2002-2012 Daihatsu Copen Workshop Repair Service Manual Best
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🏷️ Basic Information Identification Make: Daihatsu Model: Copen Model Code: L880K (primary for this generation, though variations exist) Body Style: 2-door convertible coupe Generation: First Generation (JDM) Codes Chassis Code Range: L880K Engine Code Primary: JB-DET 👋 Introduction Market Position Vehicle Segment: Kei car segment (Japan), subcompact sports convertible globally. Target Audience: Enthusiasts, owners seeking to maintain or restore their vehicle, DIY mechanics. Competitive Analysis Key Competitors: Honda Beat (previous generation), Suzuki Cappuccino (previous generation), later Mazda MX-5 Miata (though larger and different segment). Key Features Unique Selling Proposition: Compact, stylish, affordable convertible with a turbocharged engine and a unique power retractable hardtop. Manual Value Proposition: Provides comprehensive, professional-grade repair information, enabling owners to perform maintenance and repairs efficiently and accurately, saving on labor costs and ensuring longevity. 📋 Manual Details Coverage Areas Years Covered: 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012 Regions Covered: Primarily Japan (JDM), but applicable to all markets where this generation was sold or imported Model Variants Covered: All variants equipped with the JB-DET engine and relevant transmissions for the specified years. Page Count Estimated Page Count: Likely over 1000 pages (typical for a comprehensive workshop manual of this scope) Manual Type Manual Type: Workshop Repair Service Manual Language Language: English (Assumed, based on product description of universal compatibility and widespread use) Format Format: Digital Downloadable PDF 📖 Manual Coverage Systems Covered Powertrain: Engine Mechanical (block, head, pistons, crankshaft), Engine Lubrication, Engine Cooling, Engine Control System (ECU, sensors, actuators), Fuel System (injectors, pump, lines), Exhaust System Drivetrain: Clutch System, Manual Transaxle (gearbox), Automatic Transaxle, Front Axle, Rear Axle, Driveshafts, CV Joints Suspension Steering Brakes: Front Suspension (struts, control arms), Rear Suspension (multi-link), Road Wheels & Tires, Brake System (discs, calipers, lines), Parking Brake System, Brake Control Systems (ABS), Power Steering System, Steering System (rack and pinion) Body Restraints: Body Structure, Lock & Security System, Glasses, Window System & Mirrors, Roof Mechanism (power retractable hardtop), Exterior & Interior Trim, Instrument Panel, Seats, Seat Belts, Supplemental Restraint System (SRS/Airbags) Electrical Climate: Wiring Diagrams, Starting & Charging System (alternator, starter), Lighting System (headlights, taillights), Driver Information System (gauges, warning lights), Wiper, Washer & Horn, Body Control System (ECU functions), LAN System, Audio Visual, Navigation & Telephone System, Auto Cruise Control System, Power Supply, Ground & Circuit Elements, Air Conditioner System Procedures Included Repair Maintenance: Detailed step-by-step repair and maintenance procedures for all covered systems, including diagnostics, disassembly, assembly, adjustment, and replacement. Troubleshooting: Diagnostic flowcharts and symptom-based troubleshooting guides for common and uncommon issues. Technical Data: Specifications, torque values, clearances, fluid capacities, component identification, and electrical resistance/voltage values. Maintenance Schedules: Recommended maintenance intervals for routine services (oil changes, filter replacements, etc.). Technical Depth Depth Of Coverage: Comprehensive from basic maintenance to advanced diagnostics and major component rebuilds. Suitable for professional technicians and experienced DIY enthusiasts. 📊 Manual Specifications File Format File Type: PDF Readability: Searchable text and printable pages (assumed for a quality digital manual). Compatibility: All Versions of Windows, Mac, and Linux. Print Quality Graphic Quality: High Quality Photos, Illustrations, and Diagrams. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: JB-DET Engine Type: Inline 3-cylinder, DOHC, 12-valve, turbocharged, intercooled petrol. Displacement: 659 cc (0.7 L) Performance Horsepower: 64 PS (47 kW; 63 hp) @ 6400 rpm (JDM regulated output) Torque: 10.5 kg⋅m (103 N⋅m; 76 lb⋅ft) @ 3200 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline (Octane rating as per market/manufacturer recommendation, typically 95 RON or higher for optimal performance) Engine Management ECU Type: Electronic Control Unit (specific model varies by year/market, but generally Denso or Hitachi based) 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transaxle Optional Transmission Type Optional: 4-speed Automatic Transaxle Features Drive Layout: Front-engine, Front-wheel drive (FF) Clutch Type: Dry, single-plate, diaphragm spring clutch (for manual transmission) 📐 Dimensions Exterior Length: 3,395 mm (133.7 in) Width: 1,475 mm (58.1 in) Height: 1,245 mm (49.0 in) Wheelbase: 2,280 mm (90 in) Weights Curb Weight Manual: Approx. 770 kg (1,698 lb) Curb Weight Automatic: Approx. 800 kg (1,764 lb) 🛡️ Safety Features Ratings Crash Test Ratings: Specific official crash test ratings (e.g., NHTSA, Euro NCAP) are limited due to its JDM focus and niche market. Generally designed to meet Japanese safety standards of the era. Active Features Active Safety Features: Optional ABS (Anti-lock Braking System), Power Assisted Brakes. Passive Features Passive Safety Features: Front airbags (driver and passenger), Seatbelts with pre-tensioners, Reinforced chassis structure for convertible safety. 💡 Technology Features Infotainment Infotainment Features: Basic AM/FM radio, CD player, and optional navigation systems were available. Speaker quality and screen size were typical for the era. Driver Assistance Driver Assistance Systems: Limited by modern standards. Primarily ABS (optional) and power steering. No advanced driver-assistance systems (ADAS) like...
L880K (primary for this generation, though variations exist)
Body Style:
2-door convertible coupe
Generation:
First Generation (JDM)
Codes
Chassis Code Range:
L880K
Engine Code Primary:
JB-DET
👋 Introduction
Market Position
Vehicle Segment:
Kei car segment (Japan), subcompact sports convertible globally.
Target Audience:
Enthusiasts, owners seeking to maintain or restore their vehicle, DIY mechanics.
Competitive Analysis
Key Competitors:
Honda Beat (previous generation), Suzuki Cappuccino (previous generation), later Mazda MX-5 Miata (though larger and different segment).
Key Features
Unique Selling Proposition:
Compact, stylish, affordable convertible with a turbocharged engine and a unique power retractable hardtop.
Manual Value Proposition:
Provides comprehensive, professional-grade repair information, enabling owners to perform maintenance and repairs efficiently and accurately, saving on labor costs and ensuring longevity.
Front Suspension (struts, control arms), Rear Suspension (multi-link), Road Wheels & Tires, Brake System (discs, calipers, lines), Parking Brake System, Brake Control Systems (ABS), Power Steering System, Steering System (rack and pinion)
Body Restraints:
Body Structure, Lock & Security System, Glasses, Window System & Mirrors, Roof Mechanism (power retractable hardtop), Exterior & Interior Trim, Instrument Panel, Seats, Seat Belts, Supplemental Restraint System (SRS/Airbags)
Electrical Climate:
Wiring Diagrams, Starting & Charging System (alternator, starter), Lighting System (headlights, taillights), Driver Information System (gauges, warning lights), Wiper, Washer & Horn, Body Control System (ECU functions), LAN System, Audio Visual, Navigation & Telephone System, Auto Cruise Control System, Power Supply, Ground & Circuit Elements, Air Conditioner System
Procedures Included
Repair Maintenance:
Detailed step-by-step repair and maintenance procedures for all covered systems, including diagnostics, disassembly, assembly, adjustment, and replacement.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting guides for common and uncommon issues.
