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DAIHATSU TERIOS Service Repair Workshop Manual 1997-2005

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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Codes Platform Code: J100 Series Generation Generation Name: First Generation Production Years Covered By Manual: 1997-2005 👋 Introduction Market Position Vehicle Segment: Compact SUV / Mini SUV Target Audience: Individuals seeking a compact, capable, and affordable SUV for light off-roading and urban use Competitive Analysis Key Competitors Era: Suzuki Vitara, Toyota RAV4 (early models), Honda CR-V (early models), Mitsubishi Pajero Mini Key Features Vehicle Strengths: Compact dimensions, agile handling, reliable powertrain options, available 4WD, affordable maintenance Manual Value Proposition: Comprehensive coverage for DIY repairs and maintenance, ensuring optimal vehicle longevity and performance, superior to incomplete or low-quality alternatives 📋 Manual Details Coverage Areas Manual Type: Service and Repair Workshop Manual Language: English Page Count Estimated Page Count: Extensive (Typically 1000+ pages for comprehensive coverage) Format Format Type: Digital (likely PDF) 📖 Manual Coverage Systems Covered Engine Systems: Engine Mechanical, Engine Control System (ECU), Fuel System, Ignition System, Exhaust System, Cooling System, Lubrication System, Emission Control Systems Transmission Systems: Manual Transmission (MT), Automatic Transmission (AT), Transfer Case, Drivetrain Components (Driveshafts, CV Joints, Axles) Chassis Systems: Suspension (Front & Rear), Steering System, Brake System (Hydraulic, ABS if equipped), Wheels & Tires Electrical Systems: Wiring Diagrams, Battery & Charging System, Starting System, Lighting System, Instrumentation, Power Accessories, Body Electrical, ECU Diagnostics Body And Interior: Body Panels, Doors, Windows, Seats, Interior Trim, HVAC System, Body Sealing Procedures Included Maintenance Procedures: Oil Changes, Filter Replacements, Spark Plug Replacement, Fluid Checks & Top-offs, Belt Inspections & Replacement, Brake Pad Replacement, Tire Rotation Repair Procedures: Engine Component Rebuilds (e.g., cylinder head, pistons), Transmission Overhaul, Suspension Component Replacement, Brake Caliper/Master Cylinder Replacement, Steering Rack Repair, Electrical Component Diagnosis & Replacement Troubleshooting: Diagnostic Flowcharts for Common Issues, Fault Code Interpretation, Symptom-Based Troubleshooting Guides Technical Depth Diagnostic Capability: Advanced diagnostics, including ECU logic, sensor readings, and actuator testing Rebuild Instructions: Detailed step-by-step instructions for complete engine, transmission, and major component overhauls Specification Detail: Precise torque specifications, clearances, tolerances, and alignment data 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable for efficient information retrieval Print Quality Image Clarity: High-resolution images, diagrams, and schematics for clarity Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Codes: G13BA, G13BB, G15A, G16A, G16B (depending on market and specific model year) Engine Type: Inline 4-Cylinder, SOHC/DOHC, Naturally Aspirated Displacement: 1.3L (1300cc), 1.5L (1500cc), 1.6L (1600cc) Performance Horsepower Range: Approximately 63 hp to 95 hp Torque Range: Approximately 100 Nm to 130 Nm Fuel System Fuel Delivery: Multi-Point Fuel Injection (MPI) or Carburetor (early models) Fuel Type: Unleaded Gasoline Cooling System Coolant Type: Ethylene Glycol based coolant (e.g., Toyota Super Long Life Coolant or equivalent) 🔧 Transmission Standard Transmission Type Standard: 5-Speed Manual Transmission (MT) Optional Transmission Type Optional: 4-Speed Automatic Transmission (AT) Features Drivetrain: Part-time 4WD (4x4) with optional full-time 4WD or RWD depending on market Fluid Specifications Manual Transmission Fluid Spec: API GL-4 (e.g., 75W-90 or 80W-90 gear oil) Automatic Transmission Fluid Spec: Dexron III or equivalent ATF Transfer Case Fluid Spec: API GL-4 (e.g., 75W-90 or 80W-90 gear oil) 📐 Dimensions Exterior Length: Approx. 3,720 - 3,815 mm (depending on bumper and spare tire carrier) Width: Approx. 1,600 - 1,695 mm Height: Approx. 1,670 - 1,700 mm Wheelbase: Approx. 2,375 - 2,430 mm Weights Curb Weight: Approx. 1,050 - 1,250 kg Gross Vehicle Weight Rating: Varies by model, typically around 1,600 - 1,700 kg Cargo Cargo Volume Rear Seats Up: Approx. 250 - 300 Liters (estimated) Cargo Volume Rear Seats Down: Approx. 800 - 1000 Liters (estimated) 🛡️ Safety Features Ratings NHTSA Rating Era: Likely not rated or basic ratings for the era, as many compact SUVs of this period had less stringent testing Active Features ABS: Optional Anti-lock Braking System (ABS) on some higher trims/markets Passive Features Airbags: Driver Airbag (standard on most models), Passenger Airbag (optional or market dependent) Seatbelts: 3-point seatbelts with pretensioners (front), 2-point or 3-point (rear) Chassis Safety Body Structure: Reinforced chassis and body structure for impact absorption 💡 Technology Features Infotainment Audio System: Basic AM/FM radio with cassette player or single-disc CD player, optional upgraded system Speakers: Typically 2 or 4 speakers Driver Assistance Traction Control: Rarely available on this generation Parking Assistance: None typically offered Connectivity Bluetooth: Not available Usb Port: Not available 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 - 10,000 km or 6-12 months, depending on driving conditions and oil type used Air Filter Replacement Interval: Every 20,000 - 40,000 km Spark Plug Replacement Interval: Every 40,000 - 60,000 km (depending on plug type) Timing Belt Replacement Interval: Crucial! Every 80,000 - 100,000 km or 5-7 years (if applicable, some models may have timing chains) Fluid Specifications Engine Oil Spec: API SG/SH/SJ or higher, Viscosity 10W-30 or 10W-40 (check owner's manual...
