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Daihatsu Hijet 1998-2010 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Hijet Generation Generation Code: Ninth Generation (S200/S210) Codes Chassis Codes: S200, S210 Series 👋 Introduction Market Position Vehicle Segment: Kei Truck / Commercial Van (primarily) Target Audience: Small business owners, tradespeople, agricultural users, and operators requiring compact, utilitarian transport. Competitive Analysis Key Competitors: Suzuki Carry, Subaru Sambar, Honda Acty (depending on specific market) Key Features Vehicle Attributes: Compact size, fuel efficiency, low operating costs, versatile cargo capabilities, robust and simple construction. Manual Benefits: Empowers owners/technicians to perform repairs, reduces reliance on dealerships, saves money on labor costs, enhances vehicle longevity. 📋 Manual Details Coverage Areas Model Years Covered: 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Market Coverage: Global (specific applicability may vary by region, but technical content is broadly applicable) Page Count Estimated Page Count: Extensive (specific count not provided, but described as 'complete Service Manual') Manual Type Type: Workshop Service Repair Manual Language Language: English Format Delivery Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Systems: Engine Mechanical, Fuel System, Ignition System, Lubrication System, Cooling System, Exhaust System Powertrain: Engine, Transmission (Manual & Automatic, if applicable), Clutch, Drivetrain (FWD/RWD/4WD) Chassis: Suspension (Front & Rear), Steering System, Brake System, Wheels & Tires Electrical: Electrical System (Wiring Diagrams, Components, Battery, Charging, Starting), Lighting, Instruments, Audio System, HVAC Electrical Body: Body Panels, Doors, Glass, Interior Trim, Seats, Bumpers, Exterior Trim HVAC: Heating, Ventilation, and Air Conditioning System Procedures Included Maintenance: Routine Maintenance, Service Intervals, Fluid Checks and Changes, Filter Replacements, Tune-Ups Repair Overhaul: Component Removal and Installation, Disassembly and Reassembly, Major Component Overhaul (Engine, Transmission) Diagnostics: Troubleshooting Guides, Symptom-Based Diagnostics, Diagnostic Trouble Codes (DTCs) if applicable Technical Adjustments: Wheel Alignment, Brake Adjustments, Engine Timing (if adjustable) Technical Depth Depth: Comprehensive (from basic maintenance to complete engine and transmission overhaul) Special Tools: Includes identification and use of specific Daihatsu tools and recommended special tools. 📊 Manual Specifications File Format Format: PDF Searchability: Likely searchable text within PDF for efficient information retrieval. Print Quality Printable: Yes Binding Type Type: Digital (N/A for physical binding) Paper Type Type: Digital (N/A for physical paper) Delivery Method: Fast and Free Electronic Delivery via Email ⚙️ Engine Specifications Primary Engine Engine Family: EB Series (likely EB0, EB2, or similar compact 3-cylinder engines) Displacement: Typically 660cc for JDM models, with potential for larger displacements in export markets (specifics depend on variant). Configuration: Inline 3-Cylinder, DOHC (Double Overhead Camshaft) or SOHC (Single Overhead Camshaft), naturally aspirated or turbocharged. Performance Horsepower Range: Approximately 40-64 HP (JDM regulations limit Kei cars to 64 PS). Export models may vary. Torque Range: Approximately 50-80 Nm (specifics vary by engine and tuning). Fuel System Induction Type: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline 🔧 Transmission Standard Type: 5-Speed Manual Transmission (MT) Optional Type: 3-Speed or 4-Speed Automatic Transmission (AT) (availability varies by model and market) Features Drive Layout: Rear-Wheel Drive (RWD) or All-Wheel Drive (4WD) options 📐 Dimensions Exterior Length: Typically under 3.4 meters (JDM Kei regulations). Export models may be longer. Width: Typically under 1.48 meters (JDM Kei regulations). Export models may be wider. Height: Varies by body style (e.g., panel van, truck, high-roof versions). Cargo Cargo Capacity: Significant for its size, especially in panel van and truck bed configurations. Weights Curb Weight: Typically 700-900 kg (depending on configuration). 