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1997 Daihatsu Terios (1st gen) Service and Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Year: 1997 Generation: 1st Generation (J100 Series) Codes Chassis Codes: J100G, J102G, J122G Engine Codes: HC-EJ (1.3L), K3-VE (1.3L, later models, may be covered) 👋 Introduction Market Position Segment: Compact SUV / Mini SUV. Target Audience: Individuals seeking an affordable, capable, and compact off-road-oriented vehicle. Competitive Analysis Key Competitors: Suzuki Vitara, Toyota RAV4 (early models), Honda CR-V (early models), Isuzu Vehi-Cross (niche). Key Features Offroad Capability: Part-time or full-time 4WD system (depending on market/trim), short wheelbase, good ground clearance. Compact Size: Easy maneuverability in urban environments and on tight trails. Fuel Efficiency: Generally good fuel economy for its class. Utility: Practical for light towing, hauling, and recreational activities. 📋 Manual Details Coverage Areas Coverage: All Models & All Repairs A-Z Page Count Page Count: Detailed page count not specified, but implies comprehensive coverage. Manual Type Type: Service and Repair Manual Language Language: English Format Format: Not explicitly stated as print or digital, but described as the 'exact same manual used by technicians at the dealerships'. 📖 Manual Coverage Systems Covered Engine Service: Engine overhaul, timing belt replacement, cooling system, lubrication system, fuel system, ignition system, emissions control. Transmission Service: Manual and automatic transmission service, clutch, driveline components (driveshafts, differentials). Brake System: Disc and drum brake service, parking brake, hydraulic system. Suspension Steering: Front and rear suspension components, shock absorbers, springs, steering gear, power steering system. Electrical System: Battery, charging system (alternator), starting system, lighting, instrument cluster, gauges, wiring diagrams, fuses, relays. Body And Chassis: Body panel repair, interior trim, doors, windows, mirrors, chassis lubrication, structural components. HVAC System: Air conditioning, heating, ventilation system diagnostics and repair. Fuel And Exhaust: Fuel tank, fuel pump, injectors, catalytic converter, muffler, exhaust piping. Procedures Included Maintenance Procedures: Routine maintenance, oil changes, filter replacements, fluid checks, tune-ups. Troubleshooting Diagnostics: Diagnostic charts, common fault finding, symptom-based troubleshooting. Repair Procedures: Step-by-step repair instructions for all major vehicle systems. Rebuild Procedures: Engine and transmission rebuild specifications and procedures. Calibration Adjustment: Wheel alignment specifications, steering angle adjustments. Wiring Diagrams: Detailed electrical system wiring diagrams for all circuits. Technical Depth Depth: Vehicle-specific, comprehensive from basic maintenance to complete engine and transmission overhauls. Designed for dealership technicians. 📊 Manual Specifications File Format Format: Likely printed format, as per dealer technician usage. If digital, typically PDF. Print Quality Quality: High quality, professional printing suitable for workshop environments. Binding Type Binding: Likely spiral-bound or hardbound for durability and ease of use in a workshop. Paper Type Paper: Durable, high-grade paper designed to withstand workshop conditions. ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-cylinder, SOHC Displacement: 1296 cc (1.3 Liters) Engine Code: HC-EJ Bore X Stroke: 70.0 mm x 81.5 mm Compression Ratio: 9.5:1 Power Output: Approx. 70-75 PS (51-55 kW) at 6000 rpm (varies by market and tuning) Torque Output: Approx. 100-105 Nm (74-77 lb-ft) at 3500-4000 rpm (varies by market and tuning) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline Octane Rating: 91 RON minimum recommended. Cooling System Cooling Type: Water-cooled, pressurized. Lubrication System Oil Type: API SG or higher, SAE 10W-30 recommended for most conditions. Refer to manual for specific climate recommendations. Oil Capacity: Approx. 3.2 - 3.5 liters (3.4 - 3.7 US quarts) with filter change. Consult manual for exact capacity. 🔧 Transmission Standard Type: 5-speed Manual Transmission Optional Type: 4-speed Automatic Transmission Features Drivetrain: Part-time 4WD (with optional full-time 4WD system on some models/markets). Transfer Case: Two-speed transfer case (high/low range) on 4WD models. Fluid Specifications Manual Fluid: API GL-4 SAE 75W-90 or SAE 80W-90 gear oil. Automatic Fluid: Dexron II or Dexron III compatible ATF (Automatic Transmission Fluid). 📐 Dimensions Exterior Length: Approx. 3,735 mm (147.0 inches) Width: Approx. 1,600 mm (63.0 inches) Height: Approx. 1,690 - 1,705 mm (66.5 - 67.1 inches) Wheelbase: Approx. 2,340 mm (92.1 inches) Ground Clearance: Approx. 195 mm (7.7 inches) Weights Curb Weight: Approx. 1,080 - 1,150 kg (2,381 - 2,535 lbs) depending on configuration. Gross Vehicle Weight Rating: Varies by market and model, consult specific vehicle documentation. Cargo Cargo Volume: Configurable seating allows for versatile cargo space. Exact volume figures vary. 🛡️ Safety Features Ratings Crash Test Data: Specific official crash test ratings for this model year and region may be limited. Refer to regional safety authorities if available. Active Features ABS: Anti-lock Braking System (ABS) available on some models/trims, particularly later in the generation. 4Wd System: The 4WD system enhances traction and stability in various conditions. Passive Features Airbags: Driver airbag standard. Passenger airbag availability may vary by market. Seat Belts: Front and rear seat belts. Pre-tensioners on front seat belts may be present. Chassis Design: Body-on-frame construction (common for the era and class) provides a robust structure. 💡 Technology Features Infotainment Audio System: Typically a basic AM/FM radio with cassette player or CD player, depending on...