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DAIHATSU TERIOS Service Repair Workshop Manual 1997-2005
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Terios
Codes
Platform Code:
J100 Series
Generation
Generation Name:
First Generation
Production Years Covered By Manual:
1997-2005
👋 Introduction
Market Position
Vehicle Segment:
Compact SUV / Mini SUV
Target Audience:
Individuals seeking a compact, capable, and affordable SUV for light off-roading and urban use
Competitive Analysis
Key Competitors Era:
Suzuki Vitara, Toyota RAV4 (early models), Honda CR-V (early models), Mitsubishi Pajero Mini
Key Features
Vehicle Strengths:
Compact dimensions, agile handling, reliable powertrain options, available 4WD, affordable maintenance
Manual Value Proposition:
Comprehensive coverage for DIY repairs and maintenance, ensuring optimal vehicle longevity and performance, superior to incomplete or low-quality alternatives
📋 Manual Details
Coverage Areas
Manual Type:
Service and Repair Workshop Manual
Language:
English
Page Count
Estimated Page Count:
Extensive (Typically 1000+ pages for comprehensive coverage)
Format
Format Type:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine Mechanical, Engine Control System (ECU), Fuel System, Ignition System, Exhaust System, Cooling System, Lubrication System, Emission Control Systems
Transmission Systems:
Manual Transmission (MT), Automatic Transmission (AT), Transfer Case, Drivetrain Components (Driveshafts, CV Joints, Axles)
Chassis Systems:
Suspension (Front & Rear), Steering System, Brake System (Hydraulic, ABS if equipped), Wheels & Tires
Electrical Systems:
Wiring Diagrams, Battery & Charging System, Starting System, Lighting System, Instrumentation, Power Accessories, Body Electrical, ECU Diagnostics
Body And Interior:
Body Panels, Doors, Windows, Seats, Interior Trim, HVAC System, Body Sealing
Procedures Included
Maintenance Procedures:
Oil Changes, Filter Replacements, Spark Plug Replacement, Fluid Checks & Top-offs, Belt Inspections & Replacement, Brake Pad Replacement, Tire Rotation
Repair Procedures:
Engine Component Rebuilds (e.g., cylinder head, pistons), Transmission Overhaul, Suspension Component Replacement, Brake Caliper/Master Cylinder Replacement, Steering Rack Repair, Electrical Component Diagnosis & Replacement
Troubleshooting:
Diagnostic Flowcharts for Common Issues, Fault Code Interpretation, Symptom-Based Troubleshooting Guides
Technical Depth
Diagnostic Capability:
Advanced diagnostics, including ECU logic, sensor readings, and actuator testing
Rebuild Instructions:
Detailed step-by-step instructions for complete engine, transmission, and major component overhauls
Specification Detail:
Precise torque specifications, clearances, tolerances, and alignment data
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable for efficient information retrieval
Print Quality
Image Clarity:
High-resolution images, diagrams, and schematics for clarity
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Codes:
G13BA, G13BB, G15A, G16A, G16B (depending on market and specific model year)
Engine Type:
Inline 4-Cylinder, SOHC/DOHC, Naturally Aspirated
Displacement:
1.3L (1300cc), 1.5L (1500cc), 1.6L (1600cc)
Performance
Horsepower Range:
Approximately 63 hp to 95 hp
Torque Range:
Approximately 100 Nm to 130 Nm
Fuel System
Fuel Delivery:
Multi-Point Fuel Injection (MPI) or Carburetor (early models)
Fuel Type:
Unleaded Gasoline
Cooling System
Coolant Type:
Ethylene Glycol based coolant (e.g., Toyota Super Long Life Coolant or equivalent)
🔧 Transmission
Standard
Transmission Type Standard:
5-Speed Manual Transmission (MT)
Optional
Transmission Type Optional:
4-Speed Automatic Transmission (AT)
Features
Drivetrain:
Part-time 4WD (4x4) with optional full-time 4WD or RWD depending on market
Fluid Specifications
Manual Transmission Fluid Spec:
API GL-4 (e.g., 75W-90 or 80W-90 gear oil)
Automatic Transmission Fluid Spec:
Dexron III or equivalent ATF
Transfer Case Fluid Spec:
