2004-2010 Daihatsu Sirion (Boon) M300 Series Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Sirion (Boon) Chassis Code: M300 Series Production Years Covered: 2004, 2005, 2006, 2007, 2008, 2009, 2010 Codes Internal Model Code: M300 👋 Introduction Market Position Market Segment: Subcompact hatchback/MPV, often marketed as an economical and practical city car. Target Audience: Ideal for budget-conscious buyers, first-time car owners, small families, and individuals seeking an economical and reliable mode of transportation for daily commuting and city driving. Competitive Analysis Competitors: Toyota Yaris, Honda Fit/Jazz, Suzuki Swift, Mitsubishi Colt/Mirage, Ford Fiesta, Renault Clio. Key Features Value Proposition: Offers exceptional value for money, compact dimensions ideal for urban environments, surprising interior space, and reliable Japanese engineering. The M300 series represents a significant evolution in the model's design and features. Diy Benefit: Empowers owners to perform their own repairs and maintenance, saving significant costs on labor and potentially extending the vehicle's lifespan. The clear, step-by-step instructions make complex tasks manageable for novice DIYers. 📋 Manual Details Coverage Areas Covered Models Trims: All models and all engines of the M300 Series Sirion/Boon Page Count Page Count: Not Specified (Comprehensive) Manual Type Manual Type: Workshop Repair Service Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Systems: General Information, Body, Frame & Mounting, Engine, Suspension, Driveline, Brake System, Transmission/Transaxle, Clutch, Chains, Exhaust, Fuel, Steering, Shocks, Climate Control, Instrumentation & Warnings Systems, Battery & Charging Systems, Audio, Lighting, Electrical Distribution, Wiring Electrical Systems: Includes Battery & Charging Systems, Lighting, Electrical Distribution, and comprehensive Wiring Diagrams. Crucial for diagnosing electrical faults. Body And Frame: Detailed procedures for Body, Frame & Mounting, including panel repairs, adjustments, and structural integrity checks. Climate Control: Comprehensive coverage of the Air Conditioning (A/C) system, including service, charging capacities, and troubleshooting for both cooling and heating functions. Procedures Included Repair Procedures: Engine Overhaul and Rebuilding, Brakes, Sunroof, Timing Belt Replacement, Troubleshooting and Diagnostics, Computer Diagnostic Trouble Tree Charts, Engine Performance, Front End and Alignment Procedures, Suspension, Transmission Removal and Installation, Air Conditioning Service, Transmission In Car Servicing, Firing Orders, Serpentine Belt Routings, Timing Belt Service, Brake Servicing, U-Joint and CV-Joint Service, Driving Concerns, Torque Specifications, Repair Procedures, Vacuum Diagrams Engine Maintenance: Engine Overhaul and Rebuilding, Engine Performance tuning, Firing Orders, Serpentine Belt Routings, Timing Belt Service Procedures, Vacuum Diagrams, Trouble Codes, Computer Diagnostic Trouble Tree Charts. Driveline Service: Includes Driveline components, U-Joint and CV-Joint service procedures, ensuring proper maintenance of power transfer. Brake System Service: Detailed Brake Servicing Procedures, including disc and drum brake maintenance, bleeding procedures, and component replacement. Essential for safety. Technical Depth Depth: Comprehensive (A-Z), detailed illustrations, exploded diagrams, drawings, photos, step-by-step instructions, factory maintenance schedules, computer diagnostic codes, trouble codes Diagnostic Capabilities: Detailed troubleshooting procedures for engine, transmission, brakes, electrical, and climate control systems, including specific diagnostic trouble codes (DTCs) and diagnostic flowcharts. Illustrations Diagrams: Hundreds of high-quality illustrations, exploded diagrams, and photographs that visually guide the user through complex repair and maintenance tasks, simplifying understanding. Wiring Diagrams Completeness: Complete wiring diagrams are included, which is critical for diagnosing electrical system issues, ensuring correct component function, and safely performing electrical repairs. 📊 Manual Specifications File Format File Format: PDF System Compatibility: Viewable on all versions of Windows, Mac, iOS, BB, Android, etc. Requires a PDF reader. Searchability: PDF format allows for easy searching of specific terms, greatly aiding in quick information retrieval for repairs. Print Quality Print Quality: High Quality, Printable pages Binding Type Binding Type: Digital Download (No Physical Binding) Paper Type Paper Type: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Options: Primarily features the 1KR-FE 1.0L (998cc) 3-cylinder engine (often with VVT-i) and the K3-VE 1.3L (1298cc) 4-cylinder engine. The manual covers all engines included in the M300 series for the specified years. 1Kr-Fe Engine Notes: A compact and fuel-efficient 1.0-liter, three-cylinder engine known for its simplicity and good urban performance. Features Daihatsu's VVT-i (Variable Valve Timing with intelligence) for improved efficiency and power delivery. K3-Ve Engine Notes: A slightly larger and more powerful 1.3-liter, four-cylinder engine offering enhanced performance and smoother operation compared to the 1.0L, making it suitable for highway driving. Performance 1Kr-Fe Output: Typically around 69 PS (68 hp; 51 kW) and 93 Nm (69 lb-ft) torque. Specific output may vary slightly by market and year. (Manual will detail exact figures). K3-Ve Output: Typically around 87 PS (86 hp; 64 kW) and 120 Nm (89 lb-ft) torque. Specific output may vary slightly by market and year. (Manual will detail exact figures). Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI). Fuel Type: Unleaded Gasoline. 🔧 Transmission Standard Standard Transmission: 5-speed Manual Transmission (M/T). Optional Optional Transmission: 4-speed Automatic Transmission (A/T) or Continuously Variable Transmission (CVT) depending on market and specific model variant. Features Drive Type: Front-Wheel Drive (FWD). All-Wheel Drive (AWD) was also available on some variants, particularly in Japan (Boon). Transmission Fluid Type: Manual transmissions...

