DAIHATSU TERIOS 2 Service Repair Manual 2006-2011

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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Generation: Second Generation (J200 Series) Model Years Covered: 2006, 2007, 2008, 2009, 2010, 2011 Codes Chassis Codes: J200G, J200E, J202E, J210G, J210E, J212E, J230G Engine Codes: 1.3L (K3-VE, K3-VE2), 1.5L (3SZ-VE) 👋 Introduction Market Position Vehicle Segment: Compact SUV / Crossover. Target Audience: Families and individuals seeking a practical, versatile, and often budget-friendly small SUV with available AWD. Competitive Analysis Key Competitors: Honda CR-V, Toyota RAV4, Suzuki Vitara, Nissan Qashqai, Mitsubishi Outlander Sport. Key Features Distinguishing Features: Compact size, maneuverability, available four-wheel drive, fuel efficiency for its class, practical interior space, often with a more affordable price point compared to larger SUVs. Manual Value Proposition: Provides professionals and owners with the detailed technical knowledge to maintain, diagnose, and repair the Daihatsu Terios Series 2, ensuring longevity and optimal performance. 📋 Manual Details Coverage Areas Coverage Scope: All repairs A-Z, all models covered within the specified year range. Page Count Estimated Page Count: Extensive (typically 1500+ pages for comprehensive workshop manuals). Manual Type Manual Type: Service and Repair Workshop Manual Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical (including disassembly/assembly, timing systems, lubrication, cooling), fuel system (injection, pumps, injectors), exhaust system, engine management/ECU, ignition system, emissions control. Transmission Drivetrain: Manual transmission, Automatic transmission (AT), Transfer case, Differentials (front and rear), Driveshafts, Axles, Wheel bearings. Chassis Suspension: Front suspension (struts, control arms, ball joints), Rear suspension (multi-link, trailing arms), Steering system (power steering pump, rack and pinion), Brakes (hydraulic system, ABS, brake pads, rotors, calipers), Wheels and tires. Electrical Electronics: 12V battery system, charging system (alternator), starting system (starter motor), lighting (headlights, taillights, interior), instrument panel, gauges, power windows, power locks, wipers, horn, audio system, fuse box diagrams, wiring diagrams, diagnostic trouble codes (DTCs). Body Interior: Body panels, doors, hood, tailgate, bumpers, interior trim, seats, airbags, climate control system (HVAC), heater core, A/C system. Procedures Included Maintenance Tasks: Routine maintenance, oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flush, brake fluid change, transmission fluid change, differential fluid change. Repair Procedures: Engine tune-ups, component replacement (alternator, starter, water pump, fuel pump), brake caliper rebuild, suspension component replacement, exhaust system repair, radiator replacement, interior component repair. Diagnostics Troubleshooting: Step-by-step troubleshooting guides for common and uncommon faults, diagnostic trouble code (DTC) interpretation, electrical system diagnostics, mechanical system diagnostics. Component Rebuilds: Detailed instructions for engine overhaul, transmission rebuilds, differential rebuilds, and other major component repairs. Technical Specifications: Torque specifications for all fasteners, alignment specifications, engine timing settings, diagnostic parameters, fluid capacities and types. Technical Depth Depth Of Coverage: Comprehensive, suitable for professional mechanics and advanced DIY enthusiasts. Covers everything from basic checks to full engine and transmission rebuilds. 📊 Manual Specifications File Format PDF Features: Searchable text, high-resolution diagrams and illustrations, bookmark functionality for easy navigation. Print Quality Print Readability: Designed for clear viewing on screen and print. Diagrams are crisp and legible. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Quality: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine 1.3L Engine Code: K3-VE / K3-VE2 Configuration: 1.3L (1298 cc) DOHC 16-valve Inline-4 Bore X Stroke: 72.0 mm x 79.3 mm Compression Ratio: 10.0:1 Horsepower Ps: 80-87 PS @ 6000 rpm (depending on specific market/version) Torque Nm: 115-120 Nm @ 3200 rpm (depending on specific market/version) Primary Engine 1.5L Engine Code: 3SZ-VE Configuration: 1.5L (1495 cc) DOHC 16-valve Inline-4 with VVT-i (Variable Valve Timing - intelligent) Bore X Stroke: 72.0 mm x 91.8 mm Compression Ratio: 9.5:1 Horsepower Ps: 105-109 PS @ 6000 rpm (depending on specific market/version) Torque Nm: 140-145 Nm @ 4400 rpm (depending on specific market/version) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline Performance Emissions Control: Catalytic converter, EGR system (where applicable). 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission Optional Transmission Type: 4-speed Automatic Transmission (AT) Features Drivetrain Options: Available in Front-Wheel Drive (FWD) and Permanent Four-Wheel Drive (4WD/AWD) with center differential. 📐 Dimensions Exterior Length Mm: Approximately 4000-4055 mm Width Mm: Approximately 1690-1700 mm Height Mm: Approximately 1705-1740 mm Wheelbase Mm: Approximately 2580 mm Ground Clearance Mm: Approximately 190-200 mm Interior Seating Capacity: 5 occupants Cargo Cargo Volume Liters: Approximately 350-450 liters (rear seats up), expandable significantly with seats folded. Weights Curb Weight Kg: Approximately 1100-1250 kg (depending on drivetrain and equipment). 🛡️ Safety Features Ratings Crash Test Results: Varies by market and testing agency (e.g., ANCAP, Euro NCAP). Check specific model year and region for detailed ratings. Active Features Braking System: Front ventilated discs, rear drums (or discs on some higher trims/later models). Anti-lock Braking System (ABS) with Electronic Brake-force Distribution (EBD) often standard or optional. Stability Control: Electronic Stability Control (ESC) / Traction Control System (TCS) available on some models/trims. Passive Features Airbags: Front driver and passenger airbags standard. Side airbags and...

