2005 Daihatsu YRV Service and Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: YRV Year: 2005 Product Type: Service and Repair Manual Codes Platform Code: M100 👋 Introduction Market Position Segment: Subcompact hatchback/MPV, positioned as a practical, fuel-efficient, and versatile urban vehicle. Competitive Analysis Competitors: Competed against vehicles like the Toyota Yaris (Vitz), Honda Fit (Jazz), Nissan March (Micra), Suzuki Swift, and Mitsubishi Colt. Key Features Unique Selling Points: Compact dimensions for urban maneuverability, surprisingly spacious and flexible interior ('super height wagon' design concept), fuel efficiency, Daihatsu's reputation for small car engineering. Brand Heritage Daihatsu Focus: Daihatsu is known for specializing in small, lightweight, and economical vehicles, often with innovative packaging and reliable engineering. This expertise is evident in the YRV's design. 📋 Manual Details Coverage Areas Coverage Scope: All models and all repairs A-Z Page Count Estimated Page Count: Refer to product packaging for exact count, typically 800-1500 pages for a comprehensive service manual. Manual Type Type: Factory Service Manual (FSM) / Workshop Manual Language Language: English Format Format: Print (as implied by typical dealership use) 📖 Manual Coverage Systems Covered Engine: Engine mechanical, lubrication system, cooling system, fuel system, ignition system, emissions control system, engine electrical system, engine management (ECU/ECM), timing belt/chain, cylinder head, block, pistons, crankshaft, camshafts, valve train. Transmission: Manual transmission, automatic transmission (if applicable for the model year), clutch system, gear shift mechanism, transmission control module (TCM), torque converter, final drive, drive axles. Brakes: Front and rear brake systems, hydraulic system, master cylinder, brake lines, calipers, pads, rotors/drums, parking brake, Anti-lock Braking System (ABS) components and diagnostics. Steering: Steering system components, steering column, power steering system (hydraulic or electric), steering rack/gearbox, tie rod ends, steering angle sensor. Suspension: Front and rear suspension systems, shock absorbers, struts, springs, control arms, bushings, sway bars, wheel bearings. Electrical: 12V battery system, charging system (alternator), starting system (starter motor), lighting system (headlights, taillights, interior lights), wiring diagrams, fuses, relays, body control module (BCM), power windows, power locks, mirrors, wiper/washer system, horn. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant system, compressor, condenser, evaporator, blower motor, climate control panel, heater core. Body And Trim: Exterior body panels, doors, hood, trunk/tailgate, bumpers, interior trim panels, seats, dashboard, headliner, weatherstripping, glass, mirrors. Chassis: Frame structure, unibody construction details, mounting points, corrosion protection. Diagnostics: On-Board Diagnostics (OBD) II system, diagnostic trouble codes (DTCs), troubleshooting flowcharts, diagnostic procedures for all major systems, scan tool usage. Procedures Included Maintenance: Scheduled maintenance, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacement (oil, air, fuel, cabin), spark plug replacement, belt inspection and replacement, brake pad/rotor service, tire rotation and balancing. Repair: Engine component removal and installation (e.g., starter, alternator, water pump, thermostat, manifolds), transmission overhaul, clutch replacement, brake caliper/rotor replacement, suspension component replacement (e.g., struts, control arms), power steering pump replacement, HVAC component repair, door mechanism repair, body panel replacement. Troubleshooting: Systematic diagnostic steps for common and uncommon faults, electrical system troubleshooting using wiring diagrams, engine performance diagnostics, transmission shifting issues, brake system anomalies, HVAC performance problems. Diagnostics And Testing: Specific testing procedures for sensors, actuators, relays, electrical circuits, fuel pressure testing, compression testing, leak down testing, battery testing, charging system output testing. Rebuilding And Overhaul: Detailed instructions for engine rebuilding (e.g., piston ring replacement, bearing inspection, valve seat grinding), transmission overhaul procedures, brake caliper rebuilding. Technical Specifications And Data: Torque specifications for all fasteners, clearances and specifications for engine components, fluid capacities, electrical specifications, wheel alignment data, tire pressure specifications. Technical Depth Depth: Comprehensive; covers from basic maintenance and fluid checks to advanced engine diagnostics, transmission overhauls, and electrical system troubleshooting. Includes detailed diagrams, exploded views, and step-by-step repair instructions. 📊 Manual Specifications File Format Format: Typically printed book format for dealership use. If digital, likely PDF with searchable text and high-resolution diagrams. Print Quality Quality: High quality, designed for workshop environments. Clear text, sharp diagrams, and durable paper. Binding Type Binding: Likely spiral-bound or hardbound for ease of use and durability in a workshop setting. Paper Type Paper: Durable, possibly coated paper stock to resist grease and shop grime. ⚙️ Engine Specifications Primary Engine Engine Code: K3-VE (Commonly found in many YRV models of this era) Engine Type: Inline 4-cylinder, DOHC, 16-valve, naturally aspirated Displacement: 1.3 Liters (1298 cc) Bore X Stroke: 72.0 mm x 79.7 mm Performance Horsepower: Approximately 87-91 PS (metric horsepower) / 86-90 bhp (brake horsepower) at around 6000 rpm, depending on market and specific tuning. Torque: Approximately 120-123 Nm (89-91 lb-ft) at around 3200-3600 rpm. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), Sequential Multi-port Fuel Injection (MPI) Fuel Type: Unleaded gasoline (Octane rating typically 91 RON or higher) Engine Management ECU Type: Denso or similar proprietary ECU controlling fuel injection, ignition timing, and emissions. Timing Mechanism: Timing chain for the K3-VE engine, known for durability but requires periodic inspection. Cooling System Coolant Type: Ethylene...

