2009 Daihatsu Boon (2nd gen) Service and Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Boon Year: 2009 Generation: 2nd Generation (M500 Series) Codes Chassis Code: M502G, M512G 👋 Introduction Market Position Vehicle Segment: Subcompact hatchback, known for its practicality, fuel efficiency, and compact size, popular in urban environments. Competitive Analysis Key Competitors: Toyota Yaris, Honda Fit, Nissan March/Micra, Suzuki Swift, Mitsubishi Colt. Key Features Manual Value Proposition: Provides vehicle-specific, technician-level repair information, eliminating the need for guesswork and generic guides, empowering owners for DIY repairs and informed maintenance. Digital Format Benefits: Convenient, searchable, printable on demand, and avoids physical wear and tear compared to traditional paper manuals. 📋 Manual Details Coverage Areas Geographical Coverage: Primarily Japan and markets where the Daihatsu Boon was officially sold. Regional Variants: Covers all models and trim levels for the 2009 model year of the 2nd generation Daihatsu Boon. Page Count Estimated Page Count: Estimated 2000+ pages (typical for comprehensive factory service manuals, exact count not provided). Manual Type Manual Type: Factory Service and Repair Manual Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, valve train, timing system, oil pump, oil seals, gaskets. Engine Control System: ECU diagnostics, sensor operations (e.g., crankshaft position, camshaft position, oxygen, MAP, IAT, ECT), actuator control (e.g., fuel injectors, ignition coils), fuel injection system (EFI), emissions control systems (EGR, EVAP). Fuel Service: Fuel tank, fuel pump, fuel filter, fuel lines, fuel injectors, fuel pressure regulation, fuel delivery system testing. Emission Control: Catalytic converter, oxygen sensors, exhaust gas recirculation (EGR) system, evaporative emission control (EVAP) system, secondary air injection (if applicable). Intake Exhaust Cooling: Intake manifold, throttle body, air filter housing, exhaust manifold, exhaust pipes, muffler, radiator, water pump, thermostat, cooling fan, hoses, coolant specifications. Lube System: Engine oil pump, oil pan, oil filter, oil passages, lubrication specifications, oil change intervals. Ignition Charging Starting: Spark plugs, ignition coils, ignition timing, alternator, battery, starter motor, charging system testing, starting system diagnostics. Automatic Transmission: ATF specifications, torque converter, planetary gear sets, clutch packs, valve body, solenoids, hydraulic control system, electronic controls, shift interlock, transmission fluid cooler. Manual Transmission: Clutch assembly (disc, pressure plate, release bearing), flywheel, transmission gear sets, synchronizers, shift mechanism, output shaft, input shaft, transmission fluid specifications, seal replacement. Drivetrain: Propeller shaft (if AWD), universal joints, differential (front/rear), drive shafts, CV joints, hub bearings, AWD system operation and servicing. Suspension: Front suspension (struts, control arms, ball joints, stabilizer bar), rear suspension (torsion beam or multi-link depending on configuration), shock absorbers, coil springs, bushings, alignment specifications. Wheels Tires: Wheel bolt pattern, tire sizes, inflation pressures, wheel bearing replacement, tire rotation, balancing. Brake Control: ABS system, brake booster, master cylinder, proportioning valve, brake fluid specifications, bleeding procedures, diagnostic trouble codes (DTCs) for ABS. Brake Service: Front and rear brake pads, brake rotors, caliper replacement, brake shoe replacement (rear drum brakes if applicable), brake line inspection and replacement. Parking Brake: Parking brake mechanism, cables, adjustment procedures, drum or disc parking brake operation. Steering Column: Steering column assembly, tilt and telescoping mechanisms, steering wheel removal and installation, ignition switch. Power Steering: Power steering pump, fluid reservoir, steering rack/gearbox, power steering hoses, hydraulic system troubleshooting, electric power steering (EPS) system if equipped. Air Conditioning: AC system components (compressor, condenser, evaporator, receiver-drier), refrigerant types and capacities, charging procedures, leak detection, HVAC controls, blower motor, cabin air filter. Supplemental Restraint System: Airbag system components (SRS module, airbag modules, crash sensors, seatbelt pretensioners), SRS warning light diagnosis, airbag replacement procedures, safety precautions. Seatbelts: Seatbelt retractors, buckles, pretensioners, inspection and replacement. Immobilizer Cruise Control: Engine immobilizer system components and operation, cruise control system components, operation, and troubleshooting. Wiper Washer: Wiper motor, linkages, wiper blades, washer pump, washer fluid reservoir, washer nozzles, control switches. Door Locks: Door lock mechanisms, central locking system, power door locks, keyless entry system components, actuator replacement. Meter Audio Visual: Instrument cluster, gauges, warning lights, odometer, trip meter, audio system wiring, speaker installation, antenna. Horn: Horn assembly, horn relay, horn button/switch, wiring. Glass Mirrors: Windshield, side glass, rear glass, mirror replacement (side mirrors, rearview mirror), defogger elements. Instrument Panel: Instrument panel removal and installation, dash trim, lighting, HVAC controls, switch replacements. Seats: Seat removal and installation, seat adjustments, seat belt anchor points, seat frame repairs. Body Exterior Interior: Hood, doors, fenders, bumpers, body panels, interior trim panels, headliner, carpet, weatherstripping, painting and body repair guidelines. Electrical Systems: 12V battery system, charging system, starting system, lighting (headlights, taillights, interior lights), fuses, relays, wiring harness routing, common electrical diagnostic procedures. Multiplex Can Communication: Vehicle communication network (CAN bus), multiplex wiring systems, diagnostic tools for network issues, module communication. Procedures Included Maintenance Procedures: Oil and filter changes, fluid level checks and top-offs, spark plug replacement, air filter replacement, cabin filter replacement, belt inspection and replacement, brake inspection. Diagnostic Procedures: Troubleshooting guides for common...