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Description

🏷️ Basic Information

Identification

Make:

Daihatsu

Model:

Terios

Generation:

Second Generation (J200 Series)

Model Years Covered:

2006, 2007, 2008, 2009, 2010, 2011

Codes

Chassis Codes:

J200G, J200E, J202E, J210G, J210E, J212E, J230G

Engine Codes:

1.3L (K3-VE, K3-VE2), 1.5L (3SZ-VE)

👋 Introduction

Market Position

Vehicle Segment:

Compact SUV / Crossover.

Target Audience:

Families and individuals seeking a practical, versatile, and often budget-friendly small SUV with available AWD.

Competitive Analysis

Key Competitors:

Honda CR-V, Toyota RAV4, Suzuki Vitara, Nissan Qashqai, Mitsubishi Outlander Sport.

Key Features

Distinguishing Features:

Compact size, maneuverability, available four-wheel drive, fuel efficiency for its class, practical interior space, often with a more affordable price point compared to larger SUVs.

Manual Value Proposition:

Provides professionals and owners with the detailed technical knowledge to maintain, diagnose, and repair the Daihatsu Terios Series 2, ensuring longevity and optimal performance.

📋 Manual Details

Coverage Areas

Coverage Scope:

All repairs A-Z, all models covered within the specified year range.

Page Count

Estimated Page Count:

Extensive (typically 1500+ pages for comprehensive workshop manuals).

Manual Type

Manual Type:

Service and Repair Workshop Manual

Language

Language:

English

Format

Digital Format:

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical (including disassembly/assembly, timing systems, lubrication, cooling), fuel system (injection, pumps, injectors), exhaust system, engine management/ECU, ignition system, emissions control.

Transmission Drivetrain:

Manual transmission, Automatic transmission (AT), Transfer case, Differentials (front and rear), Driveshafts, Axles, Wheel bearings.

Chassis Suspension:

Front suspension (struts, control arms, ball joints), Rear suspension (multi-link, trailing arms), Steering system (power steering pump, rack and pinion), Brakes (hydraulic system, ABS, brake pads, rotors, calipers), Wheels and tires.