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Description

🏷️ Basic Information

Identification

Make:

Daihatsu

Model:

Sirion (Boon)

Chassis Code:

M300 Series

Production Years Covered:

2004, 2005, 2006, 2007, 2008, 2009, 2010

Codes

Internal Model Code:

👋 Introduction

Market Position

Market Segment:

Subcompact hatchback/MPV, often marketed as an economical and practical city car.

Target Audience:

Ideal for budget-conscious buyers, first-time car owners, small families, and individuals seeking an economical and reliable mode of transportation for daily commuting and city driving.

Competitive Analysis

Competitors:

Toyota Yaris, Honda Fit/Jazz, Suzuki Swift, Mitsubishi Colt/Mirage, Ford Fiesta, Renault Clio.

Key Features

Value Proposition:

Offers exceptional value for money, compact dimensions ideal for urban environments, surprising interior space, and reliable Japanese engineering. The M300 series represents a significant evolution in the model's design and features.

Diy Benefit:

Empowers owners to perform their own repairs and maintenance, saving significant costs on labor and potentially extending the vehicle's lifespan. The clear, step-by-step instructions make complex tasks manageable for novice DIYers.

📋 Manual Details

Coverage Areas

Covered Models Trims:

All models and all engines of the M300 Series Sirion/Boon

Page Count

Page Count:

Not Specified (Comprehensive)

Manual Type

Manual Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Systems:

General Information, Body, Frame & Mounting, Engine, Suspension, Driveline, Brake System, Transmission/Transaxle, Clutch, Chains, Exhaust, Fuel, Steering, Shocks, Climate Control, Instrumentation & Warnings Systems, Battery & Charging Systems, Audio, Lighting, Electrical Distribution, Wiring

Electrical Systems:

Includes Battery & Charging Systems, Lighting, Electrical Distribution, and comprehensive Wiring Diagrams. Crucial for diagnosing electrical faults.

Body And Frame:

Detailed procedures for Body, Frame & Mounting, including panel repairs, adjustments, and structural integrity checks.

Climate Control:

Comprehensive coverage of the Air Conditioning (A/C) system, including service, charging capacities, and troubleshooting for both cooling and heating functions.

Procedures Included

Repair Procedures:

Engine Overhaul and Rebuilding, Brakes, Sunroof, Timing Belt Replacement, Troubleshooting and Diagnostics, Computer Diagnostic Trouble Tree Charts, Engine Performance, Front End and Alignment Procedures, Suspension, Transmission Removal and Installation, Air Conditioning Service, Transmission In Car Servicing, Firing Orders, Serpentine Belt Routings, Timing Belt Service, Brake Servicing, U-Joint and CV-Joint Service, Driving Concerns, Torque Specifications, Repair Procedures, Vacuum Diagrams

Engine Maintenance:

Engine Overhaul and Rebuilding, Engine Performance tuning, Firing Orders, Serpentine Belt Routings, Timing Belt Service Procedures, Vacuum Diagrams, Trouble Codes, Computer Diagnostic Trouble Tree Charts.

