Daihatsu Sirion 2004-2010 Full Service Repair Manual
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🏷️ Basic Information Identification Make: Daihatsu Model: Sirion Generation: Second Generation (M300) Production Years Covered: 2004, 2005, 2006, 2007, 2008, 2009, 2010 👋 Introduction Market Position Segment: Subcompact/Compact Hatchback Competitive Analysis Competitors: Toyota Yaris, Honda Fit/Jazz, Suzuki Swift, Ford Fiesta, Nissan Micra/March Key Features Appeal: Affordable, fuel-efficient, compact yet surprisingly spacious interior for its class, reliable for daily commuting. Target Audience Audience: Budget-conscious car buyers, first-time car owners, individuals seeking economical transportation, DIY mechanics. 📋 Manual Details Coverage Areas Primary Regions: Global (primarily Europe, Asia, Oceania) Page Count Estimated Pages: High (typically 500-1000+ pages for comprehensive service manuals) Manual Type Type: Full Service and Repair Manual Language Language: English Format File Format: PDF Delivery Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader, WinRAR Compatibility Operating Systems: All Windows Versions, macOS 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, timing system, lubrication system, cooling system Engine Management: Fuel injection, ignition system, emissions control, engine sensors, ECU (Engine Control Unit) diagnosis and repair Transmission: Manual and Automatic transmission overhaul, clutch, gear selection, torque converter (if applicable), transmission control module (TCM) Drivetrain: Front-wheel drive (FWD), axle shafts, differentials, driveshafts Suspension: Front and rear suspension components, shock absorbers, springs, control arms, bushings, alignment specifications Steering: Steering column, power steering system (hydraulic/electric), tie rods, steering rack Brakes: Brake system components (discs, pads, calipers, master cylinder, brake lines), ABS (Anti-lock Braking System) diagnosis and repair, parking brake Electrical System: Battery, charging system (alternator), starting system (starter motor), lighting, horn, wipers, power windows, central locking, fuses, relays Body And Chassis: Body panel removal and installation, interior trim, door mechanisms, glass, bumpers, structural components HVAC: Heating, ventilation, and air conditioning (HVAC) system components, refrigerant, diagnosis Infotainment And Comfort: Audio system, climate control panel, power accessories Procedures Included Maintenance: Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspections and replacement, brake pad replacement Diagnostics: Troubleshooting guides for common problems, symptom-based diagnostics, fault code interpretation (OBD-II) Repair: Component removal and installation, rebuilding procedures, component testing Wiring Diagrams: Detailed electrical schematics for all vehicle systems, component locations, connector pinouts Engine Rebuilding: Detailed steps for engine disassembly, cleaning, inspection, measurement, and reassembly with torque specifications and clearances. Transmission Overhaul: Comprehensive guide to dismantling, inspecting, replacing components, and reassembling both manual and automatic transmissions. Body Repair: Procedures for repairing minor dents, replacing panels, adjusting doors and hinges, and interior trim removal/installation. Technical Depth Depth: Comprehensive (covering basic maintenance to in-depth engine and transmission overhauls, and complex electrical diagnostics) Diagnostic Tools: Information on using OBD-II scanners, multimeters, and specialized diagnostic equipment. 📊 Manual Specifications File Format File Type: PDF Print Quality Printable: Full Printable (all pages) Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: K3-VE (common for most models) Engine Type: Inline-3 or Inline-4 Cylinder, DOHC Displacement: 1.0L (e.g., 1SZ-FE for earlier models) and 1.3L (e.g., K3-VE) or 1.5L (e.g., 3SZ-VE) Performance Horsepower: Typically ranges from 65 hp (1.0L) to 90 hp (1.3L) to 107 hp (1.5L), depending on engine variant. Torque: Varies with engine displacement, e.g., 1.3L K3-VE around 120-130 Nm. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline Engine Features Variable Valve Timing: May be equipped on certain engine variants (e.g., VVT-i equivalent). 