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2002-2012 Daihatsu Copen Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Copen Model Generation: First Generation (L880 Series) Applicable Years: 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012 👋 Introduction Market Position Vehicle Segment: Kei car, convertible sports car Competitive Analysis Niche Appeal: Unique compact convertible offering, catering to enthusiasts seeking distinctive styling and engaging driving dynamics. Key Features Convertible Top: Retractable hardtop roof mechanism. Diy Support: Empowers owners to perform their own repairs, saving money and enhancing vehicle ownership experience. Value Proposition Cost Savings: Enables owners to save significant money on repairs by performing DIY tasks. 📋 Manual Details Coverage Areas Primary Coverage: Complete Service and Repair Engine Coverage: All engines Model Coverage: All models Page Count Estimated Page Count: Extensive (not specified, but described as 'COMPLETE' and covering 'A-Z') Manual Type Type: Workshop Repair Service Manual Language Language: English Format Delivery Format: Digital Download Accessibility: Viewable on any computer, zoomable and printable. 📖 Manual Coverage Systems Covered Powertrain: Engine, Transmission/Transaxle, Clutch, Driveline Chassis: Frame & Mounting, Suspension, Steering, Wheels, Tires, Brakes Body: Body, Frame & Mounting, Sunroof Electrical: Battery & Charging Systems, Audio, Lighting, Electrical Distribution, Wiring Comfort And Convenience: Climate Control, Instrumentation & Warnings Systems Procedures Included Routine Maintenance: Factory maintenance schedules and charts, Fluid specifications and capacities, Serpentine belt routings Repair And Rebuild: Engine overhaul and rebuilding, Transmission removal and installation, In-car servicing, Brake servicing procedures, U-joint and CV-joint service procedures Diagnostics And Troubleshooting: Trouble codes, Computer diagnostic trouble tree charts, Troubleshooting and diagnostics, Engine performance diagnostics Special Procedures: Timing belt replacement, Timing belt service procedures, Front end and alignment procedures and specifications Exhaust System: Service, repair, and replacement procedures for the exhaust system. Fuel System: Inspection, maintenance, and repair of the fuel tank, fuel pump, injectors, and lines. Shocks And Struts: Replacement and service procedures for suspension dampers. Clutch System: Inspection, adjustment, and replacement of clutch components. Driveline: Service and repair of drive axles, CV joints, and differential. Cooling System: Radiator, thermostat, water pump, and hoses service. Air Conditioning: Service and capacities for the A/C system. Steering System: Repair and adjustment of steering rack, column, and power steering system. Technical Depth Detail Level: Comprehensive (A-Z), Detailed illustrations, exploded diagrams, drawings and photos, Complete torque specifications Diagrams And Illustrations: Hundreds of detailed illustrations, exploded diagrams, and drawings to clarify repair steps. Diagnostic Charts: Vacuum diagrams, computer diagnostic codes, and trouble tree charts for systematic problem diagnosis. Parts Identification: Provides detailed part identification through diagrams and descriptions, aiding in correct part sourcing. 📊 Manual Specifications File Format Format: PDF Compatibility: All Versions of Windows, Mac, iOS, BB, Android, etc. Requirements: PDF Reader Print Quality Printability: Yes, all pages are printable Manual Quality Completeness: 100% Complete and Intact, no missing/corrupt pages/sections ⚙️ Engine Specifications Primary Engine Engine Code And Type: Typically the JB-DET (660cc, turbocharged, intercooled, DOHC, 16-valve inline-3 petrol engine) for Japanese market, and K3-VE (1.3L, naturally aspirated inline-4 petrol engine) for export markets. Manual covers all included engines. Performance Horsepower Output: 64 PS (47 kW; 63 hp) for JB-DET (JDM), ~87-90 PS (64-66 kW; 86-89 hp) for K3-VE (export). Specific figures detailed in manual. Torque Output: 93 Nm (69 lb-ft) for JB-DET, ~120 Nm (89 lb-ft) for K3-VE. Specific figures detailed in manual. Fuel System Induction: Turbocharged and Intercooled (JB-DET), Naturally Aspirated (K3-VE) Fuel Delivery: Electronic Fuel Injection (EFI) Technical Features Valve Train: DOHC, 16 valves Engine Block Material: Likely aluminum alloy for both JB-DET and K3-VE engines. 🔧 Transmission Standard Type: Manual Transmission (MT) Optional Type: Automatic Transmission (AT) Features Gear Count Mt: Typically 5-speed Gear Count At: Typically 4-speed Drivetrain: Front-wheel drive (FWD) Fluid Requirements Manual Transmission Fluid: Refer to manual for specific GL rating and capacity (e.g., GL-4 or GL-5, capacity around 1.8-2.0L) Automatic Transmission Fluid: Refer to manual for specific ATF type and capacity (e.g., Dexron III/Mercon, capacity around 4.0-4.5L for overhaul) 📐 Dimensions Exterior Length: Approx. 3,395 mm (133.7 in) Width: Approx. 1,475 mm (58.1 in) Height: Approx. 1,245 mm (49.0 in) Wheelbase: Approx. 2,430 mm (95.7 in) Weights Curb Weight: Approx. 800 - 850 kg (1760 - 1870 lb) Interior Seating Capacity: 2 seats 🛡️ Safety Features Ratings Jncsa Safety Rating: Achieved 4-star ratings in some Japanese NCAP crash tests for frontal impact. Active Features Braking System: Front ventilated discs, Rear solid discs. ABS optional or standard depending on trim/market. Steering: Power assisted rack and pinion. Tire Size Recommendation: Refer to manual for specific sizes, common sizes include 165/65R14 or 175/50R15 depending on trim. Passive Features Airbags: Driver and passenger airbags standard. Body Structure: Reinforced chassis and A-pillars for convertible safety. 💡 Technology Features Infotainment Audio System: Factory radio with CD player, speakers. Manual covers installation/removal and basic troubleshooting. Instrument Cluster: Includes tachometer, speedometer, fuel gauge, temperature gauge, and warning lights. Manual details its components and diagnostics. Driver Assistance ABS: Anti-lock...