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Sku: 458007

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Description

🏷️ Basic Information

Identification

Make:

Daihatsu

Model:

Year:

Generation:

2nd Generation (M500 Series)

Codes

Chassis Code:

M502G, M512G

👋 Introduction

Market Position

Vehicle Segment:

Subcompact hatchback, known for its practicality, fuel efficiency, and compact size, popular in urban environments.

Competitive Analysis

Key Competitors:

Toyota Yaris, Honda Fit, Nissan March/Micra, Suzuki Swift, Mitsubishi Colt.

Key Features

Manual Value Proposition:

Provides vehicle-specific, technician-level repair information, eliminating the need for guesswork and generic guides, empowering owners for DIY repairs and informed maintenance.

Digital Format Benefits:

Convenient, searchable, printable on demand, and avoids physical wear and tear compared to traditional paper manuals.

📋 Manual Details

Coverage Areas

Geographical Coverage:

Primarily Japan and markets where the Daihatsu Boon was officially sold.

Regional Variants:

Covers all models and trim levels for the 2009 model year of the 2nd generation Daihatsu Boon.

Page Count

Estimated Page Count:

Estimated 2000+ pages (typical for comprehensive factory service manuals, exact count not provided).

Manual Type

Manual Type:

Factory Service and Repair Manual

Language

Language:

English

Format

Digital Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, valve train, timing system, oil pump, oil seals, gaskets.

Engine Control System:

ECU diagnostics, sensor operations (e.g., crankshaft position, camshaft position, oxygen, MAP, IAT, ECT), actuator control (e.g., fuel injectors, ignition coils), fuel injection system (EFI), emissions control systems (EGR, EVAP).

Fuel Service:

Fuel tank, fuel pump, fuel filter, fuel lines, fuel injectors, fuel pressure regulation, fuel delivery system testing.

Emission Control:

Catalytic converter, oxygen sensors, exhaust gas recirculation (EGR) system, evaporative emission control (EVAP) system, secondary air injection (if applicable).

Intake Exhaust Cooling:

Intake manifold, throttle body, air filter housing, exhaust manifold, exhaust pipes, muffler, radiator, water pump, thermostat, cooling fan, hoses, coolant specifications.

Lube System:

Engine oil pump, oil pan, oil filter, oil passages, lubrication specifications, oil change intervals.

Ignition Charging Starting:

Spark plugs, ignition coils, ignition timing, alternator, battery, starter motor, charging system testing, starting system diagnostics.

Automatic Transmission:

ATF specifications, torque converter, planetary gear sets, clutch packs, valve body, solenoids, hydraulic control system, electronic controls, shift interlock, transmission fluid cooler.

Manual Transmission:

Clutch assembly (disc, pressure plate, release bearing), flywheel, transmission gear sets, synchronizers, shift mechanism, output shaft, input shaft, transmission fluid specifications, seal replacement.