🔧 Transmission Standard Type: 5-speed Manual Transmission Optional Type: 4-speed Automatic Transmission Features Gear Ratios: Specific ratios detailed within the manual. Fluid Specifications Manual Transmission Fluid: Likely API GL-4 SAE 75W-90 or similar (refer to manual for exact specification and capacity). Automatic Transmission Fluid: Likely ATF Dexron III or equivalent (refer to manual for exact specification and capacity). 📐 Dimensions Exterior Length: Approx. 3,600 - 3,700 mm (model dependent) Width: Approx. 1,665 - 1,690 mm (model dependent) Height: Approx. 1,520 - 1,550 mm (model dependent) Wheelbase: Approx. 2,400 - 2,430 mm (model dependent) Weights Curb Weight: Approx. 900 - 1,050 kg (model dependent) 🛡️ Safety Features Ratings Crash Test Results: Varies by region and specific model testing; consult regional safety agencies (e.g., Euro NCAP, JNCAP). The second generation typically aimed for improved safety over its predecessor. Active Features Anti Lock Brakes: Optional or standard on higher trims; ABS system diagnosis and repair covered. Electronic Brakeforce Distribution: Often paired with ABS. Passive Features Airbags: Driver and front passenger airbags standard; side airbags optional on some models. Manual covers airbag system diagnosis and replacement procedures. Seatbelts: Pre-tensioner and load-limiter seatbelts common. 💡 Technology Features Infotainment Audio System: Factory fitted radio/CD player, typically with basic speaker configuration. Upgrades and component replacement are covered. Driver Assistance Electronic Stability Control: Rarely available or standard on this generation Sirion, depending on market and trim. Connectivity Auxiliary Input: May be present on later models or as an aftermarket addition. Manual covers basic electrical system access. 🔧 Maintenance...
Front and rear suspension components, shock absorbers, springs, control arms, bushings, alignment specifications
Steering:
Steering column, power steering system (hydraulic/electric), tie rods, steering rack
Brakes:
Brake system components (discs, pads, calipers, master cylinder, brake lines), ABS (Anti-lock Braking System) diagnosis and repair, parking brake
Electrical System:
Battery, charging system (alternator), starting system (starter motor), lighting, horn, wipers, power windows, central locking, fuses, relays
Body And Chassis:
Body panel removal and installation, interior trim, door mechanisms, glass, bumpers, structural components
HVAC:
Heating, ventilation, and air conditioning (HVAC) system components, refrigerant, diagnosis
Infotainment And Comfort:
Audio system, climate control panel, power accessories
Procedures Included
Maintenance:
Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspections and replacement, brake pad replacement
Diagnostics:
Troubleshooting guides for common problems, symptom-based diagnostics, fault code interpretation (OBD-II)
Repair:
Component removal and installation, rebuilding procedures, component testing
Wiring Diagrams:
Detailed electrical schematics for all vehicle systems, component locations, connector pinouts
Engine Rebuilding:
Detailed steps for engine disassembly, cleaning, inspection, measurement, and reassembly with torque specifications and clearances.
Transmission Overhaul:
Comprehensive guide to dismantling, inspecting, replacing components, and reassembling both manual and automatic transmissions.
Body Repair:
Procedures for repairing minor dents, replacing panels, adjusting doors and hinges, and interior trim removal/installation.
Technical Depth
Depth:
Comprehensive (covering basic maintenance to in-depth engine and transmission overhauls, and complex electrical diagnostics)
Diagnostic Tools:
Information on using OBD-II scanners, multimeters, and specialized diagnostic equipment.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Printable:
Full Printable (all pages)
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
K3-VE (common for most models)
Engine Type:
Inline-3 or Inline-4 Cylinder, DOHC
Displacement:
1.0L (e.g., 1SZ-FE for earlier models) and 1.3L (e.g., K3-VE) or 1.5L (e.g., 3SZ-VE)
Performance
Horsepower:
Typically ranges from 65 hp (1.0L) to 90 hp (1.3L) to 107 hp (1.5L), depending on engine variant.
