructions, assembly procedures, torque specifications, fluid capacities and types, electrical component testing, wiring harness repair, body panel alignment, clutch service, brake bleeding, suspension component replacement, engine timing adjustment, fuel injector cleaning, EGR system service.
Technical Depth
Technical Depth:
Comprehensive from basic fluid changes and inspections to complete engine and transmission rebuilds. Includes detailed diagnostic procedures and electrical system schematics.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
Printable (allows printing of entire manual or selected pages)
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Primary Engine:
1.3L DOHC 16V Inline-4 (K3-VE)
Engine Code
Engine Code:
K3-VE
Displacement
Displacement:
1298 cc (1.3 Liters)
Bore X Stroke
Bore X Stroke:
72.0 mm x 80.5 mm
Compression Ratio
Compression Ratio:
9.0:1 (typical)
Horsepower
Horsepower:
86 hp (63 kW) @ 6000 rpm (typical)
Torque
Torque:
120 Nm (89 lb-ft) @ 3200 rpm (typical)
Valvetrain
Valvetrain:
DOHC, 16 Valves
Fuel System
Fuel System:
Electronic Fuel Injection (EFI)
Induction
Induction:
Naturally Aspirated
Emissions Control
Emissions Control:
Catalytic Converter, EGR (Exhaust Gas Recirculation)
Oil Capacity
Oil Capacity:
Approx. 3.7 Liters (3.9 US Quarts) with filter change (refer to manual for exact specification)
Cooling System Capacity
Cooling System Capacity:
Approx. 5.0 Liters (5.3 US Quarts) (refer to manual for exact specification)
Spark Plugs
Spark Plugs:
NGK BKR6E-11 or equivalent (refer to manual for precise part number and gap)
🔧 Transmission
Standard Transmission
Standard Transmission:
5-speed Manual
Optional Transmission
Optional Transmission:
4-speed Automatic
Transmission Fluid Manual
Transmission Fluid Manual:
API GL-4 SAE 75W-90 (Refer to manual for specific type and capacity)
Transmission Fluid Automatic
Transmission Fluid Automatic:
Dexron III or equivalent (Refer to manual for specific type and capacity)
Drive Type
Drive Type:
Rear-Wheel Drive (RWD) or Four-Wheel Drive (4WD)
Transfer Case
Transfer Case:
Part-time 4WD system with center differential lock (on some 4WD models)
📐 Dimensions
Exterior Length
Exterior Length:
Approx. 3995 mm (157.3 inches)
Exterior Width
Exterior Width:
Approx. 1695 mm (66.7 inches)
Exterior Height
Exterior Height:
Approx. 1705 mm (67.1 inches) (with roof rails)
Wheelbase
Wheelbase:
Approx. 2430 mm (95.7 inches)
Ground Clearance
Ground Clearance:
Approx. 195 mm (7.7 inches)
Curb Weight
Curb Weight:
Approx. 1150-1250 kg (2535-2755 lbs) depending on configuration.
Cargo Volume Rear Seats Up
Cargo Volume Rear Seats Up:
Modest, suitable for daily use, expandable with folding rear seats.
Tire Size
Tire Size:
205/70R15 (typical, refer to manual or vehicle sticker for exact fitment)
Wheel Bolt Pattern
Wheel Bolt Pattern:
5x114.3 mm (5x4.5 inches)
Wheel Size
Wheel Size:
15 x 5.5J (typical)
🛡️ Safety Features
Ratings
Ratings:
Specific crash test ratings for this exact J102 generation from major agencies like NHTSA or Euro NCAP are not widely published for all markets. Generally, compact SUVs of this era offered basic safety features.
Active Features
Active Features:
Anti-lock Braking System (ABS) (often optional or standard on higher trims), Electronic Brake-force Distribution (EBD) (on some models).
Passive Features
Passive Features:
Front airbags for driver and passenger, three-point seatbelts with pretensioners, height-adjustable seatbelts, child seat anchor points (ISOFIX/LATCH - check specific market regulations), collapsible steering column, reinforced body structure.
Brake System
Brake System:
Front: Ventilated Disc; Rear: Drum or Disc (depending on trim and market). ABS is available.
💡 Technology Features
Infotainment
Infotainment:
Basic factory-installed audio system with AM/FM radio and CD player. Speaker configuration typically 2-4. Aux input or USB ports were uncommon for this model year. Manual will cover any factory radio diagnostics and antenna system.