Driveline Service:

Includes Driveline components, U-Joint and CV-Joint service procedures, ensuring proper maintenance of power transfer.

Brake System Service:

Detailed Brake Servicing Procedures, including disc and drum brake maintenance, bleeding procedures, and component replacement. Essential for safety.

Technical Depth

Depth:

Comprehensive (A-Z), detailed illustrations, exploded diagrams, drawings, photos, step-by-step instructions, factory maintenance schedules, computer diagnostic codes, trouble codes

Diagnostic Capabilities:

Detailed troubleshooting procedures for engine, transmission, brakes, electrical, and climate control systems, including specific diagnostic trouble codes (DTCs) and diagnostic flowcharts.

Illustrations Diagrams:

Hundreds of high-quality illustrations, exploded diagrams, and photographs that visually guide the user through complex repair and maintenance tasks, simplifying understanding.

Wiring Diagrams Completeness:

Complete wiring diagrams are included, which is critical for diagnosing electrical system issues, ensuring correct component function, and safely performing electrical repairs.

📊 Manual Specifications

File Format

File Format:

System Compatibility:

Viewable on all versions of Windows, Mac, iOS, BB, Android, etc. Requires a PDF reader.

Searchability:

PDF format allows for easy searching of specific terms, greatly aiding in quick information retrieval for repairs.

Print Quality

Print Quality:

High Quality, Printable pages

Binding Type

Binding Type:

Digital Download (No Physical Binding)

Paper Type

Paper Type:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Options:

Primarily features the 1KR-FE 1.0L (998cc) 3-cylinder engine (often with VVT-i) and the K3-VE 1.3L (1298cc) 4-cylinder engine. The manual covers all engines included in the M300 series for the specified years.

1Kr-Fe Engine Notes:

A compact and fuel-efficient 1.0-liter, three-cylinder engine known for its simplicity and good urban performance. Features Daihatsu's VVT-i (Variable Valve Timing with intelligence) for improved efficiency and power delivery.

K3-Ve Engine Notes:

A slightly larger and more powerful 1.3-liter, four-cylinder engine offering enhanced performance and smoother operation compared to the 1.0L, making it suitable for highway driving.

Performance

1Kr-Fe Output:

Typically around 69 PS (68 hp; 51 kW) and 93 Nm (69 lb-ft) torque. Specific output may vary slightly by market and year. (Manual will detail exact figures).

K3-Ve Output:

Typically around 87 PS (86 hp; 64 kW) and 120 Nm (89 lb-ft) torque. Specific output may vary slightly by market and year. (Manual will detail exact figures).

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI).

Fuel Type:

Unleaded Gasoline.

🔧 Transmission

Standard

Standard Transmission:

5-speed Manual Transmission (M/T).

Optional

Optional Transmission:

4-speed Automatic Transmission (A/T) or Continuously Variable Transmission (CVT) depending on market and specific model variant.

Features

Drive Type:

Front-Wheel Drive (FWD). All-Wheel Drive (AWD) was also available on some variants, particularly in Japan (Boon).

Transmission Fluid Type:

Manual transmissions typically require API GL-4 gear oil (e.g., 75W-90). Automatic transmissions require specific ATF (Automatic Transmission Fluid), such as Dexron III or equivalent. Manual specifies exact types and capacities.

📐 Dimensions

Exterior

Overall Length:

Approximately 3610-3670 mm (142.1-144.5 inches), depending on model variant and bumper design.

Overall Width:

Approximately 1665 mm (65.6 inches).

Overall Height:

Approximately 1550 mm (61.0 inches).

Weights

Curb Weight:

Ranges from approximately 900 kg to 1050 kg (1984 lbs to 2315 lbs), depending on engine, transmission, and trim level.

Towing Capacity:

Not designed for towing. The manual will not contain towing specifications.

Interior

Passenger Capacity:

Typically seats 4-5 passengers, with a surprisingly spacious cabin for its exterior dimensions, a hallmark of the Daihatsu design philosophy for small cars.

Cargo

Cargo Volume:

Variable depending on seat configuration, but designed for practicality with foldable rear seats to maximize cargo space for a subcompact.

🛡️ Safety Features

Ratings

Ncap Rating:

Achieved 4 stars in Euro NCAP for the M300 series (e.g., 2005 assessment), indicating a good level of occupant protection for its class.