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1997 Daihatsu Terios (1st gen) Service and Repair Manual
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Terios
Year:
1997
Generation:
1st Generation (J100 Series)
Codes
Chassis Codes:
J100G, J102G, J122G
Engine Codes:
HC-EJ (1.3L), K3-VE (1.3L, later models, may be covered)
👋 Introduction
Market Position
Segment:
Compact SUV / Mini SUV.
Target Audience:
Individuals seeking an affordable, capable, and compact off-road-oriented vehicle.
Competitive Analysis
Key Competitors:
Suzuki Vitara, Toyota RAV4 (early models), Honda CR-V (early models), Isuzu Vehi-Cross (niche).
Key Features
Offroad Capability:
Part-time or full-time 4WD system (depending on market/trim), short wheelbase, good ground clearance.
Compact Size:
Easy maneuverability in urban environments and on tight trails.
Fuel Efficiency:
Generally good fuel economy for its class.
Utility:
Practical for light towing, hauling, and recreational activities.
📋 Manual Details
Coverage Areas
Coverage:
All Models & All Repairs A-Z
Page Count
Page Count:
Detailed page count not specified, but implies comprehensive coverage.
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
Not explicitly stated as print or digital, but described as the 'exact same manual used by technicians at the dealerships'.
📖 Manual Coverage
Systems Covered
Engine Service:
Engine overhaul, timing belt replacement, cooling system, lubrication system, fuel system, ignition system, emissions control.
Transmission Service:
Manual and automatic transmission service, clutch, driveline components (driveshafts, differentials).
Brake System:
Disc and drum brake service, parking brake, hydraulic system.
Suspension Steering:
Front and rear suspension components, shock absorbers, springs, steering gear, power steering system.
Electrical System:
Battery, charging system (alternator), starting system, lighting, instrument cluster, gauges, wiring diagrams, fuses, relays.
Body And Chassis:
Body panel repair, interior trim, doors, windows, mirrors, chassis lubrication, structural components.
HVAC System:
Air conditioning, heating, ventilation system diagnostics and repair.
Fuel And Exhaust:
Fuel tank, fuel pump, injectors, catalytic converter, muffler, exhaust piping.
Procedures Included
Maintenance Procedures:
Routine maintenance, oil changes, filter replacements, fluid checks, tune-ups.
Troubleshooting Diagnostics:
Diagnostic charts, common fault finding, symptom-based troubleshooting.
Repair Procedures:
Step-by-step repair instructions for all major vehicle systems.
Rebuild Procedures:
Engine and transmission rebuild specifications and procedures.
Calibration Adjustment:
Wheel alignment specifications, steering angle adjustments.
Wiring Diagrams:
Detailed electrical system wiring diagrams for all circuits.
Technical Depth
Depth:
Vehicle-specific, comprehensive from basic maintenance to complete engine and transmission overhauls. Designed for dealership technicians.
📊 Manual Specifications
File Format
Format:
Likely printed format, as per dealer technician usage. If digital, typically PDF.
Print Quality
Quality:
High quality, professional printing suitable for workshop environments.
Binding Type
Binding:
Likely spiral-bound or hardbound for durability and ease of use in a workshop.
Paper Type
Paper:
Durable, high-grade paper designed to withstand workshop conditions.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, SOHC
Displacement:
1296 cc (1.3 Liters)
Engine Code:
HC-EJ
Bore X Stroke:
70.0 mm x 81.5 mm
Compression Ratio:
9.5:1
Power Output:
Approx. 70-75 PS (51-55 kW) at 6000 rpm (varies by market and tuning)
Torque Output:
Approx. 100-105 Nm (74-77 lb-ft) at 3500-4000 rpm (varies by market and tuning)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline
Octane Rating:
91 RON minimum recommended.
Cooling System
Cooling Type:
Water-cooled, pressurized.
Lubrication System
Oil Type:
API SG or higher, SAE 10W-30 recommended for most conditions. Refer to manual for specific climate recommendations.
Oil Capacity:
Approx. 3.2 - 3.5 liters (3.4 - 3.7 US quarts) with filter change. Consult manual for exact capacity.