Electrical Electronics:

12V battery system, charging system (alternator), starting system (starter motor), lighting (headlights, taillights, interior), instrument panel, gauges, power windows, power locks, wipers, horn, audio system, fuse box diagrams, wiring diagrams, diagnostic trouble codes (DTCs).

Body Interior:

Body panels, doors, hood, tailgate, bumpers, interior trim, seats, airbags, climate control system (HVAC), heater core, A/C system.

Procedures Included

Maintenance Tasks:

Routine maintenance, oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flush, brake fluid change, transmission fluid change, differential fluid change.

Repair Procedures:

Engine tune-ups, component replacement (alternator, starter, water pump, fuel pump), brake caliper rebuild, suspension component replacement, exhaust system repair, radiator replacement, interior component repair.

Diagnostics Troubleshooting:

Step-by-step troubleshooting guides for common and uncommon faults, diagnostic trouble code (DTC) interpretation, electrical system diagnostics, mechanical system diagnostics.

Component Rebuilds:

Detailed instructions for engine overhaul, transmission rebuilds, differential rebuilds, and other major component repairs.

Technical Specifications:

Torque specifications for all fasteners, alignment specifications, engine timing settings, diagnostic parameters, fluid capacities and types.

Technical Depth

Depth Of Coverage:

Comprehensive, suitable for professional mechanics and advanced DIY enthusiasts. Covers everything from basic checks to full engine and transmission rebuilds.

📊 Manual Specifications

File Format

PDF Features:

Searchable text, high-resolution diagrams and illustrations, bookmark functionality for easy navigation.

Print Quality

Print Readability:

Designed for clear viewing on screen and print. Diagrams are crisp and legible.

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper Quality:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine 1.3L

Engine Code:

K3-VE / K3-VE2

Configuration:

1.3L (1298 cc) DOHC 16-valve Inline-4

Bore X Stroke:

72.0 mm x 79.3 mm

Compression Ratio:

10.0:1

Horsepower Ps:

80-87 PS @ 6000 rpm (depending on specific market/version)

Torque Nm:

115-120 Nm @ 3200 rpm (depending on specific market/version)

Primary Engine 1.5L

Engine Code:

3SZ-VE

Configuration:

1.5L (1495 cc) DOHC 16-valve Inline-4 with VVT-i (Variable Valve Timing - intelligent)

Bore X Stroke:

72.0 mm x 91.8 mm

Compression Ratio:

9.5:1

Horsepower Ps:

105-109 PS @ 6000 rpm (depending on specific market/version)

Torque Nm:

140-145 Nm @ 4400 rpm (depending on specific market/version)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline

Performance

Emissions Control:

Catalytic converter, EGR system (where applicable).

🔧 Transmission

Standard Transmission

Type:

5-speed Manual Transmission

Optional Transmission

Type:

4-speed Automatic Transmission (AT)

Features

Drivetrain Options:

Available in Front-Wheel Drive (FWD) and Permanent Four-Wheel Drive (4WD/AWD) with center differential.

📐 Dimensions

Exterior

Length Mm:

Approximately 4000-4055 mm

Width Mm:

Approximately 1690-1700 mm

Height Mm:

Approximately 1705-1740 mm

Wheelbase Mm:

Approximately 2580 mm

Ground Clearance Mm:

Approximately 190-200 mm

Interior

Seating Capacity:

5 occupants

Cargo

Cargo Volume Liters:

Approximately 350-450 liters (rear seats up), expandable significantly with seats folded.

Weights

Curb Weight Kg:

Approximately 1100-1250 kg (depending on drivetrain and equipment).

🛡️ Safety Features

Ratings

Crash Test Results:

Varies by market and testing agency (e.g., ANCAP, Euro NCAP). Check specific model year and region for detailed ratings.

Active Features

Braking System:

Front ventilated discs, rear drums (or discs on some higher trims/later models). Anti-lock Braking System (ABS) with Electronic Brake-force Distribution (EBD) often standard or optional.