Active Features

Active Safety:

Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Brake Assist (BA) were available on higher trims or as optional equipment. The manual will detail specific availability.

Passive Features

Passive Safety:

Driver and front passenger airbags were standard. Side airbags and curtain airbags were available on higher trim levels. Seatbelt pretensioners and load limiters.

Seatbelts:

3-point seatbelts with pretensioners and force limiters for front occupants. 3-point or 2-point seatbelts for rear occupants depending on seating position and market.

💡 Technology Features

Infotainment

Audio System:

Basic 2-DIN or single-DIN audio systems with AM/FM radio and CD player were common. Higher trims might have offered MP3 playback or auxiliary input jacks. Manual covers audio system removal and installation.

Speaker Configuration:

Typically a 2-speaker or 4-speaker setup on base models. Higher trims might have offered additional speakers. Manual covers speaker replacement.

Driver Assistance

Driver Aids:

Limited advanced driver-assistance systems. Focus was on core safety features like ABS. Parking sensors might have been available on certain trims. The manual details any electronic control systems.

Connectivity

Connectivity Options:

Basic auxiliary input for audio devices. No Bluetooth or USB connectivity typically standard on base models during this era.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 15,000 km (9,300 miles) or 12 months, whichever comes first. Refer to the manual for precise intervals based on driving conditions and specific engine oil type.

Timing Belt Interval:

The 1KR-FE engine uses a timing chain, which is generally considered maintenance-free for the life of the engine, though inspection is recommended. The K3-VE engine uses a timing belt, typically requiring replacement every 100,000 km (60,000 miles) or 5 years. The manual provides detailed replacement procedures.

Air Filter Replacement:

Recommended every 30,000 km (18,000 miles) or 24 months, or more frequently in dusty conditions. Manual provides part numbers and replacement procedures.

Spark Plug Replacement:

For the 1KR-FE, typically iridium-tipped spark plugs are used with a replacement interval of around 100,000 km (60,000 miles). The K3-VE may use different plugs with varying intervals. Manual will specify plug type and torque.

Fluid Specifications

Engine Oil Spec:

API SN/SP or ILSAC GF-5/GF-6 compliant synthetic oil, typically SAE 0W-20 or 5W-30. Manual specifies exact viscosity and capacity based on engine. Example: 1KR-FE capacity ~3.1 L with filter.

Coolant Spec:

Toyota Super Long Life Coolant (SLLC) or equivalent ethylene glycol-based coolant with organic acid technology (OAT). Manual specifies capacity and mixing ratio.

Brake Fluid Spec:

DOT 3 or DOT 4 brake fluid. Manual will specify the exact type recommended and required for optimal braking performance and system longevity.

Power Steering Fluid Spec:

If equipped with power steering (often electric power steering in later models, but hydraulic systems may exist), the manual will specify the correct fluid type. For electric power steering, no fluid is typically required. Manual will clarify.

Known Issues

Common Problems:

Potential issues can include ignition coil failures, minor oil leaks from seals, wear on suspension components due to city driving, and occasional transmission control module (TCM) faults in automatics. The manual offers diagnostic guidance for these and more.

Suspension Wear:

Strut mounts, ball joints, and tie rod ends can wear over time, especially in vehicles used extensively in urban environments with poor road surfaces. The manual provides inspection and replacement procedures.

📚 Vehicle History

Brand Heritage

Daihatsu Legacy:

Daihatsu, a subsidiary of Toyota, is known for producing small, economical, and reliable vehicles, often with innovative packaging and robust engineering for their class.

Model Evolution

M300 Generation:

The M300 Series (introduced in 2004, replacing the M100 series) was a significant redesign featuring a more modern, rounded styling and a focus on improved interior space and versatility, particularly for a subcompact vehicle. It shared its platform with the Toyota Passo and Subaru Justy in some markets.

Engine Variations M300:

While 1.0L and 1.3L were most common globally, some markets might have received variations or specific engine codes. The manual aims for comprehensive coverage of all engine options offered within the M300 series production run.

Production

Manufacturing Location:

Primarily manufactured in Japan.

🏆 Awards & Recognition

Recognitions

Industry Awards:

While specific major awards for the M300 series are not widely documented, it consistently received praise for its practicality, fuel efficiency, and value in the subcompact segment in various automotive publications and consumer surveys in its target markets.