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DAIHATSU TERIOS J100 1997-2000 Workshop Service Repair Manual

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$133.00
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$133.00
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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Chassis Code: J100 Series Model Years Covered: 1997-2000 Codes Engine Code: HC-EJ 👋 Introduction Market Position Vehicle Segment: Compact SUV / Mini SUV. Target Audience: Individuals seeking an affordable, versatile, and capable small SUV, often for light off-road use or family transport. Competitive Analysis Key Competitors: Suzuki Vitara, Mitsubishi Pajero Mini, Toyota RAV4 (earlier models), Honda CR-V (earlier models), Nissan Terrano II. Key Features Off Road Capability: Known for its compact size and optional 4WD system, offering surprising off-road prowess for its class. Practicality: Offers a good balance of interior space for its exterior dimensions and a high driving position. Durability: Daihatsu is generally known for producing reliable and durable vehicles, particularly in its smaller segments. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Repair Manual Language: English Format: Digital (likely PDF) Page Count Estimated Page Count: Varies based on specific publication, typically 300-600 pages for comprehensive manuals. Manual Type Manual Purpose: Designed for professional technicians and advanced DIY enthusiasts. 📖 Manual Coverage Systems Covered Engine Mechanical: Full coverage: Engine assembly, cylinder head, pistons, crankshaft, camshafts, timing system, seals and gaskets. Emission Control: Detailed explanation of emission control systems, components, and testing procedures. Efi System: Comprehensive coverage of the Electronic Fuel Injection system, including sensors, actuators, ECU, and diagnostic procedures. Lubrication System: In-depth information on oil pump, oil filter, oil passages, oil pressure testing, and lubrication strategies. Cooling System: Coverage includes radiator, water pump, thermostat, cooling fans, coolant types, and pressure testing. Fuel System: Information on fuel tank, fuel pump, fuel lines, injectors, fuel pressure regulation, and diagnostics. Ignition System: Details on spark plugs, ignition coils, distributor (if applicable), ignition timing, and troubleshooting. Engine Electrical System: Wiring diagrams, charging system (alternator, battery), starting system (starter motor), and component testing. Transmission Manual: Coverage for the manual transmission, including clutch, gearbox, shift mechanism, and fluid specifications. Transmission Automatic: Information on automatic transmission operation, torque converter, valve body, and fluid services (if automatic variants exist). Drivetrain: Covers front and rear differentials, drive shafts, CV joints, and 4WD system (if applicable). Suspension System: Front and rear suspension components, shock absorbers, springs, bushings, and alignment specifications. Steering System: Power steering pump, steering rack/gearbox, tie rods, and steering angle sensor (if applicable). Brake System: Front and rear brakes (discs/drums), brake fluid, ABS system (if equipped), hydraulic lines, and bleeding procedures. Body Exterior: Body panels, doors, hood, tailgate, bumpers, glass, and trim component removal/installation. Body Interior: Dashboard, seats, carpets, headliner, door panels, interior trim, and HVAC controls. Electrical System Lighting: Headlights, taillights, interior lighting, fog lights, and wiring. Electrical System Instruments: Instrument cluster, gauges, warning lights, and sensors. Electrical System Accessories: Power windows, central locking, mirrors, audio system, wipers, and horn. HVAC System: Heating, ventilation, and air conditioning system components, refrigerant, and diagnostics. Procedures Included Preventive Maintenance: Scheduled maintenance, fluid changes, filter replacements, inspections, and lubrication points. Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting, and common fault identification. Repair Procedures: Step-by-step instructions for component removal, disassembly, reassembly, and installation. Diagnostics: Procedures for checking system operation, sensor readings, actuator functionality, and using diagnostic tools. Component Replacement: Guidance on replacing major and minor components across all vehicle systems. Specifications And Tolerances: Tightening torques, clearances, measurements, and material specifications for various components. Wiring Diagrams: Detailed electrical schematics for all vehicle circuits. Technical Depth Depth Level: Comprehensive from basic maintenance to in-depth engine and transmission overhauls. 