Torque:
Varies with engine displacement, e.g., 1.3L K3-VE around 120-130 Nm.
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline
Engine Features
Variable Valve Timing:
May be equipped on certain engine variants (e.g., VVT-i equivalent).
🔧 Transmission
Standard
Type:
5-speed Manual Transmission
Optional
Type:
4-speed Automatic Transmission
Features
Gear Ratios:
Specific ratios detailed within the manual.
Fluid Specifications
Manual Transmission Fluid:
Likely API GL-4 SAE 75W-90 or similar (refer to manual for exact specification and capacity).
Automatic Transmission Fluid:
Likely ATF Dexron III or equivalent (refer to manual for exact specification and capacity).
📐 Dimensions
Exterior
Length:
Approx. 3,600 - 3,700 mm (model dependent)
Width:
Approx. 1,665 - 1,690 mm (model dependent)
Height:
Approx. 1,520 - 1,550 mm (model dependent)
Wheelbase:
Approx. 2,400 - 2,430 mm (model dependent)
Weights
Curb Weight:
Approx. 900 - 1,050 kg (model dependent)
🛡️ Safety Features
Ratings
Crash Test Results:
Varies by region and specific model testing; consult regional safety agencies (e.g., Euro NCAP, JNCAP). The second generation typically aimed for improved safety over its predecessor.
Active Features
Anti Lock Brakes:
Optional or standard on higher trims; ABS system diagnosis and repair covered.
Electronic Brakeforce Distribution:
Often paired with ABS.
Passive Features
Airbags:
Driver and front passenger airbags standard; side airbags optional on some models. Manual covers airbag system diagnosis and replacement procedures.
Seatbelts:
Pre-tensioner and load-limiter seatbelts common.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/CD player, typically with basic speaker configuration. Upgrades and component replacement are covered.
Driver Assistance
Electronic Stability Control:
Rarely available or standard on this generation Sirion, depending on market and trim.
Connectivity
Auxiliary Input:
May be present on later models or as an aftermarket addition. Manual covers basic electrical system access.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000 km (6,000 miles) or 12 months, whichever comes first. Refer to manual for specific oil type and capacity.
Air Filter Replacement:
Recommended every 20,000 - 40,000 km (12,000 - 24,000 miles) or as per manual's inspection guide.
Spark Plug Replacement:
Varies by spark plug type (copper, platinum, iridium). Typically 40,000 - 100,000 km (24,000 - 60,000 miles).
Coolant Replacement:
Initial replacement at 5 years or 100,000 km, then every 2-4 years or 40,000-80,000 km thereafter.
Fluid Specifications
Engine Oil Specification:
Likely 5W-30 or 10W-30 API SN/SM/SL or equivalent (refer to manual for exact grade and capacity).
Coolant Specification:
Ethylene glycol based coolant, typically a 50/50 mix with distilled water. Specific Daihatsu coolant or compatible type required.
Known Issues
Common Wear Items:
Brake pads and discs, clutch wear (manual transmission), suspension bushings, front wheel bearings.
Engine Idling Issues:
Can sometimes occur due to dirty throttle body or idle air control valve. Manual provides cleaning and adjustment procedures.
Electrical Gremlins:
Less common, but can affect power window motors or central locking actuators over time. Manual's wiring diagrams are crucial.
📚 Vehicle History
Brand Heritage
Daihatsu Specialty:
Daihatsu is known for producing small, fuel-efficient, and often economical city cars and kei cars. Their focus on practicality and value is a long-standing tradition.
Model Evolution
Second Generation Launch:
The second generation Sirion (M300) was launched in 2004, representing a significant redesign with a more modern appearance and improved interior packaging. It shared its platform with the Toyota Passo/Daihatsu Boon in many markets.
Production
Manufacturing Locations:
Primarily manufactured in Japan, with potential assembly in other regions depending on the market.
🏆 Awards & Recognition
Recognitions
Awards And Ratings:
While specific awards for the 2004-2010 Sirion are not widely publicized globally, it consistently received praise in its target markets for fuel economy and value for money.
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