Daihatsu Sirion 2004-2010 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Daihatsu Model: Sirion Model Generation: Second Generation (M300) Codes Chassis Code: M3xx Series 👋 Introduction Market Position Segment: Subcompact hatchback, economy car Competitive Analysis Key Competitors: Toyota Yaris, Honda Fit/Jazz, Suzuki Swift, Hyundai i10, Ford Fiesta Key Features Vehicle Strengths: Compact size, fuel efficiency, affordability, surprisingly spacious interior for its class, maneuverability in urban environments Manual Value Proposition Benefit To Owner: Empowers owners and independent mechanics to perform diagnostics, maintenance, and repairs efficiently and accurately, reducing reliance on costly dealership services. Content Quality: Contains hundreds of pages with detailed photos & diagrams, identical to professional mechanic resources. 📋 Manual Details Coverage Areas Years Covered: 2004, 2005, 2006, 2007, 2008, 2009, 2010 Page Count Estimated Page Count: Hundreds of pages (specific count not provided but implied to be extensive) Manual Type Type: Factory Service Repair Workshop Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, cylinder head, block, pistons, crankshaft, camshafts, timing system, lubrication system, cooling system Engine Management: Fuel injection, ignition system, emission control systems, sensor diagnostics, ECU troubleshooting Transmission: Manual and Automatic transmission overhaul, clutch system, torque converter, gear shifting mechanisms, transmission control units Drivetrain: Front-wheel drive system, differentials, drive shafts, CV joints Suspension: Front and rear suspension systems, shock absorbers, springs, control arms, bushings, wheel alignment specifications Steering: Power steering system, steering rack, tie rods, steering column Brakes: Front and rear brake systems (disc and drum configurations), ABS system, brake fluid specifications, bleeding procedures, component replacement Electrical System: Battery, charging system, starting system, lighting systems (headlights, taillights, interior), fuses, relays, wiring diagrams Body And Chassis: Body panel removal and installation, doors, hood, trunk, interior trim, chassis components, structural repairs HVAC: Heating, ventilation, and air conditioning system diagnosis and repair, refrigerant handling, component replacement Safety Systems: Airbag system diagnosis and repair, seatbelt mechanisms Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotation, spark plug replacement, air filter replacement Troubleshooting: Diagnostic procedures for common and uncommon faults across all systems, symptom-based troubleshooting guides Repair Procedures: Step-by-step instructions for component removal, repair, and reinstallation for all major vehicle systems Diagnostics: OBD-II code interpretation, diagnostic tool usage, sensor testing, electrical circuit tracing Rebuilding: Complete engine and transmission rebuild procedures with detailed specifications Specifications: Torque specifications for all fasteners, clearances, fluid capacities, electrical resistance values Technical Depth Depth: Comprehensive, covering from basic maintenance to complete engine and transmission overhauls and advanced electrical diagnostics 📊 Manual Specifications File Format Compatibility: Fully compatible with Windows and MAC operating systems Print Quality Printability: Printable pages (single pages or entire manual) Binding Type Binding: N/A (Digital PDF format, no physical binding) Paper Type Paper: N/A (Digital PDF format, no physical paper) Licensing Usage Rights: Unlimited usage on multiple devices, no expiry dates, no renewal fees ⚙️ Engine Specifications Primary Engine Engine Code Common: K3-VE (1.3L) Engine Type: Inline 4-cylinder, DOHC, 16-valve Displacement: 1298 cc (1.3 Liters) Performance Horsepower Ps: Approximately 87-94 PS (varies slightly by market and specific engine tune) Torque Nm: Approximately 117-120 Nm (varies slightly by market and specific engine tune) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline Ignition System Ignition