Stability Control:

Electronic Stability Control (ESC) / Traction Control System (TCS) available on some models/trims.

Passive Features

Airbags:

Front driver and passenger airbags standard. Side airbags and curtain airbags may be available on higher trims.

Seatbelts:

3-point seatbelts with pretensioners for front seats, 3-point or lap belts for rear seats.

💡 Technology Features

Infotainment

Audio System:

Factory fitted radio with CD player, MP3 capability, and often auxiliary input. Speaker configurations typically 4 or 6.

Navigation:

Optional factory-fitted navigation systems available on higher trims or as dealer-installed accessories.

Driver Assistance

Parking Sensors:

Available as an option or dealer accessory.

Cruise Control:

Available on most models, particularly with automatic transmission.

Connectivity

Bluetooth:

Rarely standard from factory during this period; often an aftermarket addition.

Usb Aux:

Auxiliary input jack common. USB ports less common in early models of this generation.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 5,000-10,000 km or 6-12 months, depending on oil type and driving conditions.

Oil Filter Replacement:

With every oil change.

Air Filter Replacement:

Every 15,000-30,000 km or as needed based on inspection.

Spark Plug Replacement:

Every 40,000-60,000 km (depending on spark plug type, e.g., iridium).

Coolant Flush:

Every 40,000-60,000 km or 2-4 years.

Transmission Fluid Change:

Manual: Every 60,000-80,000 km. Automatic: Every 40,000-60,000 km (often recommended to change filter as well).

Brake Fluid Change:

Every 2-3 years or 40,000-60,000 km.

Fluid Specifications

Engine Oil:

API SL or SM, SAE 5W-30 or 10W-30 (refer to manual for specific climate recommendations).

Coolant:

DEXCOOL-compatible or Toyota Super Long Life Coolant (SLLC), a 50/50 mix of ethylene glycol and distilled water.

Transmission Fluid Manual:

API GL-4, SAE 75W-90 synthetic gear oil.

Transmission Fluid Automatic:

Dexron III or equivalent (check manual for specific Toyota/Daihatsu ATF type).

Power Steering Fluid:

DEXRON II or III ATF.

Known Issues

Common Wear Items:

Brake pads and rotors, suspension bushings, exhaust system components, potentially clutch wear on manual transmissions.

Engine Related:

Occasional reports of oil leaks from valve cover gaskets or oil pans. Ignition coil failure can cause misfires. On the 1.5L (3SZ-VE), the timing chain tensioner may require attention over time.

Transmission Related:

Automatic transmissions can sometimes develop rough shifting or slipping if fluid is neglected. Manual transmissions are generally robust but clutch wear is normal.

Electrical Related:

Battery drain issues due to parasitic draw, power window motor failures, minor sensor failures (e.g., oxygen sensors).

Chassis Suspension:

Worn ball joints and tie rod ends, particularly on higher mileage vehicles. Bushings in control arms and sway bars can degrade.

📚 Vehicle History

Brand Heritage

Daihatsu Origins:

Daihatsu Motor Co., Ltd. is Japan's oldest automobile manufacturer, known for small, fuel-efficient vehicles and kei cars.

Model Evolution

First Generation:

Introduced in 1998 as a compact, body-on-frame SUV. Replaced the Feroza.

Second Generation J200:

Launched in 2004 (globally from 2006). Adopted a monocoque (unibody) construction, moving to a more car-like crossover platform. Offered with 1.3L and 1.5L engines. Extended wheelbase versions were also produced, sometimes marketed as Terios Largo or Grand Terios in certain markets.

Production

Manufacturing Locations:

Primarily manufactured in Japan by Daihatsu. Also produced under license or rebadged by other manufacturers in various markets (e.g., Toyota J70 series).

🏆 Awards & Recognition

Recognitions

General Accolades:

While not a recipient of major headline awards, the Terios is often recognized for its value, practicality, and capability in the compact SUV segment, particularly in markets where Daihatsu is prominent.