Daihatsu S85 Hijet Diesel Service Repair Workshop Manual
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๐ท๏ธ Basic Information Identification Make: Daihatsu Model: Hijet Model Code: S85 Vehicle Type: Light Commercial Vehicle / Kei Truck / Microvan Generation Generation Code: S80/S81/S82/S83/S85 Codes Platform: Daihatsu S80 Series ๐ Introduction Market Position Vehicle Segment: Compact commercial vehicle, often used for light hauling, delivery, and utility purposes in various markets. Competitive Analysis Competitors: Competed with other small commercial vehicles from brands like Suzuki Carry, Subaru Sambar, and Mitsubishi Minicab in its era. Key Features Manual Value Proposition: Provides comprehensive, factory-authorized repair and maintenance information, empowering owners and independent mechanics with the same data used by dealerships. Vehicle Appeal: Known for its compact size, fuel efficiency (especially in diesel variants), maneuverability, and utility in urban environments and small businesses. ๐ Manual Details Coverage Areas Coverage: All repairs, servicing, and troubleshooting procedures Page Count Page Count: Hundreds of pages (specific number not provided, but described as extensive) Manual Type Manual Type: Factory Service Repair Workshop Manual Language Language: English (implied by product description and target market) Format Format: Digital Download (PDF) ๐ Manual Coverage Systems Covered Engine: Detailed coverage of diesel engine systems, including fuel, lubrication, cooling, ignition (glow plug system), and emission control. Transmission: Service and repair procedures for manual and automatic transmissions, including clutch operation, gear shifting mechanisms, and lubrication. Drivetrain: Coverage of differential, driveshafts, and rear-wheel drive or four-wheel drive systems (if applicable). Suspension: Detailed information on front and rear suspension components, including shock absorbers, springs, bushings, and alignment procedures. Brakes: Comprehensive coverage of hydraulic brake systems, including front/rear brake pads/shoes, calipers/drums, master cylinder, and brake fluid specifications. Steering: Procedures for steering gearbox, steering column, tie rods, and power steering system (if equipped). Electrical System: Detailed wiring diagrams, fuse box layouts, starter motor, alternator, battery, lighting, and ancillary electrical components. Bodywork And Chassis: Information on body panel removal/installation, interior trim, door mechanisms, and chassis component repairs. Heating And Air Conditioning: Service and repair of HVAC systems, including refrigerant handling and component diagnosis. Procedures Included Maintenance: Routine maintenance procedures, including oil changes, filter replacements, fluid checks and top-offs, and inspection schedules. Troubleshooting: Systematic diagnostic procedures for identifying and resolving common and uncommon faults. Repair: Step-by-step instructions for component removal, repair, and reinstallation for all major vehicle systems. Rebuilding: Complete engine and transmission rebuilding procedures with detailed specifications. Diagnostics: Fault code interpretation, diagnostic tool usage, and specific component testing procedures. Technical Depth Depth: Comprehensive, covering basic maintenance to advanced diagnostics and complete overhauls, suitable for professional technicians. ๐ Manual Specifications File Format File Format: Portable Document Format (PDF) Print Quality Printability: Printable (single pages or entire manual) Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) Compatibility Operating Systems: Fully compatible with Windows and MAC computers Licensing Usage License: Lifetime usage, no expiry dates, usable on multiple computers Version Type Version: Full, unlimited version โ๏ธ Engine Specifications Primary Engine Engine Type: Diesel Engine Code Example: SD33 (common in some Hijet variants, specific code for S85 diesel not explicitly stated but inferred) Engine Displacement Example: Approx. 1.0L to 1.5L (typical for diesel Hijet models of this era) Performance Horsepower Range: Typically in the 40-60 HP range for diesel engines of this class. Torque Range: Moderate torque output, emphasizing low-end grunt for hauling. Fuel System Fuel Injection: Indirect injection or direct injection, depending on specific engine variant. Glow Plugs: Essential for cold starting, detailed testing and replacement procedures covered. Cooling System Cooling Type: Water-cooled, typically with a radiator, thermostat, and water pump. Lubrication System Oil Type Example: API CD or CF classification diesel engine oil (e.g., 10W-30, 15W-40, depending on climate). Engine Management ECU: Basic engine control unit (if equipped) or mechanical injection pump control. ๐ง Transmission Standard Transmission Type: Manual transmission (e.g., 4-speed or 5-speed). Optional Transmission Type: Automatic transmission (less common on diesel variants, but possible). Features Clutch Type: Dry single-plate clutch. Fluid Type Example: GL-4 hypoid gear oil (e.g., SAE 75W-90 or SAE 80W-90 for manual transmission). ๐ Dimensions Exterior Length Example: Approx. 3,395 mm (standard Kei vehicle length regulations). Width Example: Approx. 1,475 mm (standard Kei vehicle width regulations). Height Example: Approx. 1,800 - 1,900 mm (depending on body style, e.g., panel van vs. high-top). Weights Curb Weight Example: Approx. 800 - 950 kg (depending on configuration). Gross Vehicle Weight Rating Example: Typically around 1,500 - 1,700 kg. ๐ก๏ธ Safety Features Ratings Crash Test Information: Limited modern crash test data publicly available for older Kei vehicles due to different regulatory standards in Japan at the time of production. Active Features Braking System: Front disc brakes and rear drum brakes are common. Passive Features Seatbelts: Standard lap and shoulder belts, with specific fitting instructions in the manual. Body Structure: Reinforced chassis and body structure for its class. ๐ก Technology Features Infotainment Infotainment System: Basic AM/FM radio, possibly with cassette player. Aftermarket upgrades common. Driver...