📊 Manual Specifications File Format File Type: Likely PDF, optimized for digital viewing and printing. Searchability: Expect searchable text for efficient information retrieval. Print Quality Illustration Clarity: Diagrams and illustrations are typically clear and detailed for repair guidance. Binding Type Digital Format: N/A (Digital) Paper Type Digital Format: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Family: HC-EJ Engine Configuration: Inline 4-cylinder Engine Displacement: 1.3 Liters (1300 cc) Engine Aspiration: Naturally Aspirated Valvetrain: SOHC (Single Overhead Camshaft), 16 Valves (4 valves per cylinder) Performance Horsepower Output: Approximately 80-88 PS (metric horsepower) at around 6000 RPM. (Specific figures may vary by market). Torque Output: Approximately 110-115 Nm (Newton-meters) at around 3500-4000 RPM. (Specific figures may vary by market). Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline Technical Details Bore X Stroke: Refer to manual for precise measurements, typically around 72.0 mm x 77.5 mm. Compression Ratio: Typically around 9.4:1 to 9.5:1. Engine Oil Capacity: Approximately 3.0 - 3.5 Liters (with filter change). Refer to manual for exact capacity. Recommended Oil Viscosity: Typically 5W-30 or 10W-30. Check manual for specific grade based on climate. 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission. Optional Transmission Type: 4-speed Automatic Transmission (availability may vary by market and trim). Features Drivetrain Options: Available in 2WD (Rear-Wheel Drive) and 4WD (Four-Wheel Drive). Transfer Case 4Wd: Manual 4WD system with high/low range gear selection (on some models). Fluid Specifications Manual Transmission Fluid...
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DAIHATSU TERIOS J100 1997-2000 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Terios
Chassis Code:
J100 Series
Model Years Covered:
1997-2000
Codes
Engine Code:
HC-EJ
👋 Introduction
Market Position
Vehicle Segment:
Compact SUV / Mini SUV.
Target Audience:
Individuals seeking an affordable, versatile, and capable small SUV, often for light off-road use or family transport.
Competitive Analysis
Key Competitors:
Suzuki Vitara, Mitsubishi Pajero Mini, Toyota RAV4 (earlier models), Honda CR-V (earlier models), Nissan Terrano II.
Key Features
Off Road Capability:
Known for its compact size and optional 4WD system, offering surprising off-road prowess for its class.
Practicality:
Offers a good balance of interior space for its exterior dimensions and a high driving position.
Durability:
Daihatsu is generally known for producing reliable and durable vehicles, particularly in its smaller segments.
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Repair Manual
Language:
English
Format:
Digital (likely PDF)
Page Count
Estimated Page Count:
Varies based on specific publication, typically 300-600 pages for comprehensive manuals.
Manual Type
Manual Purpose:
Designed for professional technicians and advanced DIY enthusiasts.
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full coverage: Engine assembly, cylinder head, pistons, crankshaft, camshafts, timing system, seals and gaskets.
Emission Control:
Detailed explanation of emission control systems, components, and testing procedures.
Efi System:
Comprehensive coverage of the Electronic Fuel Injection system, including sensors, actuators, ECU, and diagnostic procedures.
Lubrication System:
In-depth information on oil pump, oil filter, oil passages, oil pressure testing, and lubrication strategies.
Cooling System:
Coverage includes radiator, water pump, thermostat, cooling fans, coolant types, and pressure testing.
Fuel System:
Information on fuel tank, fuel pump, fuel lines, injectors, fuel pressure regulation, and diagnostics.
Ignition System:
Details on spark plugs, ignition coils, distributor (if applicable), ignition timing, and troubleshooting.
Engine Electrical System:
Wiring diagrams, charging system (alternator, battery), starting system (starter motor), and component testing.
Transmission Manual:
Coverage for the manual transmission, including clutch, gearbox, shift mechanism, and fluid specifications.
Transmission Automatic:
Information on automatic transmission operation, torque converter, valve body, and fluid services (if automatic variants exist).
Drivetrain:
Covers front and rear differentials, drive shafts, CV joints, and 4WD system (if applicable).
Suspension System:
Front and rear suspension components, shock absorbers, springs, bushings, and alignment specifications.
Steering System:
Power steering pump, steering rack/gearbox, tie rods, and steering angle sensor (if applicable).
