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DAIHATSU TERIOS Service Repair Manual 1997-2005

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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Product Name: DAIHATSU TERIOS Service Repair Manual 1997-2005 👋 Introduction Market Position Positioning: The Daihatsu Terios (also known as Toyota Cami in some markets) was positioned as a compact, affordable, and rugged mini SUV or kei car crossover, appealing to buyers seeking utility and light off-road capability in a small package. Competitive Analysis Competitors: Competed with vehicles like the Suzuki Vitara/Grand Vitara, Honda CR-V (early models), Toyota RAV4 (early models), and other compact SUVs and crossover vehicles of the era. Key Features Features: Compact dimensions, available four-wheel drive, practical interior space for its size, and a reputation for reliability and fuel efficiency. Known for its distinct boxy styling. Manual Value Proposition Value: Enables owners and mechanics to perform all service and repair tasks efficiently, saving money on labor costs and ensuring proper vehicle maintenance and longevity. 'YOU CAN GET THAT REPAIR DONE TODAY!' emphasizes immediate problem-solving capability. 📋 Manual Details Coverage Areas Years Covered: 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005 Page Count Estimated Page Count: Extensive (typical service manuals of this era range from 1000-2000+ pages) Manual Type Type: Factory-Type Service Repair Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, overhaul, and specifications for all J100/J122/J132 series engines (e.g., 1.3L 4-cylinder SOHC J18, 1.3L 4-cylinder DOHC K3-VE). Transmission: Covers manual and automatic transmissions, including diagnosis, removal, installation, overhaul, and fluid specifications. Drivetrain: Front-wheel drive and four-wheel drive (4WD) system service, including differentials, drive shafts, and transfer case (if applicable). Suspension: Front and rear suspension systems, including components like struts, shocks, springs, control arms, and wheel bearings. Brakes: Front and rear brake systems (disc/drum configurations), including master cylinder, calipers, wheel cylinders, brake lines, ABS system diagnostics and repair (if equipped). Steering: Power steering system diagnosis, repair, and fluid specifications; steering column and linkage components. Cooling System: Radiator, thermostat, water pump, cooling fans, and coolant specifications and procedures. Fuel System: Fuel pump, injectors, fuel filter, fuel tank, and electronic fuel injection (EFI) system diagnostics. Electrical System: Battery, alternator, starter, ignition system, lighting, wiring diagrams, fuses, relays, and body control modules. HVAC: Air conditioning system, heater core, blower motor, and climate control system service. Body And Chassis: Body panels, doors, windows, interior trim, frame, and chassis component repair and adjustments. Emissions Control: Catalytic converter, EGR system, and evaporative emissions control system troubleshooting. Procedures Included Maintenance: Routine maintenance, fluid changes, filter replacements, tune-ups, and inspections. Troubleshooting: Diagnostic procedures for common and uncommon faults, including symptom-based troubleshooting guides. Repair: Step-by-step repair instructions for virtually every component and system on the vehicle. Overhaul: Complete engine and transmission rebuild procedures with detailed component specifications. Diagnostics: Detailed diagnostic flowcharts and explanations for all major vehicle systems. Wiring Diagrams: Comprehensive electrical wiring diagrams for all circuits, including power distribution and component locations. Technical Depth Depth: Comprehensive and detailed, covering everything from basic fluid checks and filter replacements to full engine and transmission rebuilds, complex electrical diagnostics, and chassis repairs. Suitable for professional technicians and advanced DIYers. 📊 Manual Specifications File Format Searchable Text: Likely includes searchable text for efficient information retrieval. Zoom Capability: High-resolution PDF allows for zooming into detailed diagrams and text. Print Quality Printability: Designed to be printable, allowing users to create hard copies of specific sections or the entire manual. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Code 1: 1.3L SOHC (J18/HC-EJ) Engine Displacement 1: 1296 cc Bore Stroke 1: 72.0 mm x 79.6 mm Compression Ratio 1: 9.5:1 (typical) Power Output 1: Approx. 85-90 PS (63-66 kW) at ~6000 rpm Torque Output 1: Approx. 120-125 Nm (89-92 lb-ft) at ~3200 rpm Secondary Engine Engine Code 2: 1.3L DOHC VVT-i (K3-VE) Engine Displacement 2: 1298 cc Bore Stroke 2: 72.0 mm x 80.5 mm Compression Ratio 2: 10.0:1 Power Output 2: Approx. 87-95 PS (64-70 kW) at ~6000 rpm Torque Output 2: Approx. 120-130 Nm (89-96 lb-ft) at ~3200 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline (91 RON or higher recommended) Engine Management ECU: ECU-controlled engine management system 🔧 Transmission Standard Transmission Type 1: 5-speed Manual Transmission Optional Transmission Type 2: 4-speed Automatic Transmission Features Drivetrain Options: Available in Rear-Wheel Drive (RWD) and Selectable Four-Wheel Drive (4WD). 📐 Dimensions Exterior Length: Approx. 3,720 - 3,905 mm (depending on model and market) Width: Approx. 1,600 - 1,695 mm Height: Approx. 1,670 - 1,720 mm Wheelbase: Approx. 2,430 mm Ground Clearance: Approx. 180-195 mm (for 4WD models) Weights Curb Weight: Approx. 1050 - 1200 kg (depending on configuration) 🛡️ Safety Features Ratings Crash Test Ratings: Varies by market and testing agency; early models generally had fewer safety features compared to later generations. Active Features ABS: Optional Anti-lock Braking...