🛡️ Safety Features Ratings Crash Test Ratings: Varies significantly by market and year. Early models may have limited modern safety features. Later models may incorporate basic airbags. Active Features Features: ABS (Anti-lock Braking System) may be available on higher trims or later models. Power steering on some variants. Passive Features Features: Seatbelts. Driver and passenger airbags (availability varies by market and trim). 💡 Technology Features Infotainment Audio System: Basic AM/FM radio with cassette or CD player common. Limited advanced infotainment features. Driver Assistance Assistance Features: Power steering on some models. Limited electronic driver aids. Connectivity Connectivity Options: Basic connectivity via auxiliary inputs if equipped. No modern smartphone integration. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 5,000 km or 6 months, whichever comes first (refer to manual for specific engine oil type). Air Filter Replacement: Every 15,000-20,000 km or as needed based on operating conditions. Spark Plug Replacement: Typically 40,000-60,000 km, depending on spark plug type (e.g., platinum). Fluid Specifications Engine Oil Type: API SG/SH/SJ or higher, SAE 10W-30 or 10W-40 is common. Consult manual for exact specification. Coolant Type: Ethylene Glycol based antifreeze/coolant, typically a 50/50 mix with distilled water. Transmission Fluid Type Manual: API GL-4 SAE 75W-85 or 75W-90 gear oil. Transmission Fluid Type Automatic: Dexron III/VI or equivalent ATF (Automatic Transmission Fluid). Known Issues Common Problems: Rust and corrosion (especially in certain climates), minor electrical gremlins, wear on suspension components due to heavy use, potential for oil leaks from seals. Engine Wear: Small displacement engines may experience...
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Daihatsu Hijet 1998-2010 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Hijet
Generation
Generation Code:
Ninth Generation (S200/S210)
Codes
Chassis Codes:
S200, S210 Series
👋 Introduction
Market Position
Vehicle Segment:
Kei Truck / Commercial Van (primarily)
Target Audience:
Small business owners, tradespeople, agricultural users, and operators requiring compact, utilitarian transport.
Competitive Analysis
Key Competitors:
Suzuki Carry, Subaru Sambar, Honda Acty (depending on specific market)
Key Features
Vehicle Attributes:
Compact size, fuel efficiency, low operating costs, versatile cargo capabilities, robust and simple construction.
Manual Benefits:
Empowers owners/technicians to perform repairs, reduces reliance on dealerships, saves money on labor costs, enhances vehicle longevity.
📋 Manual Details
Coverage Areas
Model Years Covered:
1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010
Market Coverage:
Global (specific applicability may vary by region, but technical content is broadly applicable)
Page Count
Estimated Page Count:
Extensive (specific count not provided, but described as 'complete Service Manual')
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Delivery Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine Mechanical, Fuel System, Ignition System, Lubrication System, Cooling System, Exhaust System
Powertrain:
Engine, Transmission (Manual & Automatic, if applicable), Clutch, Drivetrain (FWD/RWD/4WD)
Chassis:
Suspension (Front & Rear), Steering System, Brake System, Wheels & Tires
Electrical:
Electrical System (Wiring Diagrams, Components, Battery, Charging, Starting), Lighting, Instruments, Audio System, HVAC Electrical
Body:
Body Panels, Doors, Glass, Interior Trim, Seats, Bumpers, Exterior Trim
HVAC:
Heating, Ventilation, and Air Conditioning System
Procedures Included
Maintenance:
Routine Maintenance, Service Intervals, Fluid Checks and Changes, Filter Replacements, Tune-Ups
Repair Overhaul:
Component Removal and Installation, Disassembly and Reassembly, Major Component Overhaul (Engine, Transmission)
Diagnostics:
Troubleshooting Guides, Symptom-Based Diagnostics, Diagnostic Trouble Codes (DTCs) if applicable
Technical Adjustments:
Wheel Alignment, Brake Adjustments, Engine Timing (if adjustable)
Technical Depth
Depth:
Comprehensive (from basic maintenance to complete engine and transmission overhaul)
Special Tools:
Includes identification and use of specific Daihatsu tools and recommended special tools.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Likely searchable text within PDF for efficient information retrieval.
