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Daihatsu Terios 2 J211 2006 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Generation: 2nd Generation (J200 Series) Chassis Code: J211 Model Year: 2006 👋 Introduction Market Position Vehicle Segment: Compact SUV / Crossover Target Audience: Individuals seeking a versatile, capable, and compact 4x4 vehicle for light off-roading and urban driving. Competitive Analysis Key Competitors: Suzuki Vitara, Toyota RAV4 (older generations), Honda CR-V (older generations), Mitsubishi Outlander (older generations). Key Features Body Style: 5-door compact SUV with an upright stance and often a rear-mounted spare wheel. Drivetrain Options: Primarily available with permanent or selectable Four-Wheel Drive (4WD) systems, although Front-Wheel Drive (FWD) variants exist in some markets. Utility: Offers a good balance of passenger space and cargo capacity for its size, with practical seating arrangements. 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Manual Language: English Format: Downloadable PDF Page Count Page Count: Hundreds (exact number not specified, implies comprehensive) 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed overhaul procedures, component specifications, diagnosis, timing belt/chain, cooling system, lubrication system. Engine Management: Fuel injection system, ignition system, emissions control, ECU diagnosis, sensor specifications, diagnostic trouble codes (DTCs). Transmission: Automatic and Manual transmission overhaul, fluid specifications, shift control, diagnosis, torque converter. Drivetrain: Front-wheel drive (FWD) and Four-wheel drive (4WD) systems, differentials, driveshafts, CV joints, hub bearings. Suspension: Front and rear suspension components, shock absorbers, springs, bushings, alignment specifications, wheel bearings. Steering: Power steering system, steering rack, steering column, linkage, diagnosis, fluid types. Brakes: Front and rear brake systems (disc/drum), ABS, brake fluid specifications, caliper/rotor replacement, bleeding procedures. Electrical System: Battery, charging system (alternator), starting system (starter), lighting, fuses, relays, wiring diagrams. Body Exterior: Body panels, doors, hood, tailgate, bumpers, glass, seals, body repair procedures. Body Interior: Dashboard, seats, trim panels, HVAC controls, sound insulation, interior trim removal/installation. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant types, component replacement, diagnosis. Safety Systems: Airbag system, seatbelt pre-tensioners, SRS warning light diagnosis. Procedures Included Maintenance: Routine maintenance procedures, oil changes, filter replacements, spark plug replacement, fluid checks and top-offs. Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting guides, common problem identification. Repair: Step-by-step repair instructions for all major vehicle components and systems. Overhaul: Complete disassembly and reassembly procedures for engines, transmissions, and other major mechanical assemblies. Diagnostics: Detailed diagnostic procedures, including the use of scan tools and specific test equipment. Technical Depth Depth Level: Complete factory-level repair and diagnostic information. Detail Level: Includes detailed torque specifications, clearances, tolerances, and measurement procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF for efficient information retrieval. Print Quality Printability: Designed for full printout of sections or the entire manual. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: 3SZ-VE Engine Type: Inline-4, Naturally Aspirated Displacement: 1.5 liters (1495 cc) Bore X Stroke: 72.0 mm x 91.8 mm (approximate) Compression Ratio: 9.4:1 Performance Horsepower: Approx. 103-109 PS (76-80 kW) at 6000-6400 rpm (market dependent) Torque: Approx. 13.9 - 14.2 kgf·m (136 - 139 Nm) at 4400 rpm (market dependent) Fuel System Fuel Type: Unleaded Gasoline Fuel Delivery: Electronic Fuel Injection (EFI), Multi-point fuel injection (MPI) Emission Control: Catalytic converter, Oxygen sensors (O2), EGR (in some variants) 🔧 Transmission Standard Transmission Type: 4-speed Automatic Transmission Optional Transmission Type: 5-speed Manual Transmission Features Drivetrain Layout: Available in Front-Wheel Drive (FWD) and Four-Wheel Drive (4WD) configurations. 4WD system is typically a viscous coupling center differential type. 📐 Dimensions Exterior Length: Approx. 4000 - 4065 mm Width: Approx. 1695 mm Height: Approx. 1705 - 1715 mm Wheelbase: Approx. 2430 mm Ground Clearance: Approx. 190 mm Weights Curb Weight: Approx. 1240 - 1360 kg (depending on configuration) Gross Vehicle Weight Rating: Varies by market and configuration, typically around 1700-1800 kg 🛡️ Safety Features Ratings Crash Test Results: Refer to specific market safety authority ratings (e.g., ANCAP, NCAP). Likely received moderate ratings for its era. Active Features Antilock Braking System: Standard on most models, often with Electronic Brake-force Distribution (EBD). Traction Control: Available on higher trims or 4WD models in some markets. Passive Features Airbags: Front airbags for driver and passenger; side airbags and curtain airbags were optional or standard on higher trims. Seatbelts: Three-point seatbelts with pre-tensioners for front occupants, two or three-point seatbelts for rear occupants. Child Seat Anchors: ISOFIX/LATCH anchor points in rear seats. 💡 Technology Features Infotainment Audio System: Factory fitted radio/CD player with basic speaker setup. Upgrade options common. Driver Assistance Parking Sensors: Optional on higher trim levels or aftermarket installations. Connectivity Auxiliary Input: May be present on some models for connecting external audio devices. 🔧 Maintenance Service Intervals Engine Oil Change: Every 5,000 - 10,000 km or 6-12 months, depending on oil type and driving conditions (refer to manual for exact recommendation). Air Filter Replacement: Every 20,000 - 30,000 km or as needed based on inspection. Spark Plugs:...