Brake System:
Front and rear brakes (discs/drums), brake fluid, ABS system (if equipped), hydraulic lines, and bleeding procedures.
Body Exterior:
Body panels, doors, hood, tailgate, bumpers, glass, and trim component removal/installation.
Body Interior:
Dashboard, seats, carpets, headliner, door panels, interior trim, and HVAC controls.
Electrical System Lighting:
Headlights, taillights, interior lighting, fog lights, and wiring.
Electrical System Instruments:
Instrument cluster, gauges, warning lights, and sensors.
Electrical System Accessories:
Power windows, central locking, mirrors, audio system, wipers, and horn.
HVAC System:
Heating, ventilation, and air conditioning system components, refrigerant, and diagnostics.
Procedures Included
Preventive Maintenance:
Scheduled maintenance, fluid changes, filter replacements, inspections, and lubrication points.
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting, and common fault identification.
Repair Procedures:
Step-by-step instructions for component removal, disassembly, reassembly, and installation.
Diagnostics:
Procedures for checking system operation, sensor readings, actuator functionality, and using diagnostic tools.
Component Replacement:
Guidance on replacing major and minor components across all vehicle systems.
Specifications And Tolerances:
Tightening torques, clearances, measurements, and material specifications for various components.
Wiring Diagrams:
Detailed electrical schematics for all vehicle circuits.
Technical Depth
Depth Level:
Comprehensive from basic maintenance to in-depth engine and transmission overhauls.
📊 Manual Specifications
File Format
File Type:
Likely PDF, optimized for digital viewing and printing.
Searchability:
Expect searchable text for efficient information retrieval.
Print Quality
Illustration Clarity:
Diagrams and illustrations are typically clear and detailed for repair guidance.
Binding Type
Digital Format:
N/A (Digital)
Paper Type
Digital Format:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Family:
HC-EJ
Engine Configuration:
Inline 4-cylinder
Engine Displacement:
1.3 Liters (1300 cc)
Engine Aspiration:
Naturally Aspirated
Valvetrain:
SOHC (Single Overhead Camshaft), 16 Valves (4 valves per cylinder)
Performance
Horsepower Output:
Approximately 80-88 PS (metric horsepower) at around 6000 RPM. (Specific figures may vary by market).
Torque Output:
Approximately 110-115 Nm (Newton-meters) at around 3500-4000 RPM. (Specific figures may vary by market).
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Technical Details
Bore X Stroke:
Refer to manual for precise measurements, typically around 72.0 mm x 77.5 mm.
Compression Ratio:
Typically around 9.4:1 to 9.5:1.
Engine Oil Capacity:
Approximately 3.0 - 3.5 Liters (with filter change). Refer to manual for exact capacity.
Recommended Oil Viscosity:
Typically 5W-30 or 10W-30. Check manual for specific grade based on climate.
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transmission.
Optional
Transmission Type:
4-speed Automatic Transmission (availability may vary by market and trim).
Features
Drivetrain Options:
Available in 2WD (Rear-Wheel Drive) and 4WD (Four-Wheel Drive).
Transfer Case 4Wd:
Manual 4WD system with high/low range gear selection (on some models).
Fluid Specifications
Manual Transmission Fluid Type:
API GL-4, SAE 75W-90 or 80W-90 gear oil. Consult manual for specific part numbers.
Automatic Transmission Fluid Type:
Dexron II/III or equivalent. Consult manual for specific part numbers and capacity.
📐 Dimensions
Exterior
Length:
Approximately 3720 - 3760 mm (varies slightly by market and bumper design).
Width:
Approximately 1595 - 1620 mm.
Height:
Approximately 1685 - 1705 mm.
Wheelbase:
Approximately 2360 mm.
Ground Clearance:
Approximately 190 - 200 mm.
Weights
Curb Weight:
Approximately 1100 - 1250 kg (depending on configuration).
Gross Vehicle Weight Rating:
Refer to vehicle placard or manual.
Cargo
Cargo Volume:
Modular seating allows for varying cargo configurations. Specific cubic footage figures available in manual or owner's guide.
Wheels Tires
Wheel Bolt Pattern:
Typically 4x114.3 mm.
Standard Tire Size:
Commonly 205/70R15 or 205/75R15. Check manual for specific fitments.
🛡️ Safety Features
Ratings
Crash Test Results:
Safety ratings for this era of vehicle varied significantly by market and testing agency. Consult official safety databases for specific results, though detailed results for this model might be limited.
Active Features
ABS:
Anti-lock Braking System (ABS) may be optional or standard on higher trims or later production models.
Four Wheel Drive:
Optional 4WD system enhances traction and stability in various conditions.
Passive Features
Airbags:
Driver and passenger airbags were becoming more common. Availability may depend on model year and market. Check manual for specifics.
Seatbelts:
3-point seatbelts with pretensioners (front) and 2-point or 3-point seatbelts (rear).
Rollover Protection:
Body-on-frame construction offers inherent structural integrity. Specific rollover resistance figures are best found in independent testing reports.
💡 Technology Features
Infotainment
Audio System:
Typically a basic AM/FM radio with CD player or cassette deck. Speaker count and quality are entry-level for the segment.
Connectivity:
Limited connectivity options by modern standards. May include auxiliary inputs depending on trim.
Driver Assistance
Cruise Control:
Optional on some higher-trim models.
Instrumentation
Gauge Cluster:
Includes speedometer, tachometer (optional), fuel gauge, temperature gauge, and various warning lamps.
🔧 Maintenance
Service Intervals
Oil And Filter Change:
Typically every 5,000 - 7,500 miles or 6-12 months, whichever comes first. Consult manual for specific mileage/time.
Air Filter Replacement:
Inspect every 7,500 miles, replace every 15,000 - 30,000 miles or as needed based on driving conditions.
Spark Plug Replacement:
Typically every 30,000 - 60,000 miles, depending on spark plug type (e.g., standard copper vs. platinum/iridium).
Timing Belt Replacement:
The HC-EJ engine uses a timing belt. Replacement is crucial, usually around 60,000 - 90,000 miles or 5-7 years. Incorrect replacement can cause severe engine damage.
Transmission Fluid Change:
Manual: Inspect every 15,000 miles, change every 30,000 - 60,000 miles. Automatic: Inspect every 15,000 miles, change every 30,000 miles or as per manual. Often overlooked but critical.
Coolant Change:
Typically every 30,000 - 50,000 miles or 2-4 years. Use long-life coolant as specified.
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4. Always use fresh, sealed fluid.
Power Steering Fluid:
Dexron II/III or specific power steering fluid. Consult manual.
Known Issues
Timing Belt Wear:
As with all timing belt engines, neglecting replacement can lead to catastrophic engine failure if the belt breaks.
Suspension Bushings:
Wear in suspension bushings can lead to knocking noises and less precise handling, particularly with age and mileage.
Rust And Corrosion:
Depending on climate and maintenance, rust can affect body panels, frame, and exhaust components, especially in areas with road salt.
Clutch Wear:
Normal wear item for manual transmissions; replacement intervals depend on driving style.
O2 Sensor Failure:
Oxygen sensors can degrade over time, affecting fuel economy and emissions. Diagnostic trouble codes (DTCs) will typically indicate failure.
📚 Vehicle History
Brand Heritage
Daihatsu Focus:
Daihatsu, a subsidiary of Toyota, has a long history of producing small, efficient, and affordable vehicles, specializing in Kei cars and compact segments.
Model Evolution
Terios First Generation:
The J100 Series represents the first generation of the Daihatsu Terios, introduced globally in 1997. It was designed to be a compact, affordable, and capable small SUV.
Production
Manufacturing Location:
Primarily manufactured in Japan and Indonesia. (Specific assembly plants may vary).
Production Period:
First generation (J100) production ran from 1997 to 2006, with this manual covering the initial 1997-2000 phase.
🏆 Awards & Recognition
Recognitions
Segment Awards:
While not typically winning major 'Car of the Year' awards, the Terios was recognized for its value, practicality, and off-road capability within the compact SUV segment.
Ratings
Reliability Reputation:
Generally considered reliable, particularly the mechanical components, aligning with Daihatsu's reputation for robust, no-nonsense engineering.
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