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DAIHATSU TERIOS Service Repair Manual 1997-2005
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Terios
Product Name:
DAIHATSU TERIOS Service Repair Manual 1997-2005
👋 Introduction
Market Position
Positioning:
The Daihatsu Terios (also known as Toyota Cami in some markets) was positioned as a compact, affordable, and rugged mini SUV or kei car crossover, appealing to buyers seeking utility and light off-road capability in a small package.
Competitive Analysis
Competitors:
Competed with vehicles like the Suzuki Vitara/Grand Vitara, Honda CR-V (early models), Toyota RAV4 (early models), and other compact SUVs and crossover vehicles of the era.
Key Features
Features:
Compact dimensions, available four-wheel drive, practical interior space for its size, and a reputation for reliability and fuel efficiency. Known for its distinct boxy styling.
Manual Value Proposition
Value:
Enables owners and mechanics to perform all service and repair tasks efficiently, saving money on labor costs and ensuring proper vehicle maintenance and longevity. 'YOU CAN GET THAT REPAIR DONE TODAY!' emphasizes immediate problem-solving capability.
📋 Manual Details
Coverage Areas
Years Covered:
1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005
Page Count
Estimated Page Count:
Extensive (typical service manuals of this era range from 1000-2000+ pages)
Manual Type
Type:
Factory-Type Service Repair Workshop Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnostics, repair, overhaul, and specifications for all J100/J122/J132 series engines (e.g., 1.3L 4-cylinder SOHC J18, 1.3L 4-cylinder DOHC K3-VE).
Transmission:
Covers manual and automatic transmissions, including diagnosis, removal, installation, overhaul, and fluid specifications.
Drivetrain:
Front-wheel drive and four-wheel drive (4WD) system service, including differentials, drive shafts, and transfer case (if applicable).
Suspension:
Front and rear suspension systems, including components like struts, shocks, springs, control arms, and wheel bearings.
Brakes:
Front and rear brake systems (disc/drum configurations), including master cylinder, calipers, wheel cylinders, brake lines, ABS system diagnostics and repair (if equipped).
Steering:
Power steering system diagnosis, repair, and fluid specifications; steering column and linkage components.
Cooling System:
Radiator, thermostat, water pump, cooling fans, and coolant specifications and procedures.
Fuel System:
Fuel pump, injectors, fuel filter, fuel tank, and electronic fuel injection (EFI) system diagnostics.
Electrical System:
Battery, alternator, starter, ignition system, lighting, wiring diagrams, fuses, relays, and body control modules.
HVAC:
Air conditioning system, heater core, blower motor, and climate control system service.
Body And Chassis:
Body panels, doors, windows, interior trim, frame, and chassis component repair and adjustments.
Emissions Control:
Catalytic converter, EGR system, and evaporative emissions control system troubleshooting.
Procedures Included
Maintenance:
Routine maintenance, fluid changes, filter replacements, tune-ups, and inspections.
Troubleshooting:
Diagnostic procedures for common and uncommon faults, including symptom-based troubleshooting guides.
Repair:
Step-by-step repair instructions for virtually every component and system on the vehicle.
Overhaul:
Complete engine and transmission rebuild procedures with detailed component specifications.
Diagnostics:
Detailed diagnostic flowcharts and explanations for all major vehicle systems.
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all circuits, including power distribution and component locations.
Technical Depth
Depth:
Comprehensive and detailed, covering everything from basic fluid checks and filter replacements to full engine and transmission rebuilds, complex electrical diagnostics, and chassis repairs. Suitable for professional technicians and advanced DIYers.
📊 Manual Specifications
File Format
Searchable Text:
Likely includes searchable text for efficient information retrieval.
Zoom Capability:
High-resolution PDF allows for zooming into detailed diagrams and text.
