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Daihatsu J200 Terios 2006-2014 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Generation Code: J200 Model Years Covered: 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014 👋 Introduction Market Position Segment: Compact SUV / Crossover Target Audience: Families, individuals seeking versatile urban and light off-road capability. Competitive Analysis Key Competitors: Nissan Qashqai (and equivalents), Honda CR-V (earlier generations), Toyota RAV4 (earlier generations), Suzuki Vitara. Key Features Design: Compact dimensions, upright stance, practical interior with seating for up to seven in some markets (though typically 5 for J200). Drivetrain Options: Available in Front-Wheel Drive (FWD) and genuine Four-Wheel Drive (4WD) with lockable center differential. Engine Options: Primarily powered by reliable and fuel-efficient 1.5L (2SZ-FE) and 1.3L (various codes, often 1SZ-FE or similar) or 1.5L (3SZ-VE) DOHC 4-cylinder engines. 📋 Manual Details Coverage Areas Primary Coverage: Workshop Service and Repair Secondary Coverage: Maintenance, Troubleshooting, Diagnostics, Overhaul Page Count Estimated Pages: Over 1500 pages (typical for comprehensive workshop manuals of this era) Manual Type Type: Factory Authorized Workshop Service Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Engine mechanical (2SZ-FE, 3SZ-VE), cooling system, lubrication system, fuel system, ignition system, emission control system Transmission: Manual transmission (5-speed), Automatic transmission (4-speed) overhaul and service, clutch system Drivetrain: Front-wheel drive (FWD), Four-wheel drive (4WD) system (transfer case, drive shafts, differentials), hub units Suspension: Front independent suspension (MacPherson struts), Rear multi-link independent suspension, springs, shock absorbers, control arms, stabilizer bars Steering: Power steering system (hydraulic), steering rack, tie rods, steering column Brakes: Front disc brakes, rear drum or disc brakes (depending on variant), ABS system, brake fluid, brake lines, parking brake Electrical: 12V battery system, alternator, starter motor, lighting (headlights, taillights, interior), fuses, relays, wiring diagrams Body: Body construction, doors, hood, tailgate, bumpers, interior trim, seats, glass, seals HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant, compressor, evaporator, heater core Safety Systems: Airbag system, seat belt pre-tensioners Procedures Included Maintenance: Scheduled maintenance intervals, oil changes, filter replacements, spark plug replacement, belt inspection/replacement Diagnostics: Troubleshooting guides for common issues, diagnostic trouble codes (DTCs), sensor testing, component testing Repair: Engine repair (head gasket, piston rings, bearings), transmission rebuild, brake caliper overhaul, suspension component replacement, electrical component repair Overhaul: Complete engine and transmission overhaul procedures, including disassembly, inspection, and reassembly steps Adjustment: Valve clearance adjustment, parking brake adjustment, steering alignment specifications Installation: Component installation and removal procedures (e.g., alternator, starter, water pump, fuel injectors) Technical Depth Depth: Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic trees and torque specifications. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content for quick information retrieval. Print Quality Resolution: High-resolution scans of original documentation, ensuring clarity of text and diagrams. Binding Type Type: Not Applicable (Digital PDF) Paper Type Type: Not Applicable (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code 1: 3SZ-VE Displacement 1: 1.5 Liters (1495 cc) Configuration 1: Inline 4-cylinder, DOHC, 16 valves Bore X Stroke 1: 72.0 mm x 91.8 mm Compression Ratio 1: 10.2:1 Power Output 1: Approximately 109 PS (107 hp / 80 kW) at 6000 RPM Torque Output 1: Approximately 14.4 kg-m (141 Nm; 104 lb-ft) at 4400 RPM Engine Code 2 Engine Code 2: 2SZ-FE Displacement 2: 1.3 Liters (1298 cc) Configuration 2: Inline 4-cylinder, DOHC, 16 valves Power Output 2: Approximately 86 PS (85 hp / 63 kW) at 6000 RPM Torque Output 2: Approximately 12.0 kg-m (118 Nm; 87 lb-ft) at 4400 RPM Performance Fuel Type: Unleaded Gasoline Fuel System Induction: Electronic Fuel Injection (EFI), Multi-point Injection (MPI) Ignition System: Electronic ignition, Distributorless Ignition System (DIS) or Coil-on-Plug (COP) 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transmission Optional Transmission Type Optional: 4-speed Automatic Transmission Features 4Wd System: Full-time 4WD with viscous coupling center differential and optional differential lock button. 📐 Dimensions Exterior Length: Approx. 4,000 - 4,100 mm (varies by market and specific model year) Width: Approx. 1,695 mm Height: Approx. 1,705 mm (without roof rails) Wheelbase: Approx. 2,580 mm Ground Clearance: Approx. 190 mm Weights Curb Weight: Approx. 1,150 - 1,250 kg (varies by drivetrain and equipment) 🛡️ Safety Features Ratings Latin Ncap Rating: Likely achieved 3 or 4 stars in earlier Latin NCAP tests for certain configurations. Active Features ABS: Anti-lock Braking System (ABS) often standard or available. E Brake: Electronic Brake-force Distribution (EBD) often paired with ABS. Passive Features Airbags: Driver and front passenger airbags standard; side airbags and curtain airbags may be optional on higher trims or later models. Seat Belts: 3-point seat belts with pre-tensioners for front seats, 3-point or 2-point belts for rear seats. 💡 Technology Features Infotainment Head Unit Features: Typically featured a basic AM/FM radio, CD player, and optionally MP3 playback. Some markets may have offered rudimentary navigation. Speaker System: Standard 4-speaker system, with optional upgrades to 6 speakers. Driver Assistance Cruise Control:...
