2005 Daihatsu Boon (2nd gen) Service and Repair Manual
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๐ท๏ธ Basic Information Identification Make: Daihatsu Model: Boon Model Generation: 2nd Generation Year: 2005 ๐ Introduction Market Position Vehicle Segment: Subcompact car / City car Competitive Analysis Key Competitors 2005: Toyota Yaris, Honda Fit/Jazz, Nissan March/Micra, Suzuki Swift, Mazda Demio/2 Key Features Unique Selling Points: Compact dimensions, fuel efficiency, practicality for urban environments, often praised for its interior packaging and maneuverability. Manual Value Proposition Target User: DIY mechanics, independent repair shops, Daihatsu Boon owners seeking to perform maintenance and repairs. Manual Format Advantage Digital Benefits: Searchable, zoomable, printable specific pages, accessible on multiple devices, eliminates physical wear and tear. ๐ Manual Details Coverage Areas Primary Coverage: Service and Repair Page Count Estimated Page Count: Extensive (A-Z coverage implies comprehensive detail, likely exceeding 1000 pages in a physical equivalent) Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF ๐ Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, diagnostics, component testing, internal specifications Engine Control System: ECU diagnostics, sensor testing, fuel injection, ignition timing, emissions control integration Fuel System: Fuel pump, injectors, fuel pressure, evaporative emission control (EVAP) system Cooling System: Radiator, water pump, thermostat, coolant flow, fan control Lubrication System: Oil pump, oil filter, oil passages, lubrication specifications Ignition Charging Starting: Spark plugs, ignition coils, alternator, starter motor, battery diagnostics Automatic Transmission: ATF specifications, internal components, torque converter, solenoids, valve body, shift control Manual Transmission: Clutch operation, gear engagement, gearbox internals, shift linkage, fluid specifications Drivetrain: Driveshafts, CV joints, propeller shafts, differentials, axle maintenance Suspension: Struts, shocks, control arms, bushings, alignment specifications, component replacement Steering: Steering column, power steering system, rack and pinion, tie rods, steering angle sensor Brakes: Brake fluid, calipers, pads, rotors, ABS system, parking brake mechanics Climate Control: AC system operation, refrigerant, compressor, HVAC controls, blower motor Restraint Systems: Airbag system, SRS control unit, seat belt mechanisms, pre-tensioners Electrical System: Wiring schematics, component testing, fuses, relays, lighting systems Body And Interior: Door mechanisms, latches, locks, power windows, seats, interior trim removal Multiplex Can Communication: CAN bus diagnostics, network communication protocols, module integration Procedures Included Preventative Maintenance: Scheduled maintenance tasks, fluid changes, filter replacements, inspection points Troubleshooting: Diagnostic flowcharts, symptom-based diagnosis, fault code interpretation Component Replacement: Step-by-step instructions for replacing major and minor components Rebuilding: Detailed procedures for engine, transmission, and differential rebuilds Diagnostics: On-board diagnostics (OBD-II) procedures, scan tool usage, live data interpretation Wiring Analysis: Interpreting wiring diagrams, continuity testing, voltage checks Technical Depth Depth: Comprehensive (from basic fluid checks to complete engine and transmission rebuilds, including advanced diagnostics and wiring schematics) ๐ Manual Specifications File Format File Type: PDF Print Quality Print Ability: High-resolution, printable pages; ability to enlarge images Binding Type Binding: Digital (PDF) - no physical binding Paper Type Paper Type Equivalent: Digital format, designed for on-screen viewing and targeted printing of specific sections โ๏ธ Engine Specifications Primary Engine Engine Type: Inline 3-cylinder or 4-cylinder gasoline engines (common for the Boon) Displacement Options: Likely 1.0L (K3-VE) and 1.3L (K3-VE) or similar Daihatsu engine codes for this generation. Manual will detail specific codes. Performance Typical Horsepower Range: Approximately 60-90 HP depending on engine variant. Typical Torque Range: Approximately 85-120 Nm depending on engine variant. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) ๐ง Transmission Standard Transmission Type Standard: Likely a 4-speed Automatic Transmission (AT) or a 5-speed Manual Transmission (MT). Optional Transmission Type Optional: Continuously Variable Transmission (CVT) may have been an option on some models/markets. Features Transmission Features: Electronic control for AT/CVT, manual clutch operation for MT. ๐ Dimensions Exterior Overall Length Approx: Around 3,620 mm Overall Width Approx: Around 1,665 mm Overall Height Approx: Around 1,530 mm Weights Curb Weight Approx: Around 850 - 950 kg depending on configuration ๐ก๏ธ Safety Features Ratings Crash Test Results Availability: Information may vary by market. Manual will not contain crash test ratings but will cover safety system repair. Active Features ABS: Anti-lock Braking System (ABS) typically available. Ebs E Brake: Parking Brake system (manual cable operation). Passive Features Airbags: Driver and Passenger Airbags, potentially side airbags on higher trims. Seatbelts: Pre-tensioner seatbelts, height adjustable front seatbelts. ๐ก Technology Features Infotainment Audio Visual System: Basic AM/FM/CD player with speakers. Manual covers diagnostics and repair of audio components. Driver Assistance Cruise Control: Cruise control system may be present on higher trim levels. Manual covers its diagnosis and repair. Connectivity Immobilizer System: Engine Immobilizer for anti-theft. Manual details its operation and troubleshooting. ๐ง Maintenance Service Intervals Oil Change Interval: Refer to manual for specific interval (typically 5,000-10,000 km or 6-12 months, depending on driving conditions). Spark Plug Replacement: Refer to manual for specific interval and plug type (e.g., Iridium plugs may have longer intervals). Fluid Specifications Engine Oil Type: Refer to manual. Likely 0W-20, 5W-30, or 10W-30 API SN/SN+ or similar. Automatic Transmission Fluid: Refer to manual. Likely a Dexron-III/VI equivalent or specific...
