Daihatsu Terios Service Repair Workshop Manual 97-05
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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Generation: First Generation Production Years Covered: 1997-2005 Codes Chassis Codes: J100, J102, J122, J138, J140 👋 Introduction Market Position Segment: Compact SUV / Crossover Target Audience: Individuals seeking an affordable, practical, and capable compact SUV for urban and light off-road use. Competitive Analysis Key Competitors Era: Suzuki Vitara/Grand Vitara, Toyota RAV4 (early models), Honda CR-V (early models), Mitsubishi Pajero Mini/Pajero IO, Nissan Terrano/X-Trail (early models). Key Features Drivetrain Options: Available in both 2WD (rear-wheel drive) and 4WD configurations, offering versatility. Compact Size: Maneuverable in urban environments and easy to park. Practicality: Offers decent cargo space and seating for its class. Affordability: Known for its competitive pricing and lower running costs compared to larger SUVs. 📋 Manual Details Coverage Areas Market Segments Covered: All global markets where the Daihatsu Terios was sold during the specified years. Page Count Estimated Page Count: Likely 1000+ pages (typical for comprehensive service manuals of this era) Manual Type Type: Service and Repair Workshop Manual Language Language: English Format Format: Digital Download (PDF or similar e-book format) 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, and overhaul procedures for all engine variants, including timing belt replacement, cooling system, lubrication system, fuel system, and emissions control. Transmission: Repair and maintenance for both manual and automatic transmissions, including clutch, gearbox, transfer case, driveshafts, and differentials. Brakes: Front and rear brake system diagnostics, repair, bleeding procedures, ABS system, parking brake. Suspension Steering: Front and rear suspension components, alignment procedures, power steering system, steering rack, steering column. Electrical: Comprehensive electrical system schematics, lighting, ignition system, charging system, starter motor, wiring diagrams, fuse box locations, body control modules. Body Chassis: Body panel repair, door mechanisms, glass replacement, interior trim, underbody components, frame straightening (if applicable). HVAC: Heating, Ventilation, and Air Conditioning system diagnostics and repair, refrigerant handling, component replacement. Fuel System: Fuel tank, fuel pump, injectors, fuel filter replacement, fuel pressure testing. Cooling System: Radiator, thermostat, water pump, hoses, coolant specifications and flushing procedures. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, brake pad replacement. Troubleshooting: Diagnostic flowcharts and symptom-based troubleshooting for common and complex issues. Major Repairs: Engine rebuilds, transmission overhauls, suspension component replacement, major electrical system repairs. Component Replacement: Detailed steps for replacing virtually every component of the vehicle. Tightening Torques: Specific torque specifications for all critical fasteners. Wiring Diagrams: Complete and detailed wiring diagrams for all vehicle systems. Technical Depth Diagnostic Capabilities: Advanced diagnostic procedures, including using scan tools and interpreting diagnostic trouble codes (DTCs). Rebuild Procedures: Full engine and transmission rebuild instructions, including component specifications and tolerances. Special Tools: Identification and usage of specialized tools required for specific repair procedures. 📊 Manual Specifications File Format Format Details: Typically PDF, allowing for search functionality, zooming, and printing. Print Quality Quality: High-resolution scans with clear text and legible diagrams. Binding Type Binding: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code: G13BB (most common) Engine Type: Inline 4-cylinder, SOHC, 16-valve Displacement: 1.3 Liters (1300 cc) Bore X Stroke: 72.0 mm x 78.2 mm (typical for G13BB) Compression Ratio: 9.5:1 (typical for G13BB) Performance Horsepower: Approx. 85-90 PS (63-66 kW) at 6000 rpm (depending on market and specific tune) Torque: Approx. 110-120 Nm (81-89 lb-ft) at 3500-4000 rpm (depending on market and specific tune) Fuel System Induction: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (Octane rating as per local market recommendations) Other Engines Engine Options: 1.3L (G13BB), 1.3L (G13A - carbureted, earlier models), 1.3L DOHC (G13B), 1.3L VVT-i (1SZ-FE by Daihatsu, also used by Toyota), 1.3L Turbocharged (for specific performance variants/markets), 1.5L (G15A, G15SB, 3SZ-VE for later models not covered in this specific manual range). 🔧 Transmission Standard Transmission Type Standard: 5-Speed Manual Transmission Optional Transmission Type Optional: 4-Speed Automatic Transmission Features 4Wd System: Selectable 4WD system (usually with high/low range transfer case) for 4WD variants. 📐 Dimensions Exterior Length: Approx. 3,750 - 3,800 mm (varies slightly by model and bumper design) Width: Approx. 1,600 - 1,650 mm Height: Approx. 1,690 - 1,710 mm Wheelbase: Approx. 2,400 mm Ground Clearance: Approx. 190 - 200 mm (significant for its class) Weights Curb Weight: Approx. 1050 - 1150 kg (depending on configuration) Gross Vehicle Weight: Approx. 1500 - 1600 kg (typical) Cargo Cargo Volume Rear Seats Up: Approx. 300-350 Liters (varies with configuration) Cargo Volume Rear Seats Down: Approx. 750-850 Liters (estimated) 🛡️ Safety Features Ratings Crash Test Ratings: Varies by market and specific testing organization. Early 2000s vehicles often had less stringent testing standards than modern vehicles. Refer to specific market NCAP reports if available. Active Features ABS: Available on higher trim levels and later models. Traction Control: Rarely standard, potentially available on very high-spec variants or later models. Passive Features Airbags: Driver and passenger airbags...