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Daihatsu J200 Terios 2006-2014 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Terios
Generation Code:
J200
Model Years Covered:
2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014
👋 Introduction
Market Position
Segment:
Compact SUV / Crossover
Target Audience:
Families, individuals seeking versatile urban and light off-road capability.
Competitive Analysis
Key Competitors:
Nissan Qashqai (and equivalents), Honda CR-V (earlier generations), Toyota RAV4 (earlier generations), Suzuki Vitara.
Key Features
Design:
Compact dimensions, upright stance, practical interior with seating for up to seven in some markets (though typically 5 for J200).
Drivetrain Options:
Available in Front-Wheel Drive (FWD) and genuine Four-Wheel Drive (4WD) with lockable center differential.
Engine Options:
Primarily powered by reliable and fuel-efficient 1.5L (2SZ-FE) and 1.3L (various codes, often 1SZ-FE or similar) or 1.5L (3SZ-VE) DOHC 4-cylinder engines.
📋 Manual Details
Coverage Areas
Primary Coverage:
Workshop Service and Repair
Secondary Coverage:
Maintenance, Troubleshooting, Diagnostics, Overhaul
Page Count
Estimated Pages:
Over 1500 pages (typical for comprehensive workshop manuals of this era)
Manual Type
Type:
Factory Authorized Workshop Service Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Engine mechanical (2SZ-FE, 3SZ-VE), cooling system, lubrication system, fuel system, ignition system, emission control system
Transmission:
Manual transmission (5-speed), Automatic transmission (4-speed) overhaul and service, clutch system
Drivetrain:
Front-wheel drive (FWD), Four-wheel drive (4WD) system (transfer case, drive shafts, differentials), hub units
Suspension:
Front independent suspension (MacPherson struts), Rear multi-link independent suspension, springs, shock absorbers, control arms, stabilizer bars
Steering:
Power steering system (hydraulic), steering rack, tie rods, steering column
Brakes:
Front disc brakes, rear drum or disc brakes (depending on variant), ABS system, brake fluid, brake lines, parking brake
Electrical:
12V battery system, alternator, starter motor, lighting (headlights, taillights, interior), fuses, relays, wiring diagrams
Body:
Body construction, doors, hood, tailgate, bumpers, interior trim, seats, glass, seals
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant, compressor, evaporator, heater core
Safety Systems:
Airbag system, seat belt pre-tensioners
Procedures Included
Maintenance:
Scheduled maintenance intervals, oil changes, filter replacements, spark plug replacement, belt inspection/replacement
Diagnostics:
Troubleshooting guides for common issues, diagnostic trouble codes (DTCs), sensor testing, component testing
Repair:
Engine repair (head gasket, piston rings, bearings), transmission rebuild, brake caliper overhaul, suspension component replacement, electrical component repair
Overhaul:
Complete engine and transmission overhaul procedures, including disassembly, inspection, and reassembly steps
Adjustment:
Valve clearance adjustment, parking brake adjustment, steering alignment specifications
Installation:
Component installation and removal procedures (e.g., alternator, starter, water pump, fuel injectors)
Technical Depth
Depth:
Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic trees and torque specifications.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content for quick information retrieval.
Print Quality
Resolution:
High-resolution scans of original documentation, ensuring clarity of text and diagrams.