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Daihatsu Terios 2 J211 2006 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Terios
Generation:
2nd Generation (J200 Series)
Chassis Code:
J211
Model Year:
2006
👋 Introduction
Market Position
Vehicle Segment:
Compact SUV / Crossover
Target Audience:
Individuals seeking a versatile, capable, and compact 4x4 vehicle for light off-roading and urban driving.
Competitive Analysis
Key Competitors:
Suzuki Vitara, Toyota RAV4 (older generations), Honda CR-V (older generations), Mitsubishi Outlander (older generations).
Key Features
Body Style:
5-door compact SUV with an upright stance and often a rear-mounted spare wheel.
Drivetrain Options:
Primarily available with permanent or selectable Four-Wheel Drive (4WD) systems, although Front-Wheel Drive (FWD) variants exist in some markets.
Utility:
Offers a good balance of passenger space and cargo capacity for its size, with practical seating arrangements.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Manual
Language:
English
Format:
Downloadable PDF
Page Count
Page Count:
Hundreds (exact number not specified, implies comprehensive)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed overhaul procedures, component specifications, diagnosis, timing belt/chain, cooling system, lubrication system.
Engine Management:
Fuel injection system, ignition system, emissions control, ECU diagnosis, sensor specifications, diagnostic trouble codes (DTCs).
Transmission:
Automatic and Manual transmission overhaul, fluid specifications, shift control, diagnosis, torque converter.
Drivetrain:
Front-wheel drive (FWD) and Four-wheel drive (4WD) systems, differentials, driveshafts, CV joints, hub bearings.
Suspension:
Front and rear suspension components, shock absorbers, springs, bushings, alignment specifications, wheel bearings.
Steering:
Power steering system, steering rack, steering column, linkage, diagnosis, fluid types.
Brakes:
Front and rear brake systems (disc/drum), ABS, brake fluid specifications, caliper/rotor replacement, bleeding procedures.
Electrical System:
Battery, charging system (alternator), starting system (starter), lighting, fuses, relays, wiring diagrams.
Body Exterior:
Body panels, doors, hood, tailgate, bumpers, glass, seals, body repair procedures.
Body Interior:
Dashboard, seats, trim panels, HVAC controls, sound insulation, interior trim removal/installation.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant types, component replacement, diagnosis.
Safety Systems:
Airbag system, seatbelt pre-tensioners, SRS warning light diagnosis.
Procedures Included
Maintenance:
Routine maintenance procedures, oil changes, filter replacements, spark plug replacement, fluid checks and top-offs.
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting guides, common problem identification.
Repair:
Step-by-step repair instructions for all major vehicle components and systems.
Overhaul:
Complete disassembly and reassembly procedures for engines, transmissions, and other major mechanical assemblies.
Diagnostics:
Detailed diagnostic procedures, including the use of scan tools and specific test equipment.
Technical Depth
Depth Level:
Complete factory-level repair and diagnostic information.
Detail Level:
Includes detailed torque specifications, clearances, tolerances, and measurement procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable PDF for efficient information retrieval.
Print Quality
Printability:
Designed for full printout of sections or the entire manual.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
3SZ-VE
Engine Type:
Inline-4, Naturally Aspirated
Displacement:
1.5 liters (1495 cc)
Bore X Stroke:
72.0 mm x 91.8 mm (approximate)
Compression Ratio:
9.4:1
Performance
Horsepower:
Approx. 103-109 PS (76-80 kW) at 6000-6400 rpm (market dependent)
Torque:
Approx. 13.9 - 14.2 kgf·m (136 - 139 Nm) at 4400 rpm (market dependent)
Fuel System
Fuel Type:
Unleaded Gasoline
Fuel Delivery:
Electronic Fuel Injection (EFI), Multi-point fuel injection (MPI)
Emission Control:
Catalytic converter, Oxygen sensors (O2), EGR (in some variants)
🔧 Transmission
Standard
Transmission Type:
4-speed Automatic Transmission
Optional
Transmission Type:
5-speed Manual Transmission
Features
Drivetrain Layout:
Available in Front-Wheel Drive (FWD) and Four-Wheel Drive (4WD) configurations. 4WD system is typically a viscous coupling center differential type.