Drivetrain:

Propeller shaft (if AWD), universal joints, differential (front/rear), drive shafts, CV joints, hub bearings, AWD system operation and servicing.

Suspension:

Front suspension (struts, control arms, ball joints, stabilizer bar), rear suspension (torsion beam or multi-link depending on configuration), shock absorbers, coil springs, bushings, alignment specifications.

Wheels Tires:

Wheel bolt pattern, tire sizes, inflation pressures, wheel bearing replacement, tire rotation, balancing.

Brake Control:

ABS system, brake booster, master cylinder, proportioning valve, brake fluid specifications, bleeding procedures, diagnostic trouble codes (DTCs) for ABS.

Brake Service:

Front and rear brake pads, brake rotors, caliper replacement, brake shoe replacement (rear drum brakes if applicable), brake line inspection and replacement.

Parking Brake:

Parking brake mechanism, cables, adjustment procedures, drum or disc parking brake operation.

Steering Column:

Steering column assembly, tilt and telescoping mechanisms, steering wheel removal and installation, ignition switch.

Power Steering:

Power steering pump, fluid reservoir, steering rack/gearbox, power steering hoses, hydraulic system troubleshooting, electric power steering (EPS) system if equipped.

Air Conditioning:

AC system components (compressor, condenser, evaporator, receiver-drier), refrigerant types and capacities, charging procedures, leak detection, HVAC controls, blower motor, cabin air filter.

Supplemental Restraint System:

Airbag system components (SRS module, airbag modules, crash sensors, seatbelt pretensioners), SRS warning light diagnosis, airbag replacement procedures, safety precautions.

Seatbelts:

Seatbelt retractors, buckles, pretensioners, inspection and replacement.

Immobilizer Cruise Control:

Engine immobilizer system components and operation, cruise control system components, operation, and troubleshooting.

Wiper Washer:

Wiper motor, linkages, wiper blades, washer pump, washer fluid reservoir, washer nozzles, control switches.

Door Locks:

Door lock mechanisms, central locking system, power door locks, keyless entry system components, actuator replacement.

Meter Audio Visual:

Instrument cluster, gauges, warning lights, odometer, trip meter, audio system wiring, speaker installation, antenna.

Horn:

Horn assembly, horn relay, horn button/switch, wiring.

Glass Mirrors:

Windshield, side glass, rear glass, mirror replacement (side mirrors, rearview mirror), defogger elements.

Instrument Panel:

Instrument panel removal and installation, dash trim, lighting, HVAC controls, switch replacements.

Seats:

Seat removal and installation, seat adjustments, seat belt anchor points, seat frame repairs.

Body Exterior Interior:

Hood, doors, fenders, bumpers, body panels, interior trim panels, headliner, carpet, weatherstripping, painting and body repair guidelines.

Electrical Systems:

12V battery system, charging system, starting system, lighting (headlights, taillights, interior lights), fuses, relays, wiring harness routing, common electrical diagnostic procedures.

Multiplex Can Communication:

Vehicle communication network (CAN bus), multiplex wiring systems, diagnostic tools for network issues, module communication.

Procedures Included

Maintenance Procedures:

Oil and filter changes, fluid level checks and top-offs, spark plug replacement, air filter replacement, cabin filter replacement, belt inspection and replacement, brake inspection.

Diagnostic Procedures:

Troubleshooting guides for common symptoms, diagnostic trouble code (DTC) interpretation, specific system diagnostic flowcharts, component testing procedures.

Repair Procedures:

Complete step-by-step instructions for overhauling engines, rebuilding transmissions, replacing suspension components, repairing body panels, and servicing all major systems.

Component Replacement:

Detailed instructions for removing, installing, and adjusting all major and minor components of the vehicle.

Specifications Data:

Torque specifications for fasteners, fluid capacities, electrical resistance values, engine timing specifications, alignment angles, and other critical data.

Wiring Schematics:

Complete and detailed wiring diagrams for all electrical systems, including power distribution, ground points, component connections, and circuit descriptions.

Technical Depth

Depth Of Coverage:

Factory-level comprehensive, covering everything from routine maintenance to complete engine and transmission overhauls, including detailed diagnostics and electrical troubleshooting.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text within PDF for quick information retrieval.

Print Quality

Printable:

All pages are printable.

Image Scalability:

Images and diagrams can be blown up and printed in enlarged copies.

