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DAIHATSU TERIOS Service Repair Manual 1997-2005

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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Codes Model Code Range: J100, J122, J138 (depending on market and generation) 👋 Introduction Market Position Vehicle Segment: Compact SUV / Mini SUV Target Audience: Individuals seeking a compact, capable, and affordable off-road-oriented vehicle, often used as a first SUV or for light off-roading. Competitive Analysis Key Competitors: Early Suzuki Vitara, Honda CR-V (first generation), Toyota RAV4 (first generation), Mitsubishi Pajero/Montero iO, Isuzu VehiCROSS (in some markets). Key Features Vehicle Strengths: Compact size, robust 4WD system (often with center differential lock), affordable price point, good ground clearance for its class, durable reputation. Manual Value Proposition: Empowers owners and independent mechanics with the same technical information used by professionals, enabling efficient and accurate maintenance and repairs. 📋 Manual Details Coverage Areas Product Name: DAIHATSU TERIOS Service Repair Manual 1997-2005 Years Covered: 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005 Models Covered: All Terios models within the specified year range (e.g., 2-door, 4-door, 4WD variants) Page Count Estimated Page Count: Highly comprehensive; typically 1500+ pages for a full service manual of this era. Manual Type Type: Service Repair Workshop Manual Language Language: English (assumed, standard for professional manuals) Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, cylinder block, pistons, crankshaft, camshafts, timing systems, lubrication, cooling system, intake and exhaust manifolds. Engine Management: Fuel system (injection, carburetor where applicable), ignition system, emissions control, sensors, ECU diagnostics. Transmission Manual: Clutch system, gearbox assembly, gear selection, overhaul procedures. Transmission Automatic: Automatic transmission assembly, valve body, torque converter, shift control, overhaul procedures. Drivetrain: Front-wheel drive, rear-wheel drive, 4-wheel drive (4WD) system, transfer case, differentials, drive shafts, CV joints. Suspension: Front suspension (e.g., MacPherson strut), rear suspension (e.g., multi-link, coil spring), shock absorbers, springs, control arms, anti-roll bars. Steering: Steering system components, steering rack/box, power steering system (hydraulic), alignment specifications. Brakes: Front and rear brake systems (disc/drum), hydraulic system, brake fluid, ABS system (if equipped), parking brake. Electrical System: Battery, charging system (alternator), starting system, lighting system, wipers, horn, power windows, central locking. Body And Chassis: Body panels, doors, hood, tailgate, interior trim, seats, glass, chassis structure, corrosion protection. Heating Ventilation Air Conditioning HVAC: HVAC system operation, components, refrigerant system, cabin air filter. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug service, fluid checks and top-offs, tire rotation. Troubleshooting: Diagnostic procedures for common and uncommon issues across all major systems, symptom-based guides. Component Removal Installation: Step-by-step instructions for removing and installing virtually every serviceable component. Rebuilding Overhaul: Detailed instructions for rebuilding engines, transmissions, differentials, and other major assemblies. Diagnostics Testing: Procedures for testing electrical components, sensors, actuators, and mechanical systems using appropriate tools. Specifications Data: Torque values, clearances, fluid capacities, timing marks, alignment settings, electrical resistance values. Technical Depth Depth: Comprehensive, from basic maintenance to full engine/transmission rebuilds and advanced diagnostics. Detail Level: Expert-level detail, equivalent to factory service manuals used by dealership technicians. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Likely text-searchable if created from digital sources or properly OCR'd, enabling quick navigation. Print Quality Quality: High-resolution images, clear diagrams, and readable text, suitable for on-screen viewing and printing. Binding Type Digital Format: N/A (Digital PDF) Paper Type Digital Format: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code Common: G13BA (1.3L I4), G15A (1.5L I4), G16A/G16B (1.6L I4), 3SZ-VE (1.5L I4 - later models). Displacement Range: 1.3L, 1.5L, 1.6L Engine Configuration: Inline 4-cylinder (I4) Performance Horsepower Range: Approx. 70-115 hp depending on engine and market. Torque Range: Approx. 100-140 Nm depending on engine and market. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) for most models; some early variants may have carbureted options in certain markets. Fuel Type: Unleaded Gasoline 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transmission Optional Transmission Type Optional: 4-speed Automatic Transmission Features Drivetrain Options: Part-time 4WD (often with selectable 2WD/4WD modes and low-range gearing); some markets may have offered 2WD variants. 📐 Dimensions Exterior Length Range: Approx. 3,700-4,000 mm (varies by body style, e.g., 3-door vs 5-door). Width Range: Approx. 1,600-1,700 mm Height Range: Approx. 1,600-1,700 mm Ground Clearance: Typically around 180-200 mm, excellent for its class. Weights Curb Weight Range: Approx. 1,000-1,200 kg 🛡️ Safety Features Ratings Crash Test Data: Limited public crash test data available for this era; refer to specific market regulatory body reports if available. Active Features ABS: Available on higher trim levels or as an option. Traction Control: Rarely featured on models from this period. Passive Features Airbags: Driver and passenger airbags standard on later models/higher trims; older models may have only a driver airbag or none. Seatbelts: All seating positions equipped with seatbelts; pre-tensioners may be present on front belts. 💡 Technology Features Infotainment Audio System: Basic AM/FM radio with CD player or cassette player; aftermarket unit options common. Driver Assistance...
