Daihatsu Terios J102 2000-2005 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Platform Code: J102 Model Years: 2000-2005 👋 Introduction Market Position Vehicle Segment: Compact SUV / Mini SUV Target Audience: Budget-conscious buyers seeking a versatile, compact, and capable vehicle for urban driving and light off-road excursions. Competitive Analysis Key Competitors: Suzuki Vitara, Mitsubishi Pajero/Shogun Pinin, Toyota RAV4 (earlier generations), Honda CR-V (earlier generations), Nissan X-Trail (later models). Key Features Chassis Design: Body-on-frame construction, providing robustness for off-road use. Drivetrain Options: Available in rear-wheel drive (RWD) and selectable four-wheel drive (4WD) configurations, enhancing versatility. Dimensions: Compact exterior dimensions for easy maneuverability in urban environments. Utility: Practical interior space, folding rear seats for cargo capacity, and a higher driving position typical of SUVs. 📋 Manual Details Coverage Areas Geographical Coverage: Global (Factory specifications) Page Count Estimated Pages: Approx. 1000-1500+ (typical for comprehensive factory manuals of this era) Manual Type Type: Factory Service Repair Workshop Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, engine management, fuel system, ignition system, exhaust system, cooling system, lubrication system Drivetrain: Transmission (manual & automatic), transfer case, driveshafts, differentials, axles, hubs Suspension And Steering: Front suspension, rear suspension, steering system, power steering Brakes: Brake system hydraulics, front brakes, rear brakes, parking brake, ABS (if equipped) Electrical System: Battery, charging system, starting system, lighting, instrumentation, wipers, horn, power windows, central locking, audio system, fuses, relays, wiring diagrams Body And Chassis: Body panels, doors, windows, interior trim, underbody, frame (if applicable), exterior trim HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system components and servicing Procedures Included Maintenance: Regular scheduled maintenance, fluid changes, filter replacements, inspections Troubleshooting: Diagnostic procedures, symptom-based troubleshooting charts, common fault diagnosis Repair: Component removal, installation, adjustment, overhaul, and repair procedures for all systems Specifications: Torque specifications, clearances, fluid capacities, electrical specifications, diagnostic parameter values Wiring Diagrams: Detailed electrical circuit diagrams for all vehicle systems Technical Depth Depth: Comprehensive factory-level detail, suitable for professional technicians and advanced DIY enthusiasts. Covers everything from basic fluid checks to complete engine and transmission rebuilds, including electrical diagnostics. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text (depends on original scan quality) Printable: Printable pages Resolution: High-resolution scans for clarity of diagrams and text Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) Completeness Completeness: Complete factory service and repair information ⚙️ Engine Specifications Primary Engine Engine Code: 4G13 (1.3L SOHC I4) and 4G15 (1.5L SOHC I4) Engine Type: Inline 4-cylinder, SOHC (Single Overhead Camshaft) Displacement: 1298 cc (4G13) / 1468 cc (4G15) Performance Horsepower: Approx. 75-82 PS (4G13) / Approx. 88-90 PS (4G15) Torque: Approx. 105-110 Nm (4G13) / Approx. 120-130 Nm (4G15) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline Engine Management Ignition Type: Distributorless Ignition System (DIS) or Distributor ignition (depending on market/year) Cooling System Coolant Type: Ethylene Glycol based coolant (refer to manual for specific specification, e.g., Toyota Super Long Life Coolant equivalent, typically a 50/50 mix) Lubrication System Oil Viscosity: Typically SAE 10W-30 or 10W-40 (verify with manual based on climate) Oil Capacity: Approx. 