🏷️ Basic Information Identification Make: Daihatsu Model: Copen Generation Codes: L880 Chassis Codes: L880K Product Name: Daihatsu Copen Complete Workshop Service Repair Manual Applicable Model Years: 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012 👋 Introduction Market Position Vehicle Segment: Kei car convertible sports car Unique Selling Proposition: Compact, affordable, open-top sports car with distinctive styling. Competitive Analysis Key Competitors Of Era: While niche, direct competitors were limited. Primarily positioned against other small, fun-to-drive vehicles, and aspirational sports cars. Key Features Convertible Mechanism: Power-operated retractable hardtop, a significant feature for its class and era. Styling: Retro-inspired design with a focus on 'cute yet sporty' aesthetics. Manual Benefit: Empowers owners to perform maintenance and repairs, saving significant costs. 📋 Manual Details Coverage Areas Coverage Scope: All Models, Engines, Trim Levels, and Transmission Types Page Count Estimated Page Count: Extensive (exact number not specified, but described as 'complete' and 'A-Z') Manual Type Type: Complete Workshop Service Repair Manual Language Language: English (implied by marketing and typical manual language) Format Format: Downloadable Digital File Delivery Method: Instant Email Delivery 📖 Manual Coverage Systems Covered Engine Service And Repair: Detailed procedures for engine assembly, disassembly, troubleshooting, and overhaul. Transmission Service And Repair: Covers both automatic and manual transmission systems, including fluid changes, component repair, and troubleshooting. Drivetrain Service And Repair: Includes differentials, drive axles, and related components. Suspension And Steering Service And Repair: Detailed information on suspension components (struts, shocks, springs, bushings), steering rack, power steering system. Braking System Service And Repair: Covers disc and drum brakes, ABS systems, hydraulic lines, and parking brake. Cooling System Service And Repair: Radiator, water pump, thermostat, cooling fans, and coolant specifications. Fuel System Service And Repair: Fuel pump, injectors, fuel lines, fuel filter, and tank service. Exhaust System Service And Repair: Catalytic converter, mufflers, pipes, and exhaust manifold repairs. Electrical System Service And Repair: Includes battery, alternator, starter, lighting systems, wiring diagrams, and fuses. Climate Control Service And Repair: Air conditioning system, heater core, blower motor, and controls. Body And Chassis Service And Repair: Body panels, doors, convertible top mechanism, frame, and interior trim. Safety Systems Service And Repair: Airbags, seatbelts, and related safety components. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotation. Troubleshooting Guides: Diagnostic procedures for common and uncommon faults across all systems. Repair And Overhaul: Step-by-step instructions for component replacement, repair, and complete engine/transmission rebuilds. Technical Specifications: Torque specifications, tolerances, and measurement data for all components. Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems. Diagnostic Procedures: Guidance on using diagnostic tools and interpreting fault codes. Convertible Top Operation And Maintenance: Specific instructions for the Copen's electric retractable hardtop mechanism. Technical Depth Depth: Comprehensive, from basic maintenance to advanced diagnostics and full rebuilds. Visual Aids: Includes step-by-step instructions with pictures, enhancing ease of understanding. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Likely text-searchable PDF for quick information retrieval. Print Quality Printability: Printable on demand, allowing users to print specific sections or the entire manual. Binding Type Binding: Not applicable (digital download) Paper Type Paper Quality: Not applicable (digital download) Software Requirements Required Software: Adobe Reader (free, widely available) Device Compatibility Compatible Devices: All PC & MAC Computers, Tablets, Smartphones ⚙️ Engine Specifications Primary Engine Engine Code: JB-DET Engine Type: 659cc, 12-valve, DOHC, turbocharged, intercooled inline-3 cylinder Bore X Stroke: 62.0 mm x 73.7 mm Compression Ratio: 8.5:1 Performance Horsepower Ps At Rpm: 64 PS (47 kW) @ 6,400 rpm (Kei car regulations) Torque Nm At Rpm: 10.5 kg⋅m (103 N⋅m; 76 lb⋅ft) @ 3,200 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline Cooling System Cooling Type: Water-cooled 🔧 Transmission Standard Transmission Type: 4-speed automatic or 5-speed manual Optional Optional Transmission: 5-speed manual (often preferred for sporty driving) Features Drive Layout: Front-engine, Front-wheel drive (FF) Fluid Specifications Automatic Transmission Fluid: Refer to manual for specific ATF type (e.g., Dexron III equivalent) Manual Transmission Fluid: Refer to manual for specific gear oil specification (e.g., GL-4) 📐 Dimensions Exterior Length: Approx. 3,395 mm Width: Approx. 1,475 mm Height: Approx. 1,245 mm (roof up) Wheelbase: Approx. 2,070 mm Ground Clearance: Approx. 130 mm Weights Curb Weight: Approx. 820-850 kg (depending on transmission) Gross Vehicle Weight Rating: Not typically specified for Kei cars in the same way as larger vehicles. Towing Capacity: Not specified/recommended 🛡️ Safety Features Ratings Crash Test Ratings: Ratings vary by market and testing agency; detailed official ratings are scarce for Japanese Kei cars in international markets. Active Features Antilock Braking System ABS: Available on some models/trims Electronic Brakeforce Distribution Ebd: Often paired with ABS Passive Features Airbags: Driver and passenger airbags (standard on many models). Seatbelts: Three-point seatbelts with pre-tensioners Rollover Protection: Integrated roll bar structure within the windshield frame and behind the seats. 💡 Technology...