Compact commercial vehicle, often used for light hauling, delivery, and utility purposes in various markets.
Competitive Analysis
Competitors:
Competed with other small commercial vehicles from brands like Suzuki Carry, Subaru Sambar, and Mitsubishi Minicab in its era.
Key Features
Manual Value Proposition:
Provides comprehensive, factory-authorized repair and maintenance information, empowering owners and independent mechanics with the same data used by dealerships.
Vehicle Appeal:
Known for its compact size, fuel efficiency (especially in diesel variants), maneuverability, and utility in urban environments and small businesses.
๐ Manual Details
Coverage Areas
Coverage:
All repairs, servicing, and troubleshooting procedures
Page Count
Page Count:
Hundreds of pages (specific number not provided, but described as extensive)
Manual Type
Manual Type:
Factory Service Repair Workshop Manual
Language
Language:
English (implied by product description and target market)
Format
Format:
Digital Download (PDF)
๐ Manual Coverage
Systems Covered
Engine:
Detailed coverage of diesel engine systems, including fuel, lubrication, cooling, ignition (glow plug system), and emission control.
Transmission:
Service and repair procedures for manual and automatic transmissions, including clutch operation, gear shifting mechanisms, and lubrication.
Drivetrain:
Coverage of differential, driveshafts, and rear-wheel drive or four-wheel drive systems (if applicable).
Suspension:
Detailed information on front and rear suspension components, including shock absorbers, springs, bushings, and alignment procedures.
Brakes:
Comprehensive coverage of hydraulic brake systems, including front/rear brake pads/shoes, calipers/drums, master cylinder, and brake fluid specifications.
Steering:
Procedures for steering gearbox, steering column, tie rods, and power steering system (if equipped).
Information on body panel removal/installation, interior trim, door mechanisms, and chassis component repairs.
Heating And Air Conditioning:
Service and repair of HVAC systems, including refrigerant handling and component diagnosis.
Procedures Included
Maintenance:
Routine maintenance procedures, including oil changes, filter replacements, fluid checks and top-offs, and inspection schedules.
Troubleshooting:
Systematic diagnostic procedures for identifying and resolving common and uncommon faults.
Repair:
Step-by-step instructions for component removal, repair, and reinstallation for all major vehicle systems.
Rebuilding:
Complete engine and transmission rebuilding procedures with detailed specifications.
Diagnostics:
Fault code interpretation, diagnostic tool usage, and specific component testing procedures.
Technical Depth
Depth:
Comprehensive, covering basic maintenance to advanced diagnostics and complete overhauls, suitable for professional technicians.
๐ Manual Specifications
File Format
File Format:
Portable Document Format (PDF)
Print Quality
Printability:
Printable (single pages or entire manual)
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
Compatibility
Operating Systems:
Fully compatible with Windows and MAC computers
Licensing
Usage License:
Lifetime usage, no expiry dates, usable on multiple computers
Version Type
Version:
Full, unlimited version
โ๏ธ Engine Specifications
Primary Engine
Engine Type:
Diesel
Engine Code Example:
SD33 (common in some Hijet variants, specific code for S85 diesel not explicitly stated but inferred)
Engine Displacement Example:
Approx. 1.0L to 1.5L (typical for diesel Hijet models of this era)
Performance
Horsepower Range:
Typically in the 40-60 HP range for diesel engines of this class.