📐 Dimensions
Exterior
Length:
Approx. 4000 - 4065 mm
Width:
Approx. 1695 mm
Height:
Approx. 1705 - 1715 mm
Wheelbase:
Approx. 2430 mm
Ground Clearance:
Approx. 190 mm
Weights
Curb Weight:
Approx. 1240 - 1360 kg (depending on configuration)
Gross Vehicle Weight Rating:
Varies by market and configuration, typically around 1700-1800 kg
🛡️ Safety Features
Ratings
Crash Test Results:
Refer to specific market safety authority ratings (e.g., ANCAP, NCAP). Likely received moderate ratings for its era.
Active Features
Antilock Braking System:
Standard on most models, often with Electronic Brake-force Distribution (EBD).
Traction Control:
Available on higher trims or 4WD models in some markets.
Passive Features
Airbags:
Front airbags for driver and passenger; side airbags and curtain airbags were optional or standard on higher trims.
Seatbelts:
Three-point seatbelts with pre-tensioners for front occupants, two or three-point seatbelts for rear occupants.
Child Seat Anchors:
ISOFIX/LATCH anchor points in rear seats.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/CD player with basic speaker setup. Upgrade options common.
Driver Assistance
Parking Sensors:
Optional on higher trim levels or aftermarket installations.
Connectivity
Auxiliary Input:
May be present on some models for connecting external audio devices.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000 - 10,000 km or 6-12 months, depending on oil type and driving conditions (refer to manual for exact recommendation).
Air Filter Replacement:
Every 20,000 - 30,000 km or as needed based on inspection.
Spark Plugs:
Typically every 40,000 - 100,000 km, depending on spark plug type (standard, iridium, platinum).
Transmission Fluid Change:
Every 40,000 - 60,000 km for automatic transmissions, check manual for manual transmission interval. Filter replacement often recommended during fluid change.
Coolant Replacement:
Every 40,000 - 80,000 km or 2-4 years.
Fluid Specifications
Engine Oil:
API SG/SH/SJ or ILSAC GF-2/GF-3 compliant. Viscosity grade typically 5W-30 or 10W-30 (refer to manual for specific climate recommendations).
Transmission Fluid Auto:
Dexron III equivalent or specified ATF (Automatic Transmission Fluid). Capacity approx. 7-8 liters.
Transmission Fluid Manual:
API GL-4 or GL-5 SAE 75W-90 gear oil. Capacity approx. 2.5-3.0 liters.
Coolant:
Ethylene glycol based coolant, typically a 50/50 mix with distilled water. Refer to manual for specific color/type.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Known Issues
Engine Timing Chain:
Some reports of timing chain stretch or tensioner wear over high mileage, leading to rattling noise.
Rear Differential Noise:
Potential for noise from the rear differential, especially in 4WD models, which may require fluid changes or bearing inspection.
Suspension Bushings:
Wear on control arm bushings or sway bar links can lead to clunking noises and affect handling.
HVAC Blower Motor:
Occasional failures of the HVAC blower motor or resistor.
Rust Corrosion:
As with many vehicles of this age, especially those in coastal or salty environments, rust can affect body panels, chassis components, and exhaust systems.
📚 Vehicle History
Brand Heritage
Brand Focus:
Daihatsu is renowned for producing small, fuel-efficient, and robust vehicles, often with a focus on compact SUVs and kei cars.
Model Evolution
Generation Introduction:
The second generation Terios (J200 series) was introduced globally around 2006, replacing the first generation. It featured a larger, more modern design and a longer wheelbase.
Market Specific Names:
In some markets, particularly Europe and Australia, this generation was also sold as the Toyota Rush or Daihatsu Feroza (though the Feroza name was used on earlier models elsewhere).
Production
Production Period:
2006-2016 (for the J200 series globally)
Manufacturing Locations:
Primarily manufactured in Japan and Indonesia.
🏆 Awards & Recognition
Recognitions
General Reputation:
The Terios is generally recognized for its affordability, compact size, and surprising off-road capability for its class, making it a popular choice in emerging markets and for budget-conscious buyers.
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