Driver Assistance
Driver Assistance:
Limited. ABS and EBD were available as optional features on higher trims. No advanced driver-assistance systems (ADAS) like adaptive cruise control, lane keeping assist, or blind-spot monitoring were available.
Climate Control
Climate Control:
Manual air conditioning and heating system, with controls for fan speed, temperature, and air direction. Manual covers component identification, refrigerant charging procedures (R134a), and troubleshooting for the A/C compressor, blower motor, and HVAC actuators.
Keyless Entry
Keyless Entry:
Optional on some higher trim levels. Manual would detail the receiver module, key fob programming, and diagnostics.
Power Windows Locks
Power Windows Locks:
Standard on most models, or available. Manual covers motor operation, switch diagnostics, and wiring.
🔧 Maintenance
Service Intervals Oil Change
Service Intervals Oil Change:
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).
Service Intervals Air Filter
Service Intervals Air Filter:
Inspect every 15,000 km (9,000 miles), replace every 30,000 km (18,000 miles) or as needed.
Service Intervals Spark Plugs
Service Intervals Spark Plugs:
Replace every 40,000 - 100,000 km (25,000 - 60,000 miles) depending on plug type (standard vs. long-life/iridium). Refer to manual for recommended interval.
Service Intervals Transmission Fluid Manual
Service Intervals Transmission Fluid Manual:
Check level regularly, replace every 40,000 - 80,000 km (25,000 - 50,000 miles) depending on usage and conditions.
Service Intervals Transmission Fluid Automatic
Service Intervals Transmission Fluid Automatic:
Check level regularly, replace every 40,000 - 80,000 km (25,000 - 50,000 miles) depending on usage and conditions, especially for heavy use.
Service Intervals Coolant
Service Intervals Coolant:
Flush and replace every 40,000 km (25,000 miles) or 2-3 years.
Fluid Specifications Engine Oil
Fluid Specifications Engine Oil:
API SG/SH/SJ or ILSAC GF-2/GF-3, SAE 10W-30 or 10W-40 (refer to manual for specific viscosity based on ambient temperature).
Fluid Specifications Brake Fluid
Fluid Specifications Brake Fluid:
DOT 3 or DOT 4
Fluid Specifications Power Steering Fluid
Fluid Specifications Power Steering Fluid:
ATF Dexron II or III (check manual)
Known Issues
Known Issues:
Minor oil leaks (e.g., valve cover gasket, oil pan gasket), occasional issues with the EGR valve causing rough idling or stalling, clutch wear on manual transmissions with high mileage or hard use, potential for corrosion on older 4WD components if not maintained, front suspension wear (bushings, ball joints) due to typical usage for this vehicle type.
Timing Belt Or Chain
Timing Belt Or Chain:
Timing Chain (K3-VE engine). Generally maintenance-free, but the tensioner and guides can wear over time.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Daihatsu, a subsidiary of Toyota, has a long history specializing in small, fuel-efficient vehicles, particularly kei cars in Japan and compact cars and SUVs for global markets. They are known for reliability and practicality in their segment.
Model Evolution
Model Evolution:
The Daihatsu Terios was first introduced in 1997 as a compact SUV. The J100 series (including J102) represented the first generation, produced from 1997 to 2006. It was known for its compact size, available 4WD, and genuine off-road capability, often featuring a ladder-frame chassis in earlier models. It was later rebadged and sold by Toyota as the Toyota Rush in some markets. The second generation (J200 series) transitioned to a unibody platform and grew in size.
Production
Production:
The J102 generation of the Daihatsu Terios was produced globally, with manufacturing facilities often in Japan and other Daihatsu production centers.
🏆 Awards & Recognition
Recognitions
Recognitions:
Specific 'awards' for the 2002 Terios are not widely publicized. However, the Terios model line has generally been recognized for its compact SUV capability, affordability, and practicality in its segment.
Ratings
Ratings:
Reliability ratings for Daihatsu vehicles are generally considered good, often on par with parent company Toyota's reputation for dependability in similar vehicle segments. Owner satisfaction surveys often highlight its functionality for its price.
Certifications
Certifications:
Manufactured to meet regional safety and emissions standards (e.g., JSAE standards in Japan, various EPA/DOT regulations in the US for imported models if applicable).
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