Print Quality
Printable:
Yes
Binding Type
Type:
Digital (N/A for physical binding)
Paper Type
Type:
Digital (N/A for physical paper)
Delivery
Method:
Fast and Free Electronic Delivery via Email
⚙️ Engine Specifications
Primary Engine
Engine Family:
EB Series (likely EB0, EB2, or similar compact 3-cylinder engines)
Displacement:
Typically 660cc for JDM models, with potential for larger displacements in export markets (specifics depend on variant).
Configuration:
Inline 3-Cylinder, DOHC (Double Overhead Camshaft) or SOHC (Single Overhead Camshaft), naturally aspirated or turbocharged.
Performance
Horsepower Range:
Approximately 40-64 HP (JDM regulations limit Kei cars to 64 PS). Export models may vary.
Torque Range:
Approximately 50-80 Nm (specifics vary by engine and tuning).
Fuel System
Induction Type:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
🔧 Transmission
Standard
Type:
5-Speed Manual Transmission (MT)
Optional
Type:
3-Speed or 4-Speed Automatic Transmission (AT) (availability varies by model and market)
Features
Drive Layout:
Rear-Wheel Drive (RWD) or All-Wheel Drive (4WD) options
📐 Dimensions
Exterior
Length:
Typically under 3.4 meters (JDM Kei regulations). Export models may be longer.
Width:
Typically under 1.48 meters (JDM Kei regulations). Export models may be wider.
Height:
Varies by body style (e.g., panel van, truck, high-roof versions).
Cargo
Cargo Capacity:
Significant for its size, especially in panel van and truck bed configurations.
Weights
Curb Weight:
Typically 700-900 kg (depending on configuration).
🛡️ Safety Features
Ratings
Crash Test Ratings:
Varies significantly by market and year. Early models may have limited modern safety features. Later models may incorporate basic airbags.
Active Features
Features:
ABS (Anti-lock Braking System) may be available on higher trims or later models. Power steering on some variants.
Passive Features
Features:
Seatbelts. Driver and passenger airbags (availability varies by market and trim).
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with cassette or CD player common. Limited advanced infotainment features.
Driver Assistance
Assistance Features:
Power steering on some models. Limited electronic driver aids.
Connectivity
Connectivity Options:
Basic connectivity via auxiliary inputs if equipped. No modern smartphone integration.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000 km or 6 months, whichever comes first (refer to manual for specific engine oil type).
Air Filter Replacement:
Every 15,000-20,000 km or as needed based on operating conditions.
Spark Plug Replacement:
Typically 40,000-60,000 km, depending on spark plug type (e.g., platinum).
Fluid Specifications
Engine Oil Type:
API SG/SH/SJ or higher, SAE 10W-30 or 10W-40 is common. Consult manual for exact specification.
Coolant Type:
Ethylene Glycol based antifreeze/coolant, typically a 50/50 mix with distilled water.
Transmission Fluid Type Manual:
API GL-4 SAE 75W-85 or 75W-90 gear oil.
Transmission Fluid Type Automatic:
Dexron III/VI or equivalent ATF (Automatic Transmission Fluid).
Known Issues
Common Problems:
Rust and corrosion (especially in certain climates), minor electrical gremlins, wear on suspension components due to heavy use, potential for oil leaks from seals.
Engine Wear:
Small displacement engines may experience increased wear if consistently operated at high RPMs or under heavy load.
📚 Vehicle History
Brand Heritage
Daihatsu Heritage:
Daihatsu is Japan's oldest surviving automobile manufacturer, known for producing small, fuel-efficient, and reliable vehicles.
Model Evolution
Hijet Evolution:
The Hijet is one of Daihatsu's longest-running nameplates, dating back to the 1960s. The S200 series represents a significant update with modern (for its time) styling and improved engineering.
Production
Manufacturing Locations:
Primarily Japan, with potential for assembly in other international locations depending on market.
🏆 Awards & Recognition
Recognitions
General Recognition:
The Hijet is consistently recognized for its durability, practicality, and value for money in the compact commercial vehicle segment globally.
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