Step-by-step instructions for replacing major and minor components
Rebuilding:
Detailed procedures for engine, transmission, and differential rebuilds
Diagnostics:
On-board diagnostics (OBD-II) procedures, scan tool usage, live data interpretation
Wiring Analysis:
Interpreting wiring diagrams, continuity testing, voltage checks
Technical Depth
Depth:
Comprehensive (from basic fluid checks to complete engine and transmission rebuilds, including advanced diagnostics and wiring schematics)
๐ Manual Specifications
File Format
File Type:
PDF
Print Quality
Print Ability:
High-resolution, printable pages; ability to enlarge images
Binding Type
Binding:
Digital (PDF) - no physical binding
Paper Type
Paper Type Equivalent:
Digital format, designed for on-screen viewing and targeted printing of specific sections
โ๏ธ Engine Specifications
Primary Engine
Engine Type:
Inline 3-cylinder or 4-cylinder gasoline engines (common for the Boon)
Displacement Options:
Likely 1.0L (K3-VE) and 1.3L (K3-VE) or similar Daihatsu engine codes for this generation. Manual will detail specific codes.
Performance
Typical Horsepower Range:
Approximately 60-90 HP depending on engine variant.
Typical Torque Range:
Approximately 85-120 Nm depending on engine variant.
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
๐ง Transmission
Standard
Transmission Type Standard:
Likely a 4-speed Automatic Transmission (AT) or a 5-speed Manual Transmission (MT).
Optional
Transmission Type Optional:
Continuously Variable Transmission (CVT) may have been an option on some models/markets.
Features
Transmission Features:
Electronic control for AT/CVT, manual clutch operation for MT.
๐ Dimensions
Exterior
Overall Length Approx:
Around 3,620 mm
Overall Width Approx:
Around 1,665 mm
Overall Height Approx:
Around 1,530 mm
Weights
Curb Weight Approx:
Around 850 - 950 kg depending on configuration
๐ก๏ธ Safety Features
Ratings
Crash Test Results Availability:
Information may vary by market. Manual will not contain crash test ratings but will cover safety system repair.
Active Features
ABS:
Anti-lock Braking System (ABS) typically available.
Ebs E Brake:
Parking Brake system (manual cable operation).
Passive Features
Airbags:
Driver and Passenger Airbags, potentially side airbags on higher trims.
Seatbelts:
Pre-tensioner seatbelts, height adjustable front seatbelts.
๐ก Technology Features
Infotainment
Audio Visual System:
Basic AM/FM/CD player with speakers. Manual covers diagnostics and repair of audio components.
Driver Assistance
Cruise Control:
Cruise control system may be present on higher trim levels. Manual covers its diagnosis and repair.
Connectivity
Immobilizer System:
Engine Immobilizer for anti-theft. Manual details its operation and troubleshooting.
๐ง Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific interval (typically 5,000-10,000 km or 6-12 months, depending on driving conditions).
Spark Plug Replacement:
Refer to manual for specific interval and plug type (e.g., Iridium plugs may have longer intervals).
Fluid Specifications
Engine Oil Type:
Refer to manual. Likely 0W-20, 5W-30, or 10W-30 API SN/SN+ or similar.
Automatic Transmission Fluid:
Refer to manual. Likely a Dexron-III/VI equivalent or specific Daihatsu ATF.
Coolant Type:
Refer to manual. Likely a long-life ethylene glycol based coolant.
Brake Fluid Type:
Refer to manual. Typically DOT 3 or DOT 4.
Known Issues
Common Wear Items:
Wear and tear on suspension components (bushings, ball joints), minor electrical issues in older vehicles, potential for transmission solenoid issues in higher mileage AT models.
Engine Issues:
While generally reliable, potential for oil leaks from seals and gaskets over time. Carbon buildup in the intake system on some engines.
๐ Vehicle History
Brand Heritage
Daihatsu Specialty:
Daihatsu is known for producing small, fuel-efficient, and reliable vehicles, often with a focus on practicality and affordability.
Model Evolution
Boon Introduction:
The Boon (also known as Sirion in some markets) was introduced to compete in the burgeoning light car segment, offering a versatile and spacious interior for its size.
Production
Manufacturing Location Typical:
Japan
๐ Awards & Recognition
Recognitions
Industry Awards Availability:
Specific awards for the 2005 Boon are not widely documented in major international publications, but it was likely recognized in its home markets for practicality and value.