Binding Type
Type:
Not Applicable (Digital PDF)
Paper Type
Type:
Not Applicable (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
3SZ-VE
Displacement 1:
1.5 Liters (1495 cc)
Configuration 1:
Inline 4-cylinder, DOHC, 16 valves
Bore X Stroke 1:
72.0 mm x 91.8 mm
Compression Ratio 1:
10.2:1
Power Output 1:
Approximately 109 PS (107 hp / 80 kW) at 6000 RPM
Torque Output 1:
Approximately 14.4 kg-m (141 Nm; 104 lb-ft) at 4400 RPM
Engine Code 2
Engine Code 2:
2SZ-FE
Displacement 2:
1.3 Liters (1298 cc)
Configuration 2:
Inline 4-cylinder, DOHC, 16 valves
Power Output 2:
Approximately 86 PS (85 hp / 63 kW) at 6000 RPM
Torque Output 2:
Approximately 12.0 kg-m (118 Nm; 87 lb-ft) at 4400 RPM
Performance
Fuel Type:
Unleaded Gasoline
Fuel System
Induction:
Electronic Fuel Injection (EFI), Multi-point Injection (MPI)
Ignition System:
Electronic ignition, Distributorless Ignition System (DIS) or Coil-on-Plug (COP)
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission
Optional
Transmission Type Optional:
4-speed Automatic Transmission
Features
4Wd System:
Full-time 4WD with viscous coupling center differential and optional differential lock button.
📐 Dimensions
Exterior
Length:
Approx. 4,000 - 4,100 mm (varies by market and specific model year)
Width:
Approx. 1,695 mm
Height:
Approx. 1,705 mm (without roof rails)
Wheelbase:
Approx. 2,580 mm
Ground Clearance:
Approx. 190 mm
Weights
Curb Weight:
Approx. 1,150 - 1,250 kg (varies by drivetrain and equipment)
🛡️ Safety Features
Ratings
Latin Ncap Rating:
Likely achieved 3 or 4 stars in earlier Latin NCAP tests for certain configurations.
Active Features
ABS:
Anti-lock Braking System (ABS) often standard or available.
E Brake:
Electronic Brake-force Distribution (EBD) often paired with ABS.
Passive Features
Airbags:
Driver and front passenger airbags standard; side airbags and curtain airbags may be optional on higher trims or later models.
Seat Belts:
3-point seat belts with pre-tensioners for front seats, 3-point or 2-point belts for rear seats.
💡 Technology Features
Infotainment
Head Unit Features:
Typically featured a basic AM/FM radio, CD player, and optionally MP3 playback. Some markets may have offered rudimentary navigation.
Speaker System:
Standard 4-speaker system, with optional upgrades to 6 speakers.
Driver Assistance
Cruise Control:
Available on higher trim levels.
Parking Sensors:
Optional rear parking sensors may have been available.
Connectivity
Aux Input:
Auxiliary input jack for external audio devices often present.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-10,000 km (3,000-6,000 miles) or 6-12 months, depending on driving conditions and oil type used.
Air Filter Replacement:
Every 15,000-30,000 km (9,000-18,000 miles) or as needed based on inspection.
Spark Plug Replacement:
Every 40,000-100,000 km (24,000-60,000 miles) depending on spark plug type (standard vs. iridium).
Coolant Replacement:
Every 40,000-80,000 km (24,000-48,000 miles) or 2-4 years.
Fluid Specifications
Engine Oil Spec:
SAE 5W-30 or 10W-30, API SN or higher, ILSAC GF-5 or higher (refer to manual for exact specification and viscosity grade based on climate).
Engine Oil Capacity:
Approx. 3.5 - 3.9 Liters (3.7 - 4.1 US Quarts) with filter change.
Transmission Fluid Manual:
API GL-4, SAE 75W-90 or 75W-85 Gear Oil.
Transmission Fluid Automatic:
Dexron III or equivalent ATF (Automatic Transmission Fluid).
Coolant Spec:
Toyota Super Long Life Coolant (SLLC) or equivalent ethylene glycol-based coolant with deionized water (50/50 mix).
Brake Fluid Spec:
DOT 3 or DOT 4.
Power Steering Fluid:
Dexron II/III ATF or specific power steering fluid as per manual.
Known Issues
Common Issue 1:
Interior rattles and squeaks from trim panels, common in many vehicles of this class.
Common Issue 2:
Occasional issues with power steering pumps or steering racks, particularly at higher mileage.
Common Issue 3:
Water pump leaks or bearing noise, particularly after extended service life.
Common Issue 4:
Clutch wear or hydraulic issues on manual transmission models.
Common Issue 5:
Exhaust system corrosion or catalytic converter issues, especially in regions with harsh winters.
📚 Vehicle History
Brand Heritage
Daihatsu Focus:
Daihatsu, a subsidiary of Toyota, is known for producing small, efficient, and durable vehicles.
Model Evolution
Terios History:
The Terios originated in the mid-1990s as a compact, body-on-frame SUV. The J200 generation marked a shift to a monocoque construction, offering improved ride comfort and handling, and a more modern crossover appearance.
Production
Manufacturing Location:
Primarily manufactured in Japan, with significant production also in Indonesia and other markets under various brand names (e.g., Toyota Rush).
Production Period J200:
2006 - 2014
🏆 Awards & Recognition
Recognitions
Market Performance:
The Terios was a strong performer in its segment in many developing markets, valued for its affordability and utility.
Ratings
Reliability Perception:
Generally perceived as reliable, benefiting from Toyota's engineering influence.
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