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2002-2012 Daihatsu Copen Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Copen
Model Generation:
First Generation (L880 Series)
Applicable Years:
2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012
👋 Introduction
Market Position
Vehicle Segment:
Kei car, convertible sports car
Competitive Analysis
Niche Appeal:
Unique compact convertible offering, catering to enthusiasts seeking distinctive styling and engaging driving dynamics.
Key Features
Convertible Top:
Retractable hardtop roof mechanism.
Diy Support:
Empowers owners to perform their own repairs, saving money and enhancing vehicle ownership experience.
Value Proposition
Cost Savings:
Enables owners to save significant money on repairs by performing DIY tasks.
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete Service and Repair
Engine Coverage:
All engines
Model Coverage:
All models
Page Count
Estimated Page Count:
Extensive (not specified, but described as 'COMPLETE' and covering 'A-Z')
Manual Type
Type:
Workshop Repair Service Manual
Language
Language:
English
Format
Delivery Format:
Digital Download
Accessibility:
Viewable on any computer, zoomable and printable.
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Transmission/Transaxle, Clutch, Driveline
Chassis:
Frame & Mounting, Suspension, Steering, Wheels, Tires, Brakes
Body:
Body, Frame & Mounting, Sunroof
Electrical:
Battery & Charging Systems, Audio, Lighting, Electrical Distribution, Wiring
Comfort And Convenience:
Climate Control, Instrumentation & Warnings Systems
Procedures Included
Routine Maintenance:
Factory maintenance schedules and charts, Fluid specifications and capacities, Serpentine belt routings
Repair And Rebuild:
Engine overhaul and rebuilding, Transmission removal and installation, In-car servicing, Brake servicing procedures, U-joint and CV-joint service procedures
Diagnostics And Troubleshooting:
Trouble codes, Computer diagnostic trouble tree charts, Troubleshooting and diagnostics, Engine performance diagnostics
Special Procedures:
Timing belt replacement, Timing belt service procedures, Front end and alignment procedures and specifications
Exhaust System:
Service, repair, and replacement procedures for the exhaust system.
Fuel System:
Inspection, maintenance, and repair of the fuel tank, fuel pump, injectors, and lines.
Shocks And Struts:
Replacement and service procedures for suspension dampers.
Clutch System:
Inspection, adjustment, and replacement of clutch components.
Driveline:
Service and repair of drive axles, CV joints, and differential.
Cooling System:
Radiator, thermostat, water pump, and hoses service.
Air Conditioning:
Service and capacities for the A/C system.
Steering System:
Repair and adjustment of steering rack, column, and power steering system.
Technical Depth
Detail Level:
Comprehensive (A-Z), Detailed illustrations, exploded diagrams, drawings and photos, Complete torque specifications
Diagrams And Illustrations:
Hundreds of detailed illustrations, exploded diagrams, and drawings to clarify repair steps.
Diagnostic Charts:
Vacuum diagrams, computer diagnostic codes, and trouble tree charts for systematic problem diagnosis.
Parts Identification:
Provides detailed part identification through diagrams and descriptions, aiding in correct part sourcing.
📊 Manual Specifications
File Format
Format:
PDF
Compatibility:
All Versions of Windows, Mac, iOS, BB, Android, etc.
Requirements:
PDF Reader
Print Quality
Printability:
Yes, all pages are printable
Manual Quality
Completeness:
100% Complete and Intact, no missing/corrupt pages/sections
⚙️ Engine Specifications
Primary Engine
Engine Code And Type:
Typically the JB-DET (660cc, turbocharged, intercooled, DOHC, 16-valve inline-3 petrol engine) for Japanese market, and K3-VE (1.3L, naturally aspirated inline-4 petrol engine) for export markets. Manual covers all included engines.