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DAIHATSU TERIOS Service Repair Manual 1997-2005
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Terios
Codes
Model Code Range:
J100, J122, J138 (depending on market and generation)
👋 Introduction
Market Position
Vehicle Segment:
Compact SUV / Mini SUV
Target Audience:
Individuals seeking a compact, capable, and affordable off-road-oriented vehicle, often used as a first SUV or for light off-roading.
Competitive Analysis
Key Competitors:
Early Suzuki Vitara, Honda CR-V (first generation), Toyota RAV4 (first generation), Mitsubishi Pajero/Montero iO, Isuzu VehiCROSS (in some markets).
Key Features
Vehicle Strengths:
Compact size, robust 4WD system (often with center differential lock), affordable price point, good ground clearance for its class, durable reputation.
Manual Value Proposition:
Empowers owners and independent mechanics with the same technical information used by professionals, enabling efficient and accurate maintenance and repairs.
📋 Manual Details
Coverage Areas
Product Name:
DAIHATSU TERIOS Service Repair Manual 1997-2005
Years Covered:
1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005
Models Covered:
All Terios models within the specified year range (e.g., 2-door, 4-door, 4WD variants)
Page Count
Estimated Page Count:
Highly comprehensive; typically 1500+ pages for a full service manual of this era.
Manual Type
Type:
Service Repair Workshop Manual
Language
Language:
English (assumed, standard for professional manuals)
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, cylinder block, pistons, crankshaft, camshafts, timing systems, lubrication, cooling system, intake and exhaust manifolds.
Engine Management:
Fuel system (injection, carburetor where applicable), ignition system, emissions control, sensors, ECU diagnostics.
Transmission Manual:
Clutch system, gearbox assembly, gear selection, overhaul procedures.
Transmission Automatic:
Automatic transmission assembly, valve body, torque converter, shift control, overhaul procedures.
Drivetrain:
Front-wheel drive, rear-wheel drive, 4-wheel drive (4WD) system, transfer case, differentials, drive shafts, CV joints.
Suspension:
Front suspension (e.g., MacPherson strut), rear suspension (e.g., multi-link, coil spring), shock absorbers, springs, control arms, anti-roll bars.
Steering:
Steering system components, steering rack/box, power steering system (hydraulic), alignment specifications.
Brakes:
Front and rear brake systems (disc/drum), hydraulic system, brake fluid, ABS system (if equipped), parking brake.
Electrical System:
Battery, charging system (alternator), starting system, lighting system, wipers, horn, power windows, central locking.
Body And Chassis:
Body panels, doors, hood, tailgate, interior trim, seats, glass, chassis structure, corrosion protection.
Heating Ventilation Air Conditioning HVAC:
HVAC system operation, components, refrigerant system, cabin air filter.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug service, fluid checks and top-offs, tire rotation.
Troubleshooting:
Diagnostic procedures for common and uncommon issues across all major systems, symptom-based guides.
Component Removal Installation:
Step-by-step instructions for removing and installing virtually every serviceable component.
Rebuilding Overhaul:
Detailed instructions for rebuilding engines, transmissions, differentials, and other major assemblies.
Diagnostics Testing:
Procedures for testing electrical components, sensors, actuators, and mechanical systems using appropriate tools.
Specifications Data:
Torque values, clearances, fluid capacities, timing marks, alignment settings, electrical resistance values.
Technical Depth
Depth:
Comprehensive, from basic maintenance to full engine/transmission rebuilds and advanced diagnostics.