Type: Electronic ignition with distributorless ignition system (DIS) Cooling System Coolant Type: Ethylene glycol-based coolant (specific Daihatsu or equivalent recommended) Lubrication System Oil Capacity Liters: Approximately 3.2 - 3.5 Liters (with filter change, specific value in manual) Recommended Oil Viscosity: 5W-30 or 10W-30 (refer to manual for exact API/ACEA specifications) 🔧 Transmission Standard Manual Transmission: 5-speed manual Optional Automatic Transmission: 4-speed automatic (often with overdrive) Features Automatic Features: Electronically controlled, possibly with Sport/Power modes in some variants Fluid Type Automatic Transmission Fluid: Dexron III or equivalent (specific Daihatsu ATF recommended) 📐 Dimensions Exterior Length Mm: Approx. 3695 - 3760 mm (depending on minor revisions) Width Mm: Approx. 1690 mm Height Mm: Approx. 1530 - 1550 mm Weights Curb Weight Kg: Approx. 950 - 1050 kg (depending on equipment and transmission) Gross Vehicle Weight Rating Kg: Typically around 1400-1500 kg (refer to vehicle specific plate) 🛡️ Safety Features Ratings Euro Ncap Rating: 4-star (for models tested, likely referring to the early M300 generation which had significant safety improvements over its predecessor) Active Features ABS: Standard on most models/trims Ebs Edb: Electronic Brake-force Distribution (often integrated with ABS) Passive Features Airbags: Driver and passenger front airbags standard, side airbags and curtain airbags optional on higher trims Seat Belts: Front and rear seatbelts, pre-tensioners and load limiters for front seats Child Seat Anchors: ISOFIX mounting points 💡 Technology Features Infotainment Audio System: Factory fitted radio/CD player, often with 4 speakers. AUX input may be present on later models or aftermarket fitments. Driver Assistance Cruise Control: Optional on higher trim levels or specific market variants. Parking Sensors: Optional on some trims, typically aftermarket. Connectivity...
Toyota Yaris, Honda Fit/Jazz, Suzuki Swift, Hyundai i10, Ford Fiesta
Key Features
Vehicle Strengths:
Compact size, fuel efficiency, affordability, surprisingly spacious interior for its class, maneuverability in urban environments
Manual Value Proposition
Benefit To Owner:
Empowers owners and independent mechanics to perform diagnostics, maintenance, and repairs efficiently and accurately, reducing reliance on costly dealership services.
Content Quality:
Contains hundreds of pages with detailed photos & diagrams, identical to professional mechanic resources.
📋 Manual Details
Coverage Areas
Years Covered:
2004, 2005, 2006, 2007, 2008, 2009, 2010
Page Count
Estimated Page Count:
Hundreds of pages (specific count not provided but implied to be extensive)
Complete engine and transmission rebuild procedures with detailed specifications
Specifications:
Torque specifications for all fasteners, clearances, fluid capacities, electrical resistance values
Technical Depth
Depth:
Comprehensive, covering from basic maintenance to complete engine and transmission overhauls and advanced electrical diagnostics
📊 Manual Specifications
File Format
Compatibility:
Fully compatible with Windows and MAC operating systems
Print Quality
Printability:
Printable pages (single pages or entire manual)
Binding Type
Binding:
N/A (Digital PDF format, no physical binding)
Paper Type
Paper:
N/A (Digital PDF format, no physical paper)
Licensing
Usage Rights:
Unlimited usage on multiple devices, no expiry dates, no renewal fees
⚙️ Engine Specifications
Primary Engine
Engine Code Common:
K3-VE (1.3L)
Engine Type:
Inline 4-cylinder, DOHC, 16-valve
Displacement:
1298 cc (1.3 Liters)
Performance
Horsepower Ps:
Approximately 87-94 PS (varies slightly by market and specific engine tune)
Torque Nm:
Approximately 117-120 Nm (varies slightly by market and specific engine tune)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline
Ignition System
Ignition Type:
Electronic ignition with distributorless ignition system (DIS)
Cooling System
Coolant Type:
Ethylene glycol-based coolant (specific Daihatsu or equivalent recommended)