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Description

🏷️ Basic Information

Identification

Make:

Daihatsu

Model:

Year:

Product Type:

Service and Repair Manual

Codes

Platform Code:

👋 Introduction

Market Position

Segment:

Subcompact hatchback/MPV, positioned as a practical, fuel-efficient, and versatile urban vehicle.

Competitive Analysis

Competitors:

Competed against vehicles like the Toyota Yaris (Vitz), Honda Fit (Jazz), Nissan March (Micra), Suzuki Swift, and Mitsubishi Colt.

Key Features

Unique Selling Points:

Compact dimensions for urban maneuverability, surprisingly spacious and flexible interior ('super height wagon' design concept), fuel efficiency, Daihatsu's reputation for small car engineering.

Brand Heritage

Daihatsu Focus:

Daihatsu is known for specializing in small, lightweight, and economical vehicles, often with innovative packaging and reliable engineering. This expertise is evident in the YRV's design.

📋 Manual Details

Coverage Areas

Coverage Scope:

All models and all repairs A-Z

Page Count

Estimated Page Count:

Refer to product packaging for exact count, typically 800-1500 pages for a comprehensive service manual.

Manual Type

Type:

Factory Service Manual (FSM) / Workshop Manual

Language

Language:

English

Format

Format:

Print (as implied by typical dealership use)

📖 Manual Coverage

Systems Covered

Engine:

Engine mechanical, lubrication system, cooling system, fuel system, ignition system, emissions control system, engine electrical system, engine management (ECU/ECM), timing belt/chain, cylinder head, block, pistons, crankshaft, camshafts, valve train.

Transmission:

Manual transmission, automatic transmission (if applicable for the model year), clutch system, gear shift mechanism, transmission control module (TCM), torque converter, final drive, drive axles.

Brakes:

Front and rear brake systems, hydraulic system, master cylinder, brake lines, calipers, pads, rotors/drums, parking brake, Anti-lock Braking System (ABS) components and diagnostics.

Steering:

Steering system components, steering column, power steering system (hydraulic or electric), steering rack/gearbox, tie rod ends, steering angle sensor.

Suspension:

Front and rear suspension systems, shock absorbers, struts, springs, control arms, bushings, sway bars, wheel bearings.

Electrical:

12V battery system, charging system (alternator), starting system (starter motor), lighting system (headlights, taillights, interior lights), wiring diagrams, fuses, relays, body control module (BCM), power windows, power locks, mirrors, wiper/washer system, horn.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant system, compressor, condenser, evaporator, blower motor, climate control panel, heater core.

Body And Trim:

Exterior body panels, doors, hood, trunk/tailgate, bumpers, interior trim panels, seats, dashboard, headliner, weatherstripping, glass, mirrors.

Chassis:

Frame structure, unibody construction details, mounting points, corrosion protection.

Diagnostics:

On-Board Diagnostics (OBD) II system, diagnostic trouble codes (DTCs), troubleshooting flowcharts, diagnostic procedures for all major systems, scan tool usage.