Performance
Horsepower Output:
64 PS (47 kW; 63 hp) for JB-DET (JDM), ~87-90 PS (64-66 kW; 86-89 hp) for K3-VE (export). Specific figures detailed in manual.
Torque Output:
93 Nm (69 lb-ft) for JB-DET, ~120 Nm (89 lb-ft) for K3-VE. Specific figures detailed in manual.
Fuel System
Induction:
Turbocharged and Intercooled (JB-DET), Naturally Aspirated (K3-VE)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Technical Features
Valve Train:
DOHC, 16 valves
Engine Block Material:
Likely aluminum alloy for both JB-DET and K3-VE engines.
🔧 Transmission
Standard
Type:
Manual Transmission (MT)
Optional
Type:
Automatic Transmission (AT)
Features
Gear Count Mt:
Typically 5-speed
Gear Count At:
Typically 4-speed
Drivetrain:
Front-wheel drive (FWD)
Fluid Requirements
Manual Transmission Fluid:
Refer to manual for specific GL rating and capacity (e.g., GL-4 or GL-5, capacity around 1.8-2.0L)
Automatic Transmission Fluid:
Refer to manual for specific ATF type and capacity (e.g., Dexron III/Mercon, capacity around 4.0-4.5L for overhaul)
📐 Dimensions
Exterior
Length:
Approx. 3,395 mm (133.7 in)
Width:
Approx. 1,475 mm (58.1 in)
Height:
Approx. 1,245 mm (49.0 in)
Wheelbase:
Approx. 2,430 mm (95.7 in)
Weights
Curb Weight:
Approx. 800 - 850 kg (1760 - 1870 lb)
Interior
Seating Capacity:
2 seats
🛡️ Safety Features
Ratings
Jncsa Safety Rating:
Achieved 4-star ratings in some Japanese NCAP crash tests for frontal impact.
Active Features
Braking System:
Front ventilated discs, Rear solid discs. ABS optional or standard depending on trim/market.
Steering:
Power assisted rack and pinion.
Tire Size Recommendation:
Refer to manual for specific sizes, common sizes include 165/65R14 or 175/50R15 depending on trim.
Passive Features
Airbags:
Driver and passenger airbags standard.
Body Structure:
Reinforced chassis and A-pillars for convertible safety.
💡 Technology Features
Infotainment
Audio System:
Factory radio with CD player, speakers. Manual covers installation/removal and basic troubleshooting.
Instrument Cluster:
Includes tachometer, speedometer, fuel gauge, temperature gauge, and warning lights. Manual details its components and diagnostics.
Driver Assistance
ABS:
Anti-lock Braking System available on some trims, manual details its operation and diagnostics.
Connectivity
Power Windows Locks:
Power windows, power locks, and remote keyless entry are common features, all covered by the electrical and wiring sections.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 - 10,000 km (3,000 - 6,000 miles) or 6-12 months, refer to manual for specific recommendations based on driving conditions.
Timing Belt Replacement Interval:
Recommended interval varies, often around 90,000 - 120,000 km (56,000 - 75,000 miles). Critical component, covered extensively in manual.
Fluid Specifications
Engine Oil Specification:
Refer to manual for recommended viscosity grade (e.g., 5W-30 or 0W-20) and API service classification.
Coolant Type:
Ethylene glycol-based coolant, typically pink or red long-life type. Refer to manual for specific type and capacity.
Brake Fluid Type:
DOT 3 or DOT 4.
Power Steering Fluid:
Refer to manual for specific type, likely ATF or dedicated power steering fluid.
Known Issues
Retractable Hardtop Mechanism:
Potential for hydraulic leaks, motor issues, or sensor malfunctions. Manual provides troubleshooting for this.
Turbocharger Longevity:
For JB-DET models, proper maintenance and avoiding prolonged high-RPM operation without adequate cooling are crucial for turbo longevity. Manual details turbo system care.
Electrical Connections:
As with any older vehicle, corrosion or loose connections in electrical systems can cause intermittent faults. Wiring diagrams are key.
📚 Vehicle History
Brand Heritage
Daihatsu History:
Daihatsu, a subsidiary of Toyota, has a long history in producing small, economical, and innovative vehicles, particularly within the Kei car segment in Japan.
Model Evolution
Copen Development:
Developed as a stylish and fun compact convertible, directly addressing a niche market. The L880 series, produced from 2002 to 2012, featured a unique electro-hydraulic retractable hardtop.
Kei Car Classification:
The JB-DET engine version conforms to Japanese Kei car regulations, influencing its compact dimensions and engine output.
Production
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Design Awards:
The Copen has been recognized for its distinctive and attractive design.
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