Daihatsu Terios 1997-1999 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Year: 1997-1999 Codes Chassis Code: J100 👋 Introduction Market Position Segment: Compact SUV / Mini SUV Target Audience: Enthusiasts, DIY mechanics, and small workshops seeking in-depth repair and maintenance information. Competitive Analysis Key Competitors: Suzuki Vitara, Honda CR-V (first generation), Toyota RAV4 (first generation), Mitsubishi Pajero Mini. Key Features Vehicle Attributes: Compact dimensions, available 4WD, rugged styling, practical for urban and light off-road use. 📋 Manual Details Coverage Areas Covered Regions: Global (with emphasis on markets where Terios was officially sold, often Japanese Domestic Market specifications). Page Count Estimated Page Count: Likely 500-1000+ pages (typical for comprehensive factory service manuals). Exact count not provided. Manual Type Type: Factory Service Repair Workshop Manual Language Language: Primarily English (with potential for Japanese diagrams or section headings if it's a translation). Format Format: Downloadable PDF File Format File Type: PDF Print Quality Quality: Digital PDF, quality dependent on original source. Typically high resolution for clear diagrams and text. Binding Type Binding: Not applicable (digital download) Paper Type Paper Type: Not applicable (digital download) 📖 Manual Coverage Systems Covered Engine Service: Detailed procedures for engine disassembly, assembly, diagnostics, and repair for applicable engine variants. Transmission Service: Coverage for manual and automatic transmission overhaul, clutch service, and drivetrain component repair. Suspension And Steering: Information on front and rear suspension components, steering system diagnosis, and alignment procedures. Brake System: Brake caliper service, disc and drum brake maintenance, hydraulic system bleeding, and ABS (if equipped) troubleshooting. Electrical System: Wiring diagrams, component testing, starter, alternator, battery service, lighting, and accessory electrical systems. Body And Chassis: Panel removal/installation, interior trim, door mechanisms, glass replacement, and structural component information. Heating Ventilation And Air Conditioning: HVAC system component testing, refrigerant handling (with safety warnings), and diagnostics. Fuel System: Fuel pump, injectors, fuel filter replacement, and fuel tank service. Cooling System: Radiator, thermostat, water pump service, and coolant flush procedures. Exhaust System: Muffler, catalytic converter, and exhaust pipe replacement and repair. Procedures Included Maintenance Procedures: Routine maintenance tasks such as oil changes, filter replacements, spark plug service, and belt inspections. Diagnostic Procedures: Troubleshooting guides, symptom-based diagnostics, and specific repair procedures for common faults. Repair Procedures: Step-by-step instructions for component removal, installation, and adjustment. Rebuild Procedures: Detailed instructions for engine and transmission overhauls, including specifications for critical components. Tightening Specifications: Torque values for critical fasteners across all vehicle systems. Technical Depth Diagnostic Capabilities: Covers both basic visual inspections and more advanced electrical testing and component diagnosis. Rebuild Level: Suitable for complete engine and transmission rebuilds, including detailed measurements and tolerances. Wiring Diagrams Detail: Comprehensive, often color-coded wiring diagrams for all electrical circuits. ⚙️ Engine Specifications Primary Engine Engine Code: G13B (for 1.3L), G15A (for 1.5L) Engine Type: Inline 4-cylinder, SOHC, 16-valve Displacement: 1298cc (1.3L) or 1498cc (1.5L) Performance Horsepower 1.3L: Approx. 70-75 PS (51-55 kW) at around 5500 rpm Torque 1.3L: Approx. 100-105 Nm (74-77 lb-ft) at around 3500 rpm Horsepower 1.5L: Approx. 90-95 PS (66-70 kW) at around 5500 rpm Torque 1.5L: Approx. 120-125 Nm (89-92 lb-ft) at around 3500 rpm Fuel System Induction: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Cooling System Coolant Type: Ethylene Glycol based coolant (e.g., Toyota Super Long Life Coolant or equivalent Japanese coolant specification). Lubrication Oil Viscosity: Typically 10W-30 or 5W-30 depending on climate (refer to manual for exact specification). 🔧 Transmission Standard Type: 5-speed Manual Transmission Optional Type: 4-speed Automatic Transmission Features Drive System: Available in Rear-Wheel Drive (RWD) and 4-Wheel Drive (4WD). Transmission Fluid Manual Fluid Type: API GL-4 Gear Oil, SAE 75W-90 or 80W-90 (refer to manual for precise specification). Automatic Fluid Type: Dexron III / Mercon equivalent automatic transmission fluid. 📐 Dