Daihatsu Copen 2002-2012 WSM Service Manual Repair
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🏷️ Basic Information Identification Make: Daihatsu Model: Copen Generation: First Generation (L880K) Codes Chassis Code: L880K 👋 Introduction Market Position Segment: Kei car, convertible sports car Competitive Analysis Key Competitors: Suzuki Cappuccino (previous generation), Honda Beat (previous generation), Mazda Autozam AZ-1 (previous generation) Key Features Design: Unique convertible design with an electronically operated retractable hardtop. Engine Layout: Front-engine, front-wheel drive. Target Audience: Enthusiasts seeking a compact, stylish, and fun-to-drive sports convertible. 📋 Manual Details Coverage Areas Applicable Years: 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012 Page Count Estimated Pages: High (exact number not specified, but described as 'full professional quality in depth') Manual Type Type: Workshop Service Manual (WSM) / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed coverage including diagnostics, repair, and overhaul of engine components. Transmission: Manual and automatic transmission servicing, repair, and adjustment procedures. Drivetrain: Front-wheel drive system, differential, drive shafts, and CV joints. Suspension: Front and rear suspension systems, including struts, springs, control arms, and alignment. Steering: Power steering system, steering column, and tie rods. Brakes: Hydraulic brake system, ABS, disc brake components, and parking brake. Electrical System: Comprehensive coverage of the vehicle's electrical system, including battery, charging, starting, lighting, and accessories. Body And Chassis: Body panel repair, frame straightening, door mechanisms, convertible roof operation, and interior trim. Climate Control: Air conditioning system diagnostics and repair, heater core, and ventilation. Fuel System: Fuel pump, injectors, lines, and evaporative emission control system. Exhaust System: Exhaust manifold, catalytic converter, mufflers, and pipes. Cooling System: Radiator, fan, thermostat, water pump, and coolant circuits. Safety Systems: Airbag system diagnostics and replacement, seat belt mechanisms. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks, spark plug replacement, brake fluid flush, coolant flush. Troubleshooting: Diagnostic procedures for common and uncommon problems, symptom analysis. Repair And Rebuild: Step-by-step instructions for component removal, repair, reassembly, and installation. Diagnostics: On-board diagnostics (OBD-II) information, fault code interpretation. Wiring Diagrams: Detailed electrical wiring diagrams for all vehicle systems. Specifications And Tolerances: Precise measurements, clearances, torque values, and operational parameters. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complete engine and transmission overhauls, including detailed diagnostics and electrical troubleshooting. 📊 Manual Specifications File Format Format: PDF Print Quality Printability: Full Printable Binding Type Binding: Digital Download (Printable pages) Paper Type Paper: N/A (Digital) Compatibility Operating Systems: Compatible with All Versions of Windows & Mac Requirements Software: Adobe PDF Reader Delivery Method: Instant Download ⚙️ Engine Specifications Primary Engine Engine Code: JB-DET Engine Type: 659cc, turbocharged, intercooled, DOHC, 16-valve inline-3 cylinder Performance Horsepower: 64 PS (47 kW; 63 bhp) at 6400 rpm (Japan domestic market regulation for Kei cars) Torque: 10.5 kg⋅m (103 N⋅m; 76 lb⋅ft) at 3200 rpm Fuel System Injection: Electronic Fuel Injection (EFI) Engine Management ECU: ECU controlled ignition and fuel delivery Cooling System Coolant Type: Daihatsu Genuine Coolant or equivalent ethylene glycol-based coolant (refer to manual for specific part numbers and capacity). 🔧 Transmission Standard Type: 5-speed manual transmission Optional Type: 4-speed automatic transmission Features Differential: Limited Slip Differential (LSD) often available as an option or standard on certain trims. Fluid Specifications Manual Transmission Fluid: API GL-4, SAE 75W-90 or 75W-85 (refer to manual for exact specification and capacity). Automatic Transmission Fluid: Dexron III or equivalent (refer to manual for exact specification and capacity). 📐 Dimensions Exterior Length: 3,395 mm (133.7 in) Width: 1,475 mm (58.1 in) Height: 1,245 mm (49.0 in) Wheelbase: 2,230 mm (87.8 in) Ground Clearance: Approximately 135 mm (5.3 in) Weights Curb Weight: Approximately 770-820 kg (1,698-1,808 lb) depending on transmission and options. Gross Vehicle Weight Rating: Not explicitly stated but typical for Kei cars. 🛡️ Safety Features Ratings Jncsa Crash Test: Achieved 4-star rating in Japan New Car Assessment Program (JNCAP) crash tests for frontal impact (specific year may vary). Active Features ABS: Anti-lock Braking System (ABS) often standard or optional. Ebs: Electronic Brake-force Distribution (EBD) often integrated with ABS. Passive Features Airbags: Driver and passenger airbags standard. Roll Bar: Integrated roll bar behind the seats for enhanced structural integrity. Seatbelts: Three-point inertia reel seatbelts with pre-tensioners. 💡 Technology Features Infotainment Audio System: Factory-installed AM/FM/CD player with optional premium sound system. Driver Assistance Parking Assist: Rear parking sensors available on some later models or as aftermarket. Connectivity Phone Integration: No factory Bluetooth or smartphone integration typically found in this generation; aftermarket solutions are common. 🔧 Maintenance Service Intervals Oil Change: Every 5,000 km (3,100 miles) or 6 months, whichever comes first (check manual for specific driving conditions). Air Filter Replacement: Every 20,000 km (12,500 miles) or 12 months. Spark Plug Replacement: Every 40,000 km (25,000 miles) or 24 months (use specified plug type, e.g., Iridium). Coolant Replacement: Every 40,000 km (25,000 miles) or 24 months. Brake Fluid Replacement: Every 24,000 km (15,000 miles) or 24...
Detailed electrical wiring diagrams for all vehicle systems.
Specifications And Tolerances:
Precise measurements, clearances, torque values, and operational parameters.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission overhauls, including detailed diagnostics and electrical troubleshooting.
64 PS (47 kW; 63 bhp) at 6400 rpm (Japan domestic market regulation for Kei cars)
Torque:
10.5 kg⋅m (103 N⋅m; 76 lb⋅ft) at 3200 rpm
Fuel System
Injection:
Electronic Fuel Injection (EFI)
Engine Management
ECU:
ECU controlled ignition and fuel delivery
Cooling System
Coolant Type:
Daihatsu Genuine Coolant or equivalent ethylene glycol-based coolant (refer to manual for specific part numbers and capacity).
🔧 Transmission
Standard
Type:
5-speed manual transmission
Optional
Type:
4-speed automatic transmission
Features
Differential:
Limited Slip Differential (LSD) often available as an option or standard on certain trims.
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-90 or 75W-85 (refer to manual for exact specification and capacity).
Automatic Transmission Fluid:
Dexron III or equivalent (refer to manual for exact specification and capacity).
📐 Dimensions
Exterior
Length:
3,395 mm (133.7 in)
Width:
1,475 mm (58.1 in)
Height:
1,245 mm (49.0 in)
Wheelbase:
2,230 mm (87.8 in)
Ground Clearance:
Approximately 135 mm (5.3 in)
Weights
Curb Weight:
Approximately 770-820 kg (1,698-1,808 lb) depending on transmission and options.
Gross Vehicle Weight Rating:
Not explicitly stated but typical for Kei cars.
🛡️ Safety Features
Ratings
Jncsa Crash Test:
Achieved 4-star rating in Japan New Car Assessment Program (JNCAP) crash tests for frontal impact (specific year may vary).
Active Features
ABS:
Anti-lock Braking System (ABS) often standard or optional.
Ebs:
Electronic Brake-force Distribution (EBD) often integrated with ABS.
Passive Features
Airbags:
Driver and passenger airbags standard.
Roll Bar:
Integrated roll bar behind the seats for enhanced structural integrity.
Seatbelts:
Three-point inertia reel seatbelts with pre-tensioners.
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM/CD player with optional premium sound system.
Driver Assistance
Parking Assist:
Rear parking sensors available on some later models or as aftermarket.
Connectivity
Phone Integration:
No factory Bluetooth or smartphone integration typically found in this generation; aftermarket solutions are common.
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000 km (3,100 miles) or 6 months, whichever comes first (check manual for specific driving conditions).
Air Filter Replacement:
Every 20,000 km (12,500 miles) or 12 months.
Spark Plug Replacement:
Every 40,000 km (25,000 miles) or 24 months (use specified plug type, e.g., Iridium).
Coolant Replacement:
Every 40,000 km (25,000 miles) or 24 months.
Brake Fluid Replacement:
Every 24,000 km (15,000 miles) or 24 months.
Transmission Fluid Replacement:
Manual: Every 60,000 km (37,000 miles) or 36 months. Automatic: Every 40,000 km (25,000 miles) or 24 months.
Fluid Specifications
Engine Oil:
0W-20 or 5W-30 synthetic API SN/SP (check manual for exact viscosity and API rating for the JB-DET engine).
Engine Oil Capacity:
Approximately 3.9 Liters (4.1 US quarts) with filter change.
Known Issues
Turbocharger:
Potential for turbo wear or failure if not properly maintained (e.g., oil changes, cool-down periods).
Convertible Roof:
Mechanism can experience issues with seals, motors, or hydraulics if not maintained or if debris accumulates.
Ignition Coils:
Coil-on-plug ignition system can sometimes have individual coil failures.
Intercooler:
Intercooler pipes or connections can develop leaks, affecting boost pressure.
📚 Vehicle History
Brand Heritage
Daihatsu Focus:
Daihatsu has a long history of producing compact and efficient vehicles, particularly Kei cars.
Model Evolution
First Generation:
The first generation Copen (L880K) was introduced in June 2002, succeeding the Daihatsu Leeza convertible and building on the success of the Daihatsu Copen concept.
Engine Update:
The JB-DET engine was a key component, providing spirited performance within Kei car regulations.
Production
Production Period:
2002-2012 for the L880K generation.
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Kei Car Popularity:
Consistently ranked as a popular choice within the Kei car segment for its unique styling and performance.
Ratings
User Satisfaction:
Generally high user satisfaction for its fun-to-drive nature and distinctive design, despite being a niche vehicle.