Print Quality
Printability:
Designed to be printable, allowing users to create hard copies of specific sections or the entire manual.
Binding Type
Binding:
N/A (Digital PDF format)
Paper Type
Paper Type:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
1.3L SOHC (J18/HC-EJ)
Engine Displacement 1:
1296 cc
Bore Stroke 1:
72.0 mm x 79.6 mm
Compression Ratio 1:
9.5:1 (typical)
Power Output 1:
Approx. 85-90 PS (63-66 kW) at ~6000 rpm
Torque Output 1:
Approx. 120-125 Nm (89-92 lb-ft) at ~3200 rpm
Secondary Engine
Engine Code 2:
1.3L DOHC VVT-i (K3-VE)
Engine Displacement 2:
1298 cc
Bore Stroke 2:
72.0 mm x 80.5 mm
Compression Ratio 2:
10.0:1
Power Output 2:
Approx. 87-95 PS (64-70 kW) at ~6000 rpm
Torque Output 2:
Approx. 120-130 Nm (89-96 lb-ft) at ~3200 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline (91 RON or higher recommended)
Engine Management
ECU:
ECU-controlled engine management system
🔧 Transmission
Standard
Transmission Type 1:
5-speed Manual Transmission
Optional
Transmission Type 2:
4-speed Automatic Transmission
Features
Drivetrain Options:
Available in Rear-Wheel Drive (RWD) and Selectable Four-Wheel Drive (4WD).
📐 Dimensions
Exterior
Length:
Approx. 3,720 - 3,905 mm (depending on model and market)
Width:
Approx. 1,600 - 1,695 mm
Height:
Approx. 1,670 - 1,720 mm
Wheelbase:
Approx. 2,430 mm
Ground Clearance:
Approx. 180-195 mm (for 4WD models)
Weights
Curb Weight:
Approx. 1050 - 1200 kg (depending on configuration)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Varies by market and testing agency; early models generally had fewer safety features compared to later generations.
Active Features
ABS:
Optional Anti-lock Braking System (ABS) available on some trims.
Traction Control:
Rarely available on this generation.
Passive Features
Airbags:
Driver and front passenger airbags were standard or optional depending on market and trim.
Seatbelts:
Three-point seatbelts with pretensioners.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio and CD player, often with optional cassette. Speaker configurations vary by trim.
Navigation:
Navigation systems were not commonly offered on this generation.
Driver Assistance
Cruise Control:
Optional on higher trims.
Connectivity
Bluetooth:
Not available on this generation; aftermarket solutions are required.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 - 10,000 km or 6-12 months (refer to manual for exact specification based on driving conditions).
Air Filter Replacement:
Every 20,000 - 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., standard vs. iridium).
Timing Belt Replacement:
If equipped with a timing belt, typically every 80,000 - 100,000 km or 5-7 years. K3-VE engines use a timing chain, which is generally maintenance-free.
Fluid Specifications
Engine Oil Type:
API SJ or SL, SAE 5W-30 or 10W-30 (refer to manual for exact viscosity and capacity).
Coolant Type:
Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. (e.g., Toyota Super Long Life Coolant).
Transmission Fluid Manual:
API GL-4 or GL-5, SAE 75W-90 or 80W-90 gear oil.
Transmission Fluid Automatic:
Dexron III/Mercon or equivalent ATF fluid. (Capacity approx. 3-4 liters for change).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid Type:
ATF Dexron II/III or manufacturer-specified power steering fluid.
Known Issues
Common Wear Items:
Suspension components (bushings, ball joints), exhaust system rust, and minor electrical gremlins are common as the vehicle ages. Clutch wear in manual transmissions.
Engine Issues:
Overheating if coolant system is neglected. Timing belt replacement on J18 engines is crucial. K3-VE engines with timing chains are generally robust.
4Wd System:
Regular inspection and lubrication of the 4WD system components, especially if used off-road, is recommended to prevent premature wear.
📚 Vehicle History
Brand Heritage
Brand Focus:
Daihatsu has a long heritage in producing compact and fuel-efficient vehicles, specializing in the Kei car segment in Japan and smaller passenger cars globally.
Model Evolution
First Generation Code:
J100 Series (introduced 1997)
Facelift:
Minor styling updates and engine revisions occurred during its production run.
Second Generation Transition:
The second generation (J200 Series) was introduced in 2004, marking a significant redesign.
Production
Production Locations:
Primarily manufactured in Japan, with some versions potentially assembled in other countries.
🏆 Awards & Recognition
Recognitions
Awards:
Specific awards for the 1997-2005 Terios are not widely documented, but it generally received positive reviews for its practicality, fuel efficiency, and value in the mini-SUV segment.
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