Comprehensive from basic maintenance to advanced diagnostics and major component rebuilds. Suitable for professional technicians and experienced DIY enthusiasts.
📊 Manual Specifications
File Format
File Type:
PDF
Readability:
Searchable text and printable pages (assumed for a quality digital manual).
Unleaded Gasoline (Octane rating as per market/manufacturer recommendation, typically 95 RON or higher for optimal performance)
Engine Management
ECU Type:
Electronic Control Unit (specific model varies by year/market, but generally Denso or Hitachi based)
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transaxle
Optional
Transmission Type Optional:
4-speed Automatic Transaxle
Features
Drive Layout:
Front-engine, Front-wheel drive (FF)
Clutch Type:
Dry, single-plate, diaphragm spring clutch (for manual transmission)
📐 Dimensions
Exterior
Length:
3,395 mm (133.7 in)
Width:
1,475 mm (58.1 in)
Height:
1,245 mm (49.0 in)
Wheelbase:
2,280 mm (90 in)
Weights
Curb Weight Manual:
Approx. 770 kg (1,698 lb)
Curb Weight Automatic:
Approx. 800 kg (1,764 lb)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Specific official crash test ratings (e.g., NHTSA, Euro NCAP) are limited due to its JDM focus and niche market. Generally designed to meet Japanese safety standards of the era.
Active Features
Active Safety Features:
Optional ABS (Anti-lock Braking System), Power Assisted Brakes.
Passive Features
Passive Safety Features:
Front airbags (driver and passenger), Seatbelts with pre-tensioners, Reinforced chassis structure for convertible safety.
💡 Technology Features
Infotainment
Infotainment Features:
Basic AM/FM radio, CD player, and optional navigation systems were available. Speaker quality and screen size were typical for the era.
Driver Assistance
Driver Assistance Systems:
Limited by modern standards. Primarily ABS (optional) and power steering. No advanced driver-assistance systems (ADAS) like adaptive cruise control or lane keeping assist.
Connectivity
Connectivity Options:
Early Bluetooth phone integration might have been optional on later models. Primarily focused on basic audio and driver controls.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-10,000 km or 6-12 months, depending on driving conditions (refer to manual for exact specification).
Spark Plug Replacement:
Refer to manual; generally around 40,000-60,000 km for standard plugs, or 80,000-100,000 km for long-life iridium plugs (if fitted).
Fluid Specifications
Engine Oil Type:
Refer to manual for viscosity (e.g., 5W-30 or 0W-20 depending on climate) and API/ACEA specifications. Typically a synthetic or semi-synthetic blend is recommended for turbocharged engines.
Coolant Type:
Ethylene Glycol-based antifreeze, mixed with distilled water (typically 50/50 ratio). Use of Toyota Super Long Life Coolant (SLLC) or equivalent is recommended.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (check manual for specific recommendation).
Transmission Fluid Manual:
API GL-4 gear oil, viscosity typically 75W-90.
Transmission Fluid Automatic:
Dexron II/III or equivalent ATF (Automatic Transmission Fluid). Check manual for exact specification.
Oil consumption due to turbocharger wear, potential for carbon buildup in turbocharged engines if not maintained properly.
📚 Vehicle History
Brand Heritage
Daihatsu Specialization:
Daihatsu, a subsidiary of Toyota, has a long history of producing small, fuel-efficient vehicles, often excelling in the Kei car segment.
Model Evolution
Copen Concept:
The Copen was developed as a stylish and fun 'sporty Kei car' focusing on open-top driving enjoyment. It evolved from concepts shown in previous Tokyo Motor Shows.
Production
Production Period:
First generation produced from 2002 to 2012.
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Model Awards:
The Daihatsu Copen has been well-received for its unique design and driving fun, often winning accolades within the Kei car segment in Japan and gaining cult status internationally.
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