Torque Range:
Moderate torque output, emphasizing low-end grunt for hauling.
Fuel System
Fuel Injection:
Indirect injection or direct injection, depending on specific engine variant.
Glow Plugs:
Essential for cold starting, detailed testing and replacement procedures covered.
Cooling System
Cooling Type:
Water-cooled, typically with a radiator, thermostat, and water pump.
Lubrication System
Oil Type Example:
API CD or CF classification diesel engine oil (e.g., 10W-30, 15W-40, depending on climate).
Engine Management
ECU:
Basic engine control unit (if equipped) or mechanical injection pump control.
๐ง Transmission
Standard
Transmission Type:
Manual transmission (e.g., 4-speed or 5-speed).
Optional
Transmission Type:
Automatic transmission (less common on diesel variants, but possible).
Features
Clutch Type:
Dry single-plate clutch.
Fluid Type Example:
GL-4 hypoid gear oil (e.g., SAE 75W-90 or SAE 80W-90 for manual transmission).
๐ Dimensions
Exterior
Length Example:
Approx. 3,395 mm (standard Kei vehicle length regulations).
Width Example:
Approx. 1,475 mm (standard Kei vehicle width regulations).
Height Example:
Approx. 1,800 - 1,900 mm (depending on body style, e.g., panel van vs. high-top).
Weights
Curb Weight Example:
Approx. 800 - 950 kg (depending on configuration).
Gross Vehicle Weight Rating Example:
Typically around 1,500 - 1,700 kg.
๐ก๏ธ Safety Features
Ratings
Crash Test Information:
Limited modern crash test data publicly available for older Kei vehicles due to different regulatory standards in Japan at the time of production.
Active Features
Braking System:
Front disc brakes and rear drum brakes are common.
Passive Features
Seatbelts:
Standard lap and shoulder belts, with specific fitting instructions in the manual.
Body Structure:
Reinforced chassis and body structure for its class.
๐ก Technology Features
Infotainment
Infotainment System:
Basic AM/FM radio, possibly with cassette player. Aftermarket upgrades common.
Driver Assistance
Driver Assistance Features:
Minimal to none by modern standards. Focus on essential driving controls.
Connectivity
Connectivity Options:
None from the factory.
๐ง Maintenance
Service Intervals
Engine Oil And Filter:
Typically every 5,000 - 7,500 km or 6 months, whichever comes first (refer to manual for exact specification).
Fuel Filter:
Replacement recommended at intervals like 20,000 - 30,000 km.
Air Filter:
Inspection every 10,000 km, replacement every 20,000 - 30,000 km or as needed.
Transmission Fluid:
Check periodically, change every 40,000 - 60,000 km.
Coolant:
Check level regularly, flush and replace coolant every 2-3 years or 40,000 km.
Fluid Specifications
Engine Coolant:
Ethylene glycol-based antifreeze/coolant, typically a 50/50 mix with distilled water.
Brake Fluid:
DOT 3 or DOT 4 (ensure specific recommendation from manual).
Known Issues
Diesel Engine:
Potential for injector wear, glow plug failure, and turbocharger issues (if turbocharged) over time and high mileage. Regular maintenance is crucial.
Body Corrosion:
As with many vehicles of this age, especially if used in environments with salt or high humidity, rust and corrosion can be a concern.
Electrical Connectors:
Oxidized or corroded electrical connectors can lead to intermittent faults, particularly in older vehicles.
๐ Vehicle History
Brand Heritage
Daihatsu Legacy:
Daihatsu has a long history in producing small, efficient, and practical vehicles, including a strong presence in the Kei car segment.
Model Evolution
Hijet Lineage:
The Hijet is one of Daihatsu's longest-running nameplates, with numerous generations and body styles dating back to the 1960s.
Production
Production Period:
The S80 series Hijet was produced roughly from the late 1980s to the mid-1990s.
Manufacturing Location:
Primarily manufactured in Japan.
๐ Awards & Recognition
Recognitions
Vehicle Awards:
The Hijet line generally received acclaim for its practicality and value in the light commercial vehicle sector, though specific awards for the S85 diesel variant are not widely documented.