Lubrication System
Oil Capacity Liters:
Approximately 3.2 - 3.5 Liters (with filter change, specific value in manual)
Recommended Oil Viscosity:
5W-30 or 10W-30 (refer to manual for exact API/ACEA specifications)
🔧 Transmission
Standard
Manual Transmission:
5-speed manual
Optional
Automatic Transmission:
4-speed automatic (often with overdrive)
Features
Automatic Features:
Electronically controlled, possibly with Sport/Power modes in some variants
Fluid Type
Automatic Transmission Fluid:
Dexron III or equivalent (specific Daihatsu ATF recommended)
📐 Dimensions
Exterior
Length Mm:
Approx. 3695 - 3760 mm (depending on minor revisions)
Width Mm:
Approx. 1690 mm
Height Mm:
Approx. 1530 - 1550 mm
Weights
Curb Weight Kg:
Approx. 950 - 1050 kg (depending on equipment and transmission)
Gross Vehicle Weight Rating Kg:
Typically around 1400-1500 kg (refer to vehicle specific plate)
🛡️ Safety Features
Ratings
Euro Ncap Rating:
4-star (for models tested, likely referring to the early M300 generation which had significant safety improvements over its predecessor)
Active Features
ABS:
Standard on most models/trims
Ebs Edb:
Electronic Brake-force Distribution (often integrated with ABS)
Passive Features
Airbags:
Driver and passenger front airbags standard, side airbags and curtain airbags optional on higher trims
Seat Belts:
Front and rear seatbelts, pre-tensioners and load limiters for front seats
Child Seat Anchors:
ISOFIX mounting points
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/CD player, often with 4 speakers. AUX input may be present on later models or aftermarket fitments.
Driver Assistance
Cruise Control:
Optional on higher trim levels or specific market variants.
Parking Sensors:
Optional on some trims, typically aftermarket.
Connectivity
Bluetooth:
Rarely standard from factory for this period; typically aftermarket.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 10,000 km or 12 months, whichever comes first (refer to manual for specific conditions and oil type)
Oil Filter Replacement:
Replace with engine oil change
Air Filter Replacement:
Every 20,000 km or 24 months (inspect more frequently)
Spark Plug Replacement:
Every 40,000 km (depending on plug type, refer to manual)
Timing Belt Or Chain:
This generation (K3-VE engine) typically uses a timing chain, which is designed to last the life of the engine but requires periodic inspection for tensioner noise.
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for exact specification and replacement interval)
Coolant Capacity Liters:
Approximately 4.5 - 5.0 Liters (refer to manual)
Known Issues
Common Wear Items:
Suspension bushings, brake pads and discs, clutch wear (manual transmission), catalytic converter (depending on maintenance and fuel quality).
Engine Reliability:
Generally reliable K3-VE engine, but like all engines, requires proper maintenance. Timing chain tensioner can sometimes develop noise if not properly lubricated.
Transmission Performance:
Automatic transmissions are generally durable, but fluid changes are crucial. Manual transmissions are typically robust.
Electrical Quirks:
Less common, but general wear on electrical connectors or minor sensor issues can occur with age.
📚 Vehicle History
Brand Heritage
Daihatsu Specialty:
Daihatsu is known for producing small, fuel-efficient, and reliable vehicles, often focusing on urban mobility and kei car derivatives.
Model Evolution
Second Generation Introduction:
The second generation (M300) Sirion was a significant redesign, built on a new platform shared with the Toyota Passo/Daihatsu Boon. It offered improved styling, safety, and interior space compared to the first generation.
Production
Production Location:
Primarily manufactured in Japan, with potential assembly in other Daihatsu or Toyota facilities globally.
Model Life Cycle:
2004-2010 for the second generation, preceding the third generation (M700).
🏆 Awards & Recognition
Recognitions
Safety Recognition:
Euro NCAP 4-star rating highlights the improved safety structure of this generation compared to many competitors of its time.