Detail Level:
Expert-level detail, equivalent to factory service manuals used by dealership technicians.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Likely text-searchable if created from digital sources or properly OCR'd, enabling quick navigation.
Print Quality
Quality:
High-resolution images, clear diagrams, and readable text, suitable for on-screen viewing and printing.
Binding Type
Digital Format:
N/A (Digital PDF)
Paper Type
Digital Format:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code Common:
G13BA (1.3L I4), G15A (1.5L I4), G16A/G16B (1.6L I4), 3SZ-VE (1.5L I4 - later models).
Displacement Range:
1.3L, 1.5L, 1.6L
Engine Configuration:
Inline 4-cylinder (I4)
Performance
Horsepower Range:
Approx. 70-115 hp depending on engine and market.
Torque Range:
Approx. 100-140 Nm depending on engine and market.
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) for most models; some early variants may have carbureted options in certain markets.
Fuel Type:
Unleaded Gasoline
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission
Optional
Transmission Type Optional:
4-speed Automatic Transmission
Features
Drivetrain Options:
Part-time 4WD (often with selectable 2WD/4WD modes and low-range gearing); some markets may have offered 2WD variants.
📐 Dimensions
Exterior
Length Range:
Approx. 3,700-4,000 mm (varies by body style, e.g., 3-door vs 5-door).
Width Range:
Approx. 1,600-1,700 mm
Height Range:
Approx. 1,600-1,700 mm
Ground Clearance:
Typically around 180-200 mm, excellent for its class.
Weights
Curb Weight Range:
Approx. 1,000-1,200 kg
🛡️ Safety Features
Ratings
Crash Test Data:
Limited public crash test data available for this era; refer to specific market regulatory body reports if available.
Active Features
ABS:
Available on higher trim levels or as an option.
Traction Control:
Rarely featured on models from this period.
Passive Features
Airbags:
Driver and passenger airbags standard on later models/higher trims; older models may have only a driver airbag or none.
Seatbelts:
All seating positions equipped with seatbelts; pre-tensioners may be present on front belts.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with CD player or cassette player; aftermarket unit options common.
Driver Assistance
Cruise Control:
Available on some higher trim levels or as an aftermarket addition.
Parking Assist:
Not typically equipped with factory parking sensors or cameras.
Connectivity
Bluetooth:
Not factory-equipped; requires aftermarket installation.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000-10,000 km or 6-12 months, depending on driving conditions and oil type used.
Air Filter Replacement:
Every 20,000-30,000 km or as needed based on inspection.
Spark Plug Replacement:
Every 40,000-60,000 km for standard plugs, or 80,000-100,000 km for iridium/platinum plugs (check specific engine).
Coolant Flush:
Every 40,000-80,000 km or 2-4 years.
Fluid Specifications
Engine Oil Type:
API SG/SH or higher, viscosity typically 10W-30 or 5W-30 (refer to owner's manual for exact specification).
Transmission Fluid Manual:
API GL-4, SAE 75W-90 or 80W-90 gear oil.
Transmission Fluid Automatic:
Dexron II/III or equivalent ATF (Automatic Transmission Fluid).
Brake Fluid Type:
DOT 3 or DOT 4.
Coolant Type:
Ethylene glycol based, typically a 50/50 mix with deionized water (refer to manual for specific type).
Known Issues
Common Wear Items:
Clutch wear (manual), front brake pads/rotors, CV joint boots, exhaust system components, suspension bushings.
Potential Issues:
Rust/corrosion on chassis and bodywork in humid/salty environments, occasional head gasket issues on older/high-mileage engines, minor electrical gremlins.
📚 Vehicle History
Brand Heritage
Daihatsu Focus:
Daihatsu is a Japanese automobile manufacturer with a long history, specializing in compact and light commercial vehicles. It is a subsidiary of Toyota Motor Corporation.
Model Evolution
First Generation Introduction:
The first generation Daihatsu Terios (also known as Toyota Cami/Duet in some markets) was introduced in 1997.
Platform Development:
Developed as a compact, body-on-frame (ladder chassis) SUV, providing genuine off-road capability unlike many monocoque crossovers of the time.
Production
Manufacturing Locations:
Primarily Japan, with production also occurring in other Daihatsu plants globally and through licensing agreements.
🏆 Awards & Recognition
Recognitions
Model Awards:
Generally recognized for its value, compact size, and off-road capability in its segment rather than winning major awards.
Ratings
Reliability Reputation:
Generally considered reliable with proper maintenance, especially the mechanical components. Durability is a strong point for its class.
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