API GL-4 (e.g., 75W-90 or 80W-90 gear oil)
📐 Dimensions
Exterior
Length:
Approx. 3,720 - 3,815 mm (depending on bumper and spare tire carrier)
Width:
Approx. 1,600 - 1,695 mm
Height:
Approx. 1,670 - 1,700 mm
Wheelbase:
Approx. 2,375 - 2,430 mm
Weights
Curb Weight:
Approx. 1,050 - 1,250 kg
Gross Vehicle Weight Rating:
Varies by model, typically around 1,600 - 1,700 kg
Cargo
Cargo Volume Rear Seats Up:
Approx. 250 - 300 Liters (estimated)
Cargo Volume Rear Seats Down:
Approx. 800 - 1000 Liters (estimated)
🛡️ Safety Features
Ratings
NHTSA Rating Era:
Likely not rated or basic ratings for the era, as many compact SUVs of this period had less stringent testing
Active Features
ABS:
Optional Anti-lock Braking System (ABS) on some higher trims/markets
Passive Features
Airbags:
Driver Airbag (standard on most models), Passenger Airbag (optional or market dependent)
Seatbelts:
3-point seatbelts with pretensioners (front), 2-point or 3-point (rear)
Chassis Safety
Body Structure:
Reinforced chassis and body structure for impact absorption
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with cassette player or single-disc CD player, optional upgraded system
Speakers:
Typically 2 or 4 speakers
Driver Assistance
Traction Control:
Rarely available on this generation
Parking Assistance:
None typically offered
Connectivity
Bluetooth:
Not available
Usb Port:
Not available
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 - 10,000 km or 6-12 months, depending on driving conditions and oil type used
Air Filter Replacement Interval:
Every 20,000 - 40,000 km
Spark Plug Replacement Interval:
Every 40,000 - 60,000 km (depending on plug type)
Timing Belt Replacement Interval:
Crucial! Every 80,000 - 100,000 km or 5-7 years (if applicable, some models may have timing chains)
Fluid Specifications
Engine Oil Spec:
API SG/SH/SJ or higher, Viscosity 10W-30 or 10W-40 (check owner's manual for exact specifications)
Engine Oil Capacity:
Approx. 3.5 - 4.0 Liters (with filter change)
Coolant Capacity:
Approx. 4.5 - 5.0 Liters
Brake Fluid Spec:
DOT 3 or DOT 4
Known Issues
Common Wear Items:
Clutch wear (manual transmission), Suspension bushings, CV joint boots, Exhaust system components, Radiator
Engine Specific:
Potential for oil leaks from gaskets, occasional rough idling if sensors (e.g., IAC valve) become dirty
Transmission Specific:
Wear on synchronizers in manual transmissions, potential for automatic transmission fluid leaks
Part Numbers
Oil Filter Example:
e.g., Daihatsu 90047-82005, or equivalent aftermarket like Fram PH2870, Wix 51348
Air Filter Example:
e.g., Daihatsu 17801-87101, or equivalent aftermarket like Fram CA4305
📚 Vehicle History
Brand Heritage
Daihatsu Specialization:
Daihatsu is known for producing reliable and economical small vehicles, including Kei cars and compact SUVs.
Model Evolution
Terios Introduction:
The Terios was developed to fill the niche of a compact, lightweight SUV with genuine off-road capability, often based on a ladder-frame chassis or robust monocoque construction.
Market Release:
First launched in 1997, it was a popular choice in many Asian and European markets.
Production
Manufacturing Locations:
Primarily Japan, with production also occurring in other Daihatsu/Toyota affiliated plants globally.
Global Availability:
Sold in numerous markets worldwide, often under different badges (e.g., Toyota Cami, Toyota Rush in some regions).
🏆 Awards & Recognition
Recognitions
Offroad Capability Recognition:
Praised for its surprising off-road capability for its size and class, often outperforming larger, heavier SUVs on rough terrain.
Ratings
Reliability Ratings Era:
Generally considered reliable due to Daihatsu's focus on robust, simple engineering, though specific market ratings may vary.
Certifications
Emission Standards:
Compliant with prevailing emission standards for the model years in its primary markets (e.g., Euro II/III, JPN emission standards)
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