5-speed manual (often preferred for sporty driving)
Features
Drive Layout:
Front-engine, Front-wheel drive (FF)
Fluid Specifications
Automatic Transmission Fluid:
Refer to manual for specific ATF type (e.g., Dexron III equivalent)
Manual Transmission Fluid:
Refer to manual for specific gear oil specification (e.g., GL-4)
📐 Dimensions
Exterior
Length:
Approx. 3,395 mm
Width:
Approx. 1,475 mm
Height:
Approx. 1,245 mm (roof up)
Wheelbase:
Approx. 2,070 mm
Ground Clearance:
Approx. 130 mm
Weights
Curb Weight:
Approx. 820-850 kg (depending on transmission)
Gross Vehicle Weight Rating:
Not typically specified for Kei cars in the same way as larger vehicles.
Towing Capacity:
Not specified/recommended
🛡️ Safety Features
Ratings
Crash Test Ratings:
Ratings vary by market and testing agency; detailed official ratings are scarce for Japanese Kei cars in international markets.
Active Features
Antilock Braking System ABS:
Available on some models/trims
Electronic Brakeforce Distribution Ebd:
Often paired with ABS
Passive Features
Airbags:
Driver and passenger airbags (standard on many models).
Seatbelts:
Three-point seatbelts with pre-tensioners
Rollover Protection:
Integrated roll bar structure within the windshield frame and behind the seats.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/CD player with varying speaker configurations depending on trim.
Gauges And Displays:
Includes tachometer, speedometer, fuel gauge, and coolant temperature gauge. Some models may have additional driver information displays.
Driver Assistance
Power Steering:
Hydraulic power steering system.
Traction Control:
Available on some higher-spec models or as an option.
Connectivity
Factory Options:
Limited by modern standards; focus was on mechanical and basic comfort features.
🔧 Maintenance
Service Intervals
Engine Oil And Filter Change:
Typically every 5,000-10,000 km or 6-12 months (refer to manual for exact recommendation).
Air Filter Replacement:
Every 20,000-40,000 km or as needed based on operating conditions.
Spark Plug Replacement:
Typically every 40,000-60,000 km, depending on spark plug type (e.g., standard vs. iridium).
Timing Belt Replacement:
The JB-DET uses a timing chain, which generally does not require regular replacement unless issues arise.
Fluid Specifications
Engine Oil Capacity:
Approx. 3.7 liters (with filter change)
Engine Oil Viscosity:
Refer to manual for recommended viscosity grade (e.g., 5W-30, 10W-30 depending on climate).
Coolant Capacity:
Approx. 4.5 liters
Coolant Type:
Ethylene glycol based antifreeze, typically pink or red in color.
Known Issues
Turbocharger Wear:
Like all turbocharged engines, oil starvation or contamination can lead to turbo failure. Regular maintenance is crucial.
Convertible Top Mechanism:
Potential for hydraulic leaks or motor failure in the retractable hardtop system; requires regular inspection and lubrication.
Ignition Coils:
Individual coil-on-plug ignition systems can sometimes develop faults, leading to misfires.
Oxygen Sensors:
Can degrade over time, affecting fuel economy and emissions.
📚 Vehicle History
Brand Heritage
Daihatsu Focus:
Daihatsu is Japan's oldest car manufacturer, known for producing small, efficient, and affordable vehicles (Kei cars).
Model Evolution
First Generation Launch:
The L880 generation Copen was launched in 2002 in Japan, succeeding the L880K prototype.
Market Availability:
Primarily sold in Japan, with limited official exports to markets like the UK, Australia, and some parts of Europe.
Production
Production Period:
2002-2012 for the L880 generation covered by this manual.
Production Location:
Japan
🏆 Awards & Recognition
Recognitions
Kei Car Design Awards:
Often lauded for its unique and appealing design within the Kei car segment. Specific awards not readily documented but it was a popular and distinctive model.
Ratings
Customer Satisfaction:
Generally positive among owners who appreciate its niche appeal and driving experience.
Certifications
Japanese Kei Car Compliance:
Meets Japanese Kei car regulations for engine size, dimensions, and power output.
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