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DAIHATSU TERIOS J100 Service Repair Manual 1997-2000

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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Generation Code: J100 Model Years Covered: 1997-2000 👋 Introduction Market Position Vehicle Segment: Compact SUV / Mini SUV Target Audience: DIY enthusiasts, independent repair shops, owners seeking to reduce dealership maintenance costs Competitive Analysis Key Competitors Era: Suzuki Vitara, Toyota RAV4 (early models), Honda CR-V (early models), Mitsubishi Pajero Mini Key Features Vehicle Selling Points: Compact size, affordable pricing, genuine 4WD capability, fuel efficiency, maneuverability Manual Value Proposition Cost Savings: Enables users to perform repairs and maintenance themselves, significantly reducing labor costs 📋 Manual Details Coverage Areas Primary Regions: Global (focus on markets where J100 was prevalent, likely including Asia, Europe, Oceania) Page Count Estimated Pages: 1000+ Manual Type Type: Service and Repair Workshop Manual Language Language: English (likely comprehensive, technical automotive language) Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, internal component specifications, timing belt/chain, cooling system, lubrication system Fuel System: Fuel injection (MPI/EFI), fuel pump, injectors, fuel pressure regulator, fuel tank, lines Ignition System: Ignition coils, spark plugs, ignition timing, distributor (if applicable) Emission Control: Catalytic converter, O2 sensors, EGR system, EVAP system diagnosis and repair Transmission Manual: Manual transmission overhaul, clutch system, gear shift mechanism, lubrication Transmission Automatic: Automatic transmission overhaul, hydraulic control, torque converter, shift solenoids, fluid service (if applicable to engine variant) Drivetrain 4Wd: Transfer case operation and repair, front/rear differential service, drive shafts, CV joints (critical for Terios) Suspension: Front struts/coil springs, rear shock absorbers/leaf springs (common configuration), control arms, bushings, sway bars Steering: Power steering system, steering rack/box, tie rod ends, steering column Brakes: Front disc brakes, rear drum brakes (common), hydraulic system, ABS components (if equipped), brake bleeding procedures Electrical System: Battery, alternator, starter motor, wiring diagrams, fuses, relays, lighting system Body Electrical: Power windows, central locking, mirrors, interior/exterior lighting, instrument cluster Body And Chassis: Frame inspection, body panel repair, door mechanisms, interior trim removal and installation HVAC: Air conditioning system diagnosis and repair, heater core, blower motor, climate controls Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection Troubleshooting: Diagnostic flowcharts for common drivability issues, electrical faults, starting problems Component Removal Installation: Detailed step-by-step instructions for removing and installing major and minor components Engine Rebuild: Piston ring replacement, bearing service, cylinder head gasket replacement, complete engine disassembly and reassembly Transmission Service: Clutch replacement, transmission fluid flush and fill, seal replacement Brake Service: Brake pad and rotor replacement, brake shoe and drum relining, brake fluid flush Suspension Repair: Strut replacement, shock absorber replacement, bushing replacement, ball joint replacement Electrical Diagnostics: Using multimeter, interpreting wiring diagrams, diagnosing sensor failures Bodywork Repair: Dent removal, panel alignment, seal replacement Technical Depth Depth: Comprehensive: Covers basic maintenance to complete overhauls and advanced diagnostics Diagnostic Tools: Information on using scan tools (OBD-I/OBD-II if applicable), multimeters, pressure gauges Specifications: Torque specifications, clearances, fluid capacities, electrical resistance values Diagrams Illustrations: Detailed exploded views, wiring diagrams, system schematics, repair process illustrations 📊 Manual Specifications File Format Format: PDF Searchability: Searchable text content for efficient information retrieval Print Quality Printability: Printable for users who prefer hard copies or specific sections Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Completeness Completeness: Complete workshop manual, not a condensed or owner's manual ⚙️ Engine Specifications Primary Engine Engine Code Common: HE-EG (1.6L 16V DOHC MPI) Engine Displacement Cc: 1589 cc Engine Configuration: Inline 4-cylinder Engine Aspiratio: Naturally Aspirated Engine Valvetrain: DOHC (Double Overhead Camshaft), 16 Valves Performance Horsepower Ps Approx: 90-100 PS Torque Nm Approx: 130-140 Nm Fuel System Fuel Delivery: Electronic Multi-Point Fuel Injection (MPI) / Electronic Fuel Injection (EFI) Recommended Fuel: Unleaded Gasoline (Octane Rating as per local market standards) Fluid Specifications Engine Oil Type: API SG, SH, SJ or ACEA A2/A3 (e.g., 10W-30, 10W-40, 20W-50 depending on climate) Engine Oil Capacity Liters Approx: 3.7 - 4.0 L (with filter) Coolant Type: Ethylene Glycol based coolant (typically a 50/50 mix with distilled water) 🔧 Transmission Standard Type Standard: 5-speed Manual Transmission Optional Type Optional: 4-speed Automatic Transmission Features Drivetrain Layout: Selectable 4WD (4x4) with low range, or 2WD (Rear-Wheel Drive) Fluid Specifications Manual Transmission Fluid Type: API GL-4 SAE 75W-90 or 75W-85 Automatic Transmission Fluid Type: Dexron II/III compatible fluid Transfer Case Fluid Type: API GL-5 SAE 75W-90 📐 Dimensions Exterior Length Mm Approx: 3700 - 3750 mm Width Mm Approx: 1600 - 1650 mm Height Mm Approx: 1650 - 1700 mm Wheelbase Mm: 2430 mm Ground Clearance Mm Approx: 190 - 200 mm Weights Curb Weight Kg Approx: 1150 - 1250 kg Gross Vehicle Weight Rating Kg Approx: 1600 - 1700 kg Wheels Tires Wheel Bolt Pattern: 5x114.3 Wheel Size Standard: 15 inch Tire Size Standard Approx: 205/70 R15 🛡️ Safety Features Ratings Crash Test Results: Limited official global crash test data available...
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DAIHATSU TERIOS J100 Service Repair Manual 1997-2000
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Terios
Generation Code:
J100
Model Years Covered:
1997-2000
👋 Introduction
Market Position
Vehicle Segment:
Compact SUV / Mini SUV
Target Audience:
DIY enthusiasts, independent repair shops, owners seeking to reduce dealership maintenance costs
Competitive Analysis
Key Competitors Era:
Suzuki Vitara, Toyota RAV4 (early models), Honda CR-V (early models), Mitsubishi Pajero Mini
Key Features
Vehicle Selling Points:
Compact size, affordable pricing, genuine 4WD capability, fuel efficiency, maneuverability
Manual Value Proposition
Cost Savings:
Enables users to perform repairs and maintenance themselves, significantly reducing labor costs
📋 Manual Details
Coverage Areas
Primary Regions:
Global (focus on markets where J100 was prevalent, likely including Asia, Europe, Oceania)
Page Count
Estimated Pages:
1000+
Manual Type
Type:
Service and Repair Workshop Manual
Language
Language:
English (likely comprehensive, technical automotive language)
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete engine overhaul, internal component specifications, timing belt/chain, cooling system, lubrication system
Fuel System:
Fuel injection (MPI/EFI), fuel pump, injectors, fuel pressure regulator, fuel tank, lines
Ignition System:
Ignition coils, spark plugs, ignition timing, distributor (if applicable)
Emission Control:
Catalytic converter, O2 sensors, EGR system, EVAP system diagnosis and repair
Transmission Manual:
Manual transmission overhaul, clutch system, gear shift mechanism, lubrication
Transmission Automatic:
Automatic transmission overhaul, hydraulic control, torque converter, shift solenoids, fluid service (if applicable to engine variant)
Drivetrain 4Wd:
Transfer case operation and repair, front/rear differential service, drive shafts, CV joints (critical for Terios)
Suspension:
Front struts/coil springs, rear shock absorbers/leaf springs (common configuration), control arms, bushings, sway bars
Steering:
Power steering system, steering rack/box, tie rod ends, steering column
Brakes:
Front disc brakes, rear drum brakes (common), hydraulic system, ABS components (if equipped), brake bleeding procedures
Electrical System:
Battery, alternator, starter motor, wiring diagrams, fuses, relays, lighting system
Body Electrical:
Power windows, central locking, mirrors, interior/exterior lighting, instrument cluster
Body And Chassis:
Frame inspection, body panel repair, door mechanisms, interior trim removal and installation
HVAC:
Air conditioning system diagnosis and repair, heater core, blower motor, climate controls
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection
Troubleshooting:
Diagnostic flowcharts for common drivability issues, electrical faults, starting problems
Component Removal Installation:
Detailed step-by-step instructions for removing and installing major and minor components
Engine Rebuild:
Piston ring replacement, bearing service, cylinder head gasket replacement, complete engine disassembly and reassembly
Transmission Service:
Clutch replacement, transmission fluid flush and fill, seal replacement
Brake Service:
Brake pad and rotor replacement, brake shoe and drum relining, brake fluid flush
Suspension Repair:
Strut replacement, shock absorber replacement, bushing replacement, ball joint replacement
Electrical Diagnostics:
Using multimeter, interpreting wiring diagrams, diagnosing sensor failures
Bodywork Repair:
Dent removal, panel alignment, seal replacement
Technical Depth
Depth:
Comprehensive: Covers basic maintenance to complete overhauls and advanced diagnostics
Diagnostic Tools:
Information on using scan tools (OBD-I/OBD-II if applicable), multimeters, pressure gauges
Specifications:
Torque specifications, clearances, fluid capacities, electrical resistance values
Diagrams Illustrations:
Detailed exploded views, wiring diagrams, system schematics, repair process illustrations
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Searchable text content for efficient information retrieval
Print Quality
Printability:
Printable for users who prefer hard copies or specific sections
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Completeness
Completeness:
Complete workshop manual, not a condensed or owner's manual
⚙️ Engine Specifications
Primary Engine
Engine Code Common:
HE-EG (1.6L 16V DOHC MPI)
Engine Displacement Cc:
1589 cc
Engine Configuration:
Inline 4-cylinder
Engine Aspiratio:
Naturally Aspirated
Engine Valvetrain:
DOHC (Double Overhead Camshaft), 16 Valves
Performance
Horsepower Ps Approx:
90-100 PS
Torque Nm Approx:
130-140 Nm
Fuel System
Fuel Delivery:
Electronic Multi-Point Fuel Injection (MPI) / Electronic Fuel Injection (EFI)
Recommended Fuel:
Unleaded Gasoline (Octane Rating as per local market standards)
Fluid Specifications
Engine Oil Type:
API SG, SH, SJ or ACEA A2/A3 (e.g., 10W-30, 10W-40, 20W-50 depending on climate)
Engine Oil Capacity Liters Approx:
3.7 - 4.0 L (with filter)
Coolant Type:
Ethylene Glycol based coolant (typically a 50/50 mix with distilled water)
🔧 Transmission
Standard
Type Standard:
5-speed Manual Transmission
Optional
Type Optional:
4-speed Automatic Transmission
Features
Drivetrain Layout:
Selectable 4WD (4x4) with low range, or 2WD (Rear-Wheel Drive)
Fluid Specifications
Manual Transmission Fluid Type:
API GL-4 SAE 75W-90 or 75W-85
Automatic Transmission Fluid Type:
Dexron II/III compatible fluid
Transfer Case Fluid Type:
API GL-5 SAE 75W-90
📐 Dimensions
Exterior
Length Mm Approx:
3700 - 3750 mm
Width Mm Approx:
1600 - 1650 mm
Height Mm Approx:
1650 - 1700 mm
Wheelbase Mm:
2430 mm
Ground Clearance Mm Approx:
190 - 200 mm
Weights
Curb Weight Kg Approx:
1150 - 1250 kg
Gross Vehicle Weight Rating Kg Approx:
1600 - 1700 kg
Wheels Tires
Wheel Bolt Pattern:
5x114.3
Wheel Size Standard:
15 inch
Tire Size Standard Approx:
205/70 R15
🛡️ Safety Features
Ratings
Crash Test Results:
Limited official global crash test data available for this specific generation and market; primarily focused on regional compliance.
Active Features
ABS:
Optional on some trims/markets
Passive Features
Airbags:
Driver airbag standard on most models; Passenger airbag optional/market dependent.
Seatbelts:
3-point ELR front seatbelts with pre-tensioners, 3-point or 2-point rear seatbelts
💡 Technology Features
Infotainment
Features 1997 2000:
Basic AM/FM radio, cassette player or single-CD player, analog gauges. Limited advanced tech by modern standards.
Driver Assistance
Features 1997 2000:
ABS was often optional. No traction control or stability control systems typically fitted to this generation.
Connectivity
Features 1997 2000:
No integrated Bluetooth, USB, or smartphone connectivity. Auxiliary input might be available on later models/specific trims.
🔧 Maintenance
Service Intervals
Engine Oil Filter Replacement:
Every 5,000 - 10,000 km or 6-12 months, whichever comes first (refer to manual for specific recommendations).
Air Filter Replacement:
Every 15,000 - 30,000 km or as needed based on inspection (especially in dusty conditions).
Spark Plug Replacement:
Every 30,000 - 60,000 km, depending on spark plug type (standard or platinum/iridium).
Timing Belt Replacement:
Critical: Typically every 60,000 - 100,000 km or 4-6 years. Failure can cause catastrophic engine damage (HE-EG is an interference engine).
Transmission Fluid Change Manual:
Every 40,000 - 60,000 km or as recommended.
Transmission Fluid Change Automatic:
Every 40,000 - 60,000 km or as recommended.
Brake Fluid Replacement:
Every 2-3 years, regardless of mileage.
Fluid Specifications
Power Steering Fluid Type:
ATF (Automatic Transmission Fluid) compatible with Dexron II/III
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Common Wear Items:
Clutch wear, suspension bushings, exhaust system components, minor oil leaks from seals, potential for transfer case seal leaks.
Timing Belt Maintenance Criticality:
Due to interference engine design, timely timing belt replacement is paramount to prevent severe engine damage.
📚 Vehicle History
Brand Heritage
Daihatsu Focus:
Daihatsu, a subsidiary of Toyota, has a long history of producing small, fuel-efficient, and reliable vehicles, often targeting emerging markets and compact segments.
Model Evolution
Terios J100 Introduction:
The first generation Terios (J100) was launched in 1997 as a compact, body-on-frame SUV designed for off-road capability and everyday usability in a small package.
Terios J100 Design Philosophy:
Emphasized its compact dimensions, lightweight construction, and effective 4WD system, differentiating it from larger, more cumbersome SUVs.
Terios J100 Market Reception:
Gained popularity for its affordability, practicality, and surprising off-road prowess for its size.
Production
Manufacturing Locations:
Primarily Japan, with potential assembly in other Daihatsu or Toyota facilities globally.
🏆 Awards & Recognition
Recognitions
Market Perception:
Generally regarded as a dependable and practical small SUV, especially in markets where it was popular. Often praised for its value and off-road capability for its class.
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