Procedures Included

Maintenance:

Scheduled maintenance, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacement (oil, air, fuel, cabin), spark plug replacement, belt inspection and replacement, brake pad/rotor service, tire rotation and balancing.

Repair:

Engine component removal and installation (e.g., starter, alternator, water pump, thermostat, manifolds), transmission overhaul, clutch replacement, brake caliper/rotor replacement, suspension component replacement (e.g., struts, control arms), power steering pump replacement, HVAC component repair, door mechanism repair, body panel replacement.

Troubleshooting:

Systematic diagnostic steps for common and uncommon faults, electrical system troubleshooting using wiring diagrams, engine performance diagnostics, transmission shifting issues, brake system anomalies, HVAC performance problems.

Diagnostics And Testing:

Specific testing procedures for sensors, actuators, relays, electrical circuits, fuel pressure testing, compression testing, leak down testing, battery testing, charging system output testing.

Rebuilding And Overhaul:

Detailed instructions for engine rebuilding (e.g., piston ring replacement, bearing inspection, valve seat grinding), transmission overhaul procedures, brake caliper rebuilding.

Technical Specifications And Data:

Torque specifications for all fasteners, clearances and specifications for engine components, fluid capacities, electrical specifications, wheel alignment data, tire pressure specifications.

Technical Depth

Depth:

Comprehensive; covers from basic maintenance and fluid checks to advanced engine diagnostics, transmission overhauls, and electrical system troubleshooting. Includes detailed diagrams, exploded views, and step-by-step repair instructions.

📊 Manual Specifications

File Format

Format:

Typically printed book format for dealership use. If digital, likely PDF with searchable text and high-resolution diagrams.

Print Quality

Quality:

High quality, designed for workshop environments. Clear text, sharp diagrams, and durable paper.

Binding Type

Binding:

Likely spiral-bound or hardbound for ease of use and durability in a workshop setting.

Paper Type

Paper:

Durable, possibly coated paper stock to resist grease and shop grime.

⚙️ Engine Specifications

Primary Engine

Engine Code:

K3-VE (Commonly found in many YRV models of this era)

Engine Type:

Inline 4-cylinder, DOHC, 16-valve, naturally aspirated

Displacement:

1.3 Liters (1298 cc)

Bore X Stroke:

72.0 mm x 79.7 mm

Performance

Horsepower:

Approximately 87-91 PS (metric horsepower) / 86-90 bhp (brake horsepower) at around 6000 rpm, depending on market and specific tuning.

Torque:

Approximately 120-123 Nm (89-91 lb-ft) at around 3200-3600 rpm.

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI), Sequential Multi-port Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline (Octane rating typically 91 RON or higher)

Engine Management

ECU Type:

Denso or similar proprietary ECU controlling fuel injection, ignition timing, and emissions.

Timing Mechanism:

Timing chain for the K3-VE engine, known for durability but requires periodic inspection.

Cooling System

Coolant Type:

Ethylene Glycol based coolant, typically a 50/50 mix with distilled water. Refer to manual for specific Daihatsu coolant specification (e.g., Long Life Coolant).

Lubrication

Engine Oil Type:

API SG or higher, SAE 5W-30 or 10W-30 is common. Refer to manual for exact specification based on climate and usage.

🔧 Transmission

Standard

Transmission Type:

4-speed Automatic Transmission (often referred to as 'Super ECT' or similar proprietary name)

Optional

Transmission Type Optional:

5-speed Manual Transmission

Features

Automatic Features:

Electronically controlled shifting, potentially with different drive modes (e.g., Power/Economy).

Fluid Specifications

Automatic Transmission Fluid:

Refer to manual for specific Daihatsu ATF specification (e.g., Dexron III or equivalent). Do not use universal ATF.

Fluid Capacities

Automatic Transmission Fluid Capacity:

Approximately 3.0 - 3.5 liters for a dry fill, less for a simple drain and fill. Refer to manual for precise capacity.

Gear Ratios

Manual Transmission Ratios:

Specific ratios vary by model and market, but typical for this class of vehicle.

📐 Dimensions

Exterior

Length:

Approximately 3845 mm (151.4 in)

Width:

Approximately 1685 mm (66.3 in)

Height:

Approximately 1600 mm (63.0 in) (can vary slightly with roof rails/option)

Interior

Wheelbase:

Approximately 2370 mm (93.3 in)

Weights

Curb Weight:

Approximately 1000 - 1100 kg (2205 - 2425 lbs) depending on configuration.