🔧 Transmission
Standard
Type:
5-speed Manual Transmission
Optional
Type:
4-speed Automatic Transmission
Features
Drivetrain:
Part-time 4WD (with optional full-time 4WD system on some models/markets).
Transfer Case:
Two-speed transfer case (high/low range) on 4WD models.
Fluid Specifications
Manual Fluid:
API GL-4 SAE 75W-90 or SAE 80W-90 gear oil.
Automatic Fluid:
Dexron II or Dexron III compatible ATF (Automatic Transmission Fluid).
📐 Dimensions
Exterior
Length:
Approx. 3,735 mm (147.0 inches)
Width:
Approx. 1,600 mm (63.0 inches)
Height:
Approx. 1,690 - 1,705 mm (66.5 - 67.1 inches)
Wheelbase:
Approx. 2,340 mm (92.1 inches)
Ground Clearance:
Approx. 195 mm (7.7 inches)
Weights
Curb Weight:
Approx. 1,080 - 1,150 kg (2,381 - 2,535 lbs) depending on configuration.
Gross Vehicle Weight Rating:
Varies by market and model, consult specific vehicle documentation.
Cargo
Cargo Volume:
Configurable seating allows for versatile cargo space. Exact volume figures vary.
🛡️ Safety Features
Ratings
Crash Test Data:
Specific official crash test ratings for this model year and region may be limited. Refer to regional safety authorities if available.
Active Features
ABS:
Anti-lock Braking System (ABS) available on some models/trims, particularly later in the generation.
4Wd System:
The 4WD system enhances traction and stability in various conditions.
Passive Features
Airbags:
Driver airbag standard. Passenger airbag availability may vary by market.
Seat Belts:
Front and rear seat belts. Pre-tensioners on front seat belts may be present.
Chassis Design:
Body-on-frame construction (common for the era and class) provides a robust structure.
💡 Technology Features
Infotainment
Audio System:
Typically a basic AM/FM radio with cassette player or CD player, depending on trim level and market. Aftermarket upgrades are common.
Speakers:
Standard 2 or 4 speaker configuration.
Driver Assistance
Cruise Control:
Optional on higher trim levels or specific markets.
Parking Assistance:
No factory parking sensors or backup cameras on this generation.
Connectivity
Connectivity Options:
No Bluetooth or USB connectivity available from the factory. Auxiliary input might be present on later models or via aftermarket additions.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 - 10,000 km (3,000 - 6,000 miles) or 6-12 months, whichever comes first. Consult manual for precise recommendation based on driving conditions.
Air Filter Replacement:
Every 20,000 - 30,000 km (12,000 - 18,000 miles). Inspect more frequently.
Fuel Filter Replacement:
Every 40,000 - 60,000 km (25,000 - 37,000 miles), especially for in-tank filters.
Spark Plug Replacement:
Every 40,000 - 60,000 km (25,000 - 37,000 miles) with standard copper plugs. Platinum or iridium plugs may have longer intervals.
Timing Belt Replacement:
Crucial: Every 80,000 - 100,000 km (50,000 - 60,000 miles) or 4-5 years, as it is an interference engine. Failure will cause catastrophic engine damage.
Fluid Specifications
Coolant Type:
Ethylene glycol-based coolant, typically a green or blue color. Mix 50/50 with distilled water. Refer to manual for specific Daihatsu/Toyota recommendation.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid:
ATF Dexron II or III compatible, or specific power steering fluid as per manual.
Known Issues
Timing Belt:
As mentioned, crucial to replace on schedule due to interference design. Lack of maintenance leads to engine failure.
Rust Corrosion:
As with many vehicles of this age, particularly in rust-prone climates, check chassis, body panels, and suspension components for rust.
Suspension Wear:
Bushings and ball joints can wear over time, leading to clunks and poor handling.
Exhaust System:
Corrosion can affect exhaust pipes, mufflers, and catalytic converters.
Electrical Connectors:
Corrosion or degradation of electrical connectors can cause intermittent issues.
📚 Vehicle History
Brand Heritage
Daihatsu Focus:
Daihatsu, a subsidiary of Toyota, has a long history of producing small, efficient, and reliable vehicles.
Model Evolution
Terios Introduction:
The first-generation Terios was introduced in 1997, designed to fill the niche of a compact, capable SUV.
Platform:
Based on Daihatsu's proprietary platform, featuring a ladder frame chassis.
Production
Manufacturing Location:
Primarily manufactured in Japan.
Production Years:
1st Generation: 1997-2006.
Global Presence:
Sold in numerous markets worldwide, often under different badges (e.g., Toyota Cami in Japan).
🏆 Awards & Recognition
Recognitions
Awards Citations:
While not typically winning major 'Car of the Year' awards, the Daihatsu Terios was recognized for its value, affordability, and capability in the compact SUV segment.
Reliability Perception:
Daihatsu vehicles are generally perceived as reliable, particularly given their Toyota lineage. Proper maintenance, as detailed in this manual, is key to long-term reliability.
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