3.5 - 4.0 Liters (including filter, verify with manual) 🔧 Transmission Standard Type: 5-speed Manual Transmission Optional Type: 4-speed Automatic Transmission Features Transfer Case: Selectable 2WD/4WD system with Low Range (4WD models) Fluid Specifications Manual Transmission Fluid: API GL-4, SAE 75W-90 or 80W-90 Gear Oil (verify with manual) Automatic Transmission Fluid: Dexron II / Dexron III or equivalent (verify with manual) 📐 Dimensions Exterior Length: Approx. 3900-4070 mm Width: Approx. 1600-1695 mm Height: Approx. 1670-1700 mm Wheelbase: Approx. 2430 mm Ground Clearance: Approx. 190-200 mm Weights Curb Weight: Approx. 1100-1250 kg Gross Vehicle Weight: Approx. 1600-1700 kg Cargo Cargo Volume: Variable, with folding rear seats. Approx. 300-350 Liters with seats up. Wheels Tires Wheel Size: Typically 15-inch or 16-inch alloy or steel wheels Tire Size: Typically 205/70 R15 or 215/65 R16 Bolt Pattern: 5x114.3 mm (5x4.5 inches) 🛡️ Safety Features Ratings NHTSA Rating: Not consistently rated across all markets; generally considered basic safety for its era. Active Features ABS: Optional Anti-lock Braking System (ABS) available on higher trims or later models. Traction Control: Generally not available on this generation. Passive Features Airbags: Driver airbag standard; passenger airbag often optional or market-dependent. Seatbelts: 3-point seatbelts with pretensioners for front occupants. Body Structure: Reinforced cabin structure with side-impact beams. 💡 Technology Features Infotainment Audio System: Basic AM/FM radio with CD player or cassette player, often with aftermarket upgrades. Navigation: Generally not factory-equipped; available as aftermarket accessory. Driver Assistance Cruise Control: Available on some higher trim levels, particularly in export markets. Connectivity Bluetooth: Not factory-equipped; available via aftermarket head units or adapters. 🔧 Maintenance Service Intervals Oil And Filter Change: Every 5,000 - 10,000 km or 6-12 months, whichever comes first (refer to manual for exact interval and driving conditions)....
Detailed electrical circuit diagrams for all vehicle systems
Technical Depth
Depth:
Comprehensive factory-level detail, suitable for professional technicians and advanced DIY enthusiasts. Covers everything from basic fluid checks to complete engine and transmission rebuilds, including electrical diagnostics.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely searchable text (depends on original scan quality)
Printable:
Printable pages
Resolution:
High-resolution scans for clarity of diagrams and text
Distributorless Ignition System (DIS) or Distributor ignition (depending on market/year)
Cooling System
Coolant Type:
Ethylene Glycol based coolant (refer to manual for specific specification, e.g., Toyota Super Long Life Coolant equivalent, typically a 50/50 mix)
Lubrication System
Oil Viscosity:
Typically SAE 10W-30 or 10W-40 (verify with manual based on climate)
Oil Capacity:
Approx. 3.5 - 4.0 Liters (including filter, verify with manual)
🔧 Transmission
Standard
Type:
5-speed Manual Transmission
Optional
Type:
4-speed Automatic Transmission
Features
Transfer Case:
Selectable 2WD/4WD system with Low Range (4WD models)
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-90 or 80W-90 Gear Oil (verify with manual)
Automatic Transmission Fluid:
Dexron II / Dexron III or equivalent (verify with manual)
📐 Dimensions
Exterior
Length:
Approx. 3900-4070 mm
Width:
Approx. 1600-1695 mm
Height:
Approx. 1670-1700 mm
Wheelbase:
Approx. 2430 mm
Ground Clearance:
Approx. 190-200 mm
Weights
Curb Weight:
Approx. 1100-1250 kg
Gross Vehicle Weight:
Approx. 1600-1700 kg
Cargo
Cargo Volume:
Variable, with folding rear seats. Approx. 300-350 Liters with seats up.
Wheels Tires
Wheel Size:
Typically 15-inch or 16-inch alloy or steel wheels
Tire Size:
Typically 205/70 R15 or 215/65 R16
Bolt Pattern:
5x114.3 mm (5x4.5 inches)
🛡️ Safety Features
Ratings
NHTSA Rating:
Not consistently rated across all markets; generally considered basic safety for its era.
Active Features
ABS:
Optional Anti-lock Braking System (ABS) available on higher trims or later models.
Traction Control:
Generally not available on this generation.
Passive Features
Airbags:
Driver airbag standard; passenger airbag often optional or market-dependent.
Seatbelts:
3-point seatbelts with pretensioners for front occupants.
Body Structure:
Reinforced cabin structure with side-impact beams.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with CD player or cassette player, often with aftermarket upgrades.
Navigation:
Generally not factory-equipped; available as aftermarket accessory.
Driver Assistance
Cruise Control:
Available on some higher trim levels, particularly in export markets.
Connectivity
Bluetooth:
Not factory-equipped; available via aftermarket head units or adapters.
🔧 Maintenance
Service Intervals
Oil And Filter Change:
Every 5,000 - 10,000 km or 6-12 months, whichever comes first (refer to manual for exact interval and driving conditions).
Air Filter Replacement:
Every 20,000 - 40,000 km or as needed based on dusty conditions.
Spark Plug Replacement:
Every 40,000 - 60,000 km (depending on spark plug type: standard, platinum, iridium).
Coolant Replacement:
Every 40,000 - 80,000 km or 2-4 years (using appropriate long-life coolant).
Transmission Fluid Change:
Manual: Every 40,000 - 60,000 km. Automatic: Every 40,000 - 50,000 km (critical for longevity).
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4 (refer to manual for specific type and replacement interval, typically every 2 years).
Power Steering Fluid:
ATF Dexron II / III or specific power steering fluid (verify with manual).
Transfer Case Fluid:
API GL-4 or GL-5, SAE 75W-90 or 80W-90 Gear Oil (verify with manual).
Differential Fluid:
API GL-5, SAE 75W-90 or 80W-90 Gear Oil (verify with manual).
Known Issues
Common Wear Items:
Clutch wear (manual transmission), suspension bushings, exhaust system components, catalytic converter (due to age).
Engine Reliability:
Generally reliable engines, but oil leaks can develop with age. Timing belt replacement is crucial (typically every 100,000 km or 5-7 years).
Electrical Gremlins:
Minor electrical issues, such as faulty window regulators or central locking, can occur in older vehicles. Corrosion in wiring connectors is also a possibility.
4Wd System:
Transfer case and hub actuators on 4WD models can require maintenance or repair due to wear and tear.
Troubleshooting Tips
Engine Performance:
Ensure correct ignition timing, clean fuel injectors, and check for vacuum leaks for optimal performance. The manual details diagnostic procedures for these.
📚 Vehicle History
Brand Heritage
Daihatsu Heritage:
Daihatsu, a subsidiary of Toyota, has a long history of producing small, efficient, and reliable vehicles, often known for their kei cars and compact SUVs.
Model Evolution
First Generation:
The J102 generation (introduced 1998, covered by this manual 2000-2005) was the first generation of the Terios, establishing its niche as a compact, affordable, and capable SUV.
Second Generation Transition:
This generation was replaced by the J200 series globally around 2006, which adopted a monocoque chassis and different styling.
Production
Manufacturing Locations:
Primarily manufactured in Japan and Indonesia (for various markets).
Sales Performance
Market Reception:
Well-received in markets where affordability, compact size, and basic off-road capability were prioritized. It found a strong following in Southeast Asia, Europe, and Australia.
🏆 Awards & Recognition
Recognitions
Notable Awards:
While specific individual awards are not widely publicized for the J102 Terios, it consistently received positive recognition in its segment for its value, practicality, and off-road competence relative to its price point and size.
Ratings
Consumer Reports Style:
Likely rated as a good value proposition, with strengths in affordability and utility, and potential weaknesses in refinement and safety features compared to larger, more expensive SUVs of the era.