Gross Vehicle Weight Rating:

Refer to vehicle's compliance plate or manual.

🛡️ Safety Features

Ratings

Crash Test Results:

Varies by market and testing agency (e.g., Euro NCAP, JNCAP). Typically received moderate ratings for its class and era, with structural improvements in later iterations.

Passive Features

Airbags:

Driver and front passenger airbags were standard. Side airbags and curtain airbags may have been optional on higher trims or in specific markets.

Seatbelts:

3-point seatbelts with pretensioners for front occupants, 3-point or 2-point for rear occupants depending on seating position. ISOFIX child seat anchors.

Chassis Safety:

Energy-absorbing crumple zones, reinforced safety cabin structure.

Active Features

Anti-lock Braking System (ABS) was often an optional or standard feature depending on the trim level and market.

E Brake:

Mechanical parking brake (handbrake or foot-operated).

💡 Technology Features

Infotainment

Audio System:

Factory fitted radio/CD player, often with AM/FM tuner and speakers. Digital media support may be limited.

User Interface:

Basic dashboard layout with physical buttons and knobs for climate control and audio functions.

Driver Assistance

Optional Features:

Features like parking sensors or a rear-view camera were uncommon for this model and era, typically not standard.

Connectivity

Connectivity Options:

Limited to basic audio connectivity (e.g., auxiliary input may be present on some models/aftermarket units). Bluetooth or USB connectivity was not factory standard.

Instrument Cluster

Instrumentation:

Analog gauges for speedometer, tachometer (optional on some trims), fuel level, and engine temperature. Warning lights for various systems.

🔧 Maintenance

Service Intervals

Oil Change:

Every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, whichever comes first. Refer to manual for specific mileage/time recommendations based on driving conditions (severe vs. normal).

Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or annually. Inspect more frequently.

Spark Plug Replacement:

Typically every 30,000-60,000 miles (48,000-96,000 km) depending on spark plug type (standard vs. iridium/platinum).

Coolant Flush:

Initial flush at 5 years or 100,000 miles, then every 2-5 years or 30,000-60,000 miles thereafter, depending on coolant type.

Transmission Fluid Change:

Automatic transmission fluid: Every 30,000-60,000 miles (48,000-96,000 km). Manual transmission fluid: Every 60,000-100,000 miles (96,000-160,000 km). Always refer to the manual.

Fluid Specifications

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid (refer to cap or manual for specific requirement).

Power Steering Fluid:

If hydraulically assisted, typically Dexron II/III compatible ATF or specific power steering fluid. Check manual.

Known Issues

Common Wear Items:

Suspension components (bushings, ball joints, tie rod ends) due to urban driving and potentially less robust OEM parts. Water pump leaks, alternator failures, ignition coil issues, and exhaust system corrosion can occur with age and mileage.

Automatic Transmission Concerns:

Some users report occasional rough shifting or delayed engagement in older automatic transmissions if fluid changes are neglected. Regular fluid maintenance is crucial.

Engine Performance Issues:

Clogged fuel injectors or a failing fuel pump can lead to poor acceleration or rough idling. Carbon build-up on valves can affect performance if not maintained.

Preventative Maintenance

Timing Chain Inspection:

While generally robust, the timing chain tensioner and guides should be inspected during major services to ensure proper operation and prevent potential chain stretch.

📚 Vehicle History

Brand Heritage

Daihatsu Specialization:

Daihatsu has a long history of producing small, efficient, and affordable vehicles, often with distinctive styling and clever interior packaging, dating back to the early 20th century.

Model Evolution

Yrv Introduction:

The YRV (Yaris Replacement Vehicle - though not directly related to the Toyota Yaris) was introduced in 1999 as a successor to the Daihatsu Pyzar. It was designed to be a 'super height wagon' offering a compact exterior with a tall, spacious interior, emphasizing practicality and versatility.

Production

Production Years:

First generation produced from 1999 to 2006.

Manufacturing Locations:

Primarily manufactured in Japan.

🏆 Awards & Recognition

Recognitions

Industry Accolades:

While specific major awards for the YRV are not widely publicized, Daihatsu vehicles in general often receive recognition in their respective markets for reliability, fuel efficiency, and value for money, particularly in compact car segments.

Ratings

Consumer Reports Style Ratings:

Consumer satisfaction ratings would vary by region, but Daihatsu generally has a reputation for producing dependable small cars. Specific detailed ratings for the 2005 YRV would require localized consumer surveys from that period.