Binding Type

Binding:

Digital (PDF), no physical binding.

Paper Type

Paper Type:

Not applicable (digital format).

Compatibility

Operating Systems:

Windows Vista (32 and 64-bit), XP, ME, 98, NT, 2000, and Mac compatible.

Required Software:

Adobe PDF Reader, WinZip (both free online).

⚙️ Engine Specifications

Primary Engine

Engine Code And Type:

Likely K3-VE (1.3L) or 1KR-FE (1.0L) DOHC inline-3 or inline-4 gasoline engines.

Performance

Displacement:

Approximately 996cc (1.0L) or 1298cc (1.3L).

Horsepower Range:

Estimated 65-70 HP for 1.0L, 85-90 HP for 1.3L.

Torque Range:

Estimated 85-90 Nm for 1.0L, 120-130 Nm for 1.3L.

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline

🔧 Transmission

Standard

Transmission Type Standard:

Likely 4-speed automatic transmission (e.g., Super ECT) or 5-speed manual transmission.

Optional

Transmission Type Optional:

Continuously Variable Transmission (CVT) may be available on some models/markets.

Features

AWD Option:

All-Wheel Drive (AWD) available on certain configurations, particularly with the 1.3L engine.

📐 Dimensions

Exterior

Length:

Approximately 3670 mm (standard wheelbase).

Width:

Approximately 1665 mm.

Height:

Approximately 1540 mm.

Weights

Curb Weight:

Varies by model and configuration, typically 900-1000 kg.

🛡️ Safety Features

Ratings

Safety Certification:

Likely meets Japanese safety standards (JNCAP) for its era.

Active Features

Active Safety Features:

Anti-lock Braking System (ABS) with Electronic Brake-force Distribution (EBD), possibly Brake Assist (BA).

Passive Features

Passive Safety Features:

Driver and front passenger airbags, side airbags (optional on some trims), seatbelt pretensioners, reinforced body structure.

💡 Technology Features

Infotainment

Audio System:

Factory fitted radio/CD player with 2-4 speakers. Auxiliary input or USB connectivity may be optional on higher trims.

Driver Assistance

Advanced Features:

Limited advanced driver-assistance systems for this era; primary focus on safety essentials like ABS.

Connectivity

Connectivity Options:

Basic connectivity via Bluetooth hands-free (if equipped), or aftermarket integration.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000-10,000 km or 6-12 months, depending on driving conditions and oil type.

Air Filter Replacement:

Recommended every 20,000-30,000 km or as needed based on inspection.

Spark Plug Replacement:

Intervals vary by spark plug type (e.g., standard, iridium), typically 40,000-100,000 km.

Fluid Specifications

Engine Oil Type:

Likely API SN/SP or ILSAC GF-5/GF-6, viscosity grade 0W-20 or 5W-30 (refer to manual for exact specification and capacity).

Transmission Fluid Atf:

Specific Daihatsu ATF (e.g., Dexron III equivalent or proprietary fluid) for automatic transmissions. Manual transmission uses API GL-4 gear oil.

Coolant Type:

Ethylene glycol-based, long-life coolant (pink or red color often indicates this).

Brake Fluid Type:

DOT 3 or DOT 4.

Known Issues

Common Wear Items:

Brake pads and rotors, suspension bushings, catalytic converter (with high mileage), clutch wear (manual transmission).

Electrical Quirks:

Occasional issues with window regulators, power lock actuators, or HVAC blower motors, typical for vehicles of this age.

Engine Performance Issues:

Potential for carbon buildup on intake valves with direct injection engines (though less common on the 2009 models), or minor oil leaks from seals with age.

📚 Vehicle History

Brand Heritage

Daihatsu Legacy:

Daihatsu, a subsidiary of Toyota, has a long history of producing small, efficient, and reliable vehicles, often referred to as 'kei' cars and compact cars.

Model Evolution

Boon Lineage:

The Boon (also known as Sirion in many export markets) is a key model in Daihatsu's compact car lineup, designed for urban mobility and fuel economy. The 2nd generation (M500) introduced updated styling, improved interior space, and refined powertrains.

Production

Manufacturing Origin:

Primarily manufactured in Japan.

🏆 Awards & Recognition

Recognitions

Safety Awards:

While specific awards for the 2009 model year are not widely publicized, Daihatsu vehicles generally aim for good safety ratings within their class.