Available in both 2WD (rear-wheel drive) and 4WD configurations, offering versatility.
Compact Size:
Maneuverable in urban environments and easy to park.
Practicality:
Offers decent cargo space and seating for its class.
Affordability:
Known for its competitive pricing and lower running costs compared to larger SUVs.
📋 Manual Details
Coverage Areas
Market Segments Covered:
All global markets where the Daihatsu Terios was sold during the specified years.
Page Count
Estimated Page Count:
Likely 1000+ pages (typical for comprehensive service manuals of this era)
Manual Type
Type:
Service and Repair Workshop Manual
Language
Language:
English
Format
Format:
Digital Download (PDF or similar e-book format)
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnostics, repair, and overhaul procedures for all engine variants, including timing belt replacement, cooling system, lubrication system, fuel system, and emissions control.
Transmission:
Repair and maintenance for both manual and automatic transmissions, including clutch, gearbox, transfer case, driveshafts, and differentials.
Brakes:
Front and rear brake system diagnostics, repair, bleeding procedures, ABS system, parking brake.
Suspension Steering:
Front and rear suspension components, alignment procedures, power steering system, steering rack, steering column.
Electrical:
Comprehensive electrical system schematics, lighting, ignition system, charging system, starter motor, wiring diagrams, fuse box locations, body control modules.
Body Chassis:
Body panel repair, door mechanisms, glass replacement, interior trim, underbody components, frame straightening (if applicable).
HVAC:
Heating, Ventilation, and Air Conditioning system diagnostics and repair, refrigerant handling, component replacement.
Radiator, thermostat, water pump, hoses, coolant specifications and flushing procedures.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, brake pad replacement.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting for common and complex issues.
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement, major electrical system repairs.
Component Replacement:
Detailed steps for replacing virtually every component of the vehicle.
Tightening Torques:
Specific torque specifications for all critical fasteners.
Wiring Diagrams:
Complete and detailed wiring diagrams for all vehicle systems.
Technical Depth
Diagnostic Capabilities:
Advanced diagnostic procedures, including using scan tools and interpreting diagnostic trouble codes (DTCs).
Rebuild Procedures:
Full engine and transmission rebuild instructions, including component specifications and tolerances.
Special Tools:
Identification and usage of specialized tools required for specific repair procedures.
📊 Manual Specifications
File Format
Format Details:
Typically PDF, allowing for search functionality, zooming, and printing.
Print Quality
Quality:
High-resolution scans with clear text and legible diagrams.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
G13BB (most common)
Engine Type:
Inline 4-cylinder, SOHC, 16-valve
Displacement:
1.3 Liters (1300 cc)
Bore X Stroke:
72.0 mm x 78.2 mm (typical for G13BB)
Compression Ratio:
9.5:1 (typical for G13BB)
Performance
Horsepower:
Approx. 85-90 PS (63-66 kW) at 6000 rpm (depending on market and specific tune)
Torque:
Approx. 110-120 Nm (81-89 lb-ft) at 3500-4000 rpm (depending on market and specific tune)
Fuel System
Induction:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (Octane rating as per local market recommendations)
Other Engines
Engine Options:
1.3L (G13BB), 1.3L (G13A - carbureted, earlier models), 1.3L DOHC (G13B), 1.3L VVT-i (1SZ-FE by Daihatsu, also used by Toyota), 1.3L Turbocharged (for specific performance variants/markets), 1.5L (G15A, G15SB, 3SZ-VE for later models not covered in this specific manual range).
🔧 Transmission
Standard
Transmission Type Standard:
5-Speed Manual Transmission
Optional
Transmission Type Optional:
4-Speed Automatic Transmission
Features
4Wd System:
Selectable 4WD system (usually with high/low range transfer case) for 4WD variants.
📐 Dimensions
Exterior
Length:
Approx. 3,750 - 3,800 mm (varies slightly by model and bumper design)
Width:
Approx. 1,600 - 1,650 mm
Height:
Approx. 1,690 - 1,710 mm
Wheelbase:
Approx. 2,400 mm
Ground Clearance:
Approx. 190 - 200 mm (significant for its class)
Weights
Curb Weight:
Approx. 1050 - 1150 kg (depending on configuration)
Gross Vehicle Weight:
Approx. 1500 - 1600 kg (typical)
Cargo
Cargo Volume Rear Seats Up:
Approx. 300-350 Liters (varies with configuration)
Cargo Volume Rear Seats Down:
Approx. 750-850 Liters (estimated)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Varies by market and specific testing organization. Early 2000s vehicles often had less stringent testing standards than modern vehicles. Refer to specific market NCAP reports if available.
Active Features
ABS:
Available on higher trim levels and later models.
Traction Control:
Rarely standard, potentially available on very high-spec variants or later models.
Passive Features
Airbags:
Driver and passenger airbags were becoming standard or optional during this period. Side airbags were rare.
Seatbelts:
Three-point seatbelts with pretensioners for front occupants.
Child Seat Anchors:
ISOFIX or similar anchor points for child safety seats may be present depending on market and year.
💡 Technology Features
Infotainment
Audio System:
Typically a basic AM/FM radio with CD player. Some higher trims may feature cassette players or multiple speakers. Aux-in ports or Bluetooth were uncommon in this generation.
Driver Assistance
Cruise Control:
Optional on higher trim levels and later models.
Connectivity
Connectivity Features:
Very limited by modern standards. Primarily basic vehicle functions and audio. No integrated navigation, smartphone mirroring, or advanced telematics.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000 - 10,000 km or 6-12 months, whichever comes first (refer to manual for exact spec).
Oil Filter Replacement:
At every engine oil change.
Air Filter Replacement:
Every 20,000 - 30,000 km or annually.
Spark Plug Replacement:
Every 40,000 - 60,000 km (depending on plug type, e.g., standard vs. iridium).
Timing Belt Replacement:
Crucial: Typically every 60,000 - 90,000 km or 4-5 years for this era. Failure can cause catastrophic engine damage.
Fluid Specifications
Engine Oil:
API SJ/SL or higher, SAE 10W-30 or 10W-40 (check manual for exact viscosity based on climate).
Coolant:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. Use Toyota Super Long Life Coolant or equivalent for later models if specified.
Transmission Fluid Manual:
API GL-4 SAE 75W-90 or 75W-85 gear oil (check manual).
Transmission Fluid Automatic:
Dexron III / Mercon equivalent automatic transmission fluid (ATF).
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid:
Dexron II or III equivalent ATF, or specific power steering fluid as per manual.
Known Issues
Timing Belt Wear:
Critical maintenance item. Premature wear or failure can lead to severe engine damage. Adherence to replacement intervals is paramount.
Clutch Wear:
As with many vehicles with manual transmissions, clutch wear is a common maintenance item, especially with extensive city driving or off-road use.
Suspension Bushings:
Bushings in the suspension and steering components can wear over time, leading to noise and handling degradation.
Ignition Coil Failure:
Individual ignition coils can fail, leading to misfires and rough running.
Rust Corrosion:
Depending on climate and maintenance, rust can affect body panels, exhaust systems, and undercarriage components.
📚 Vehicle History
Brand Heritage
Daihatsu Focus:
Daihatsu, a subsidiary of Toyota, has a long history specializing in small, affordable, and reliable vehicles, often with a focus on compact and fuel-efficient designs.
Model Evolution
First Generation Launch:
The Daihatsu Terios was first introduced in 1997 as a response to the growing demand for compact SUVs and crossovers.
Design Philosophy:
Designed to offer the functionality and higher driving position of an SUV in a compact, city-friendly package with available 4WD capability.
Production
Manufacturing Locations:
Primarily manufactured in Japan by Daihatsu, with some production or assembly also occurring in other markets through licensing or joint ventures.
🏆 Awards & Recognition
Recognitions
Awards And Accolades:
While specific awards are not widely publicized for the first-generation Terios, it was generally well-regarded for its value, practicality, and capability in the compact SUV segment, particularly for its price point.
Ratings
Reliability Perception:
Daihatsu vehicles are generally perceived as reliable and economical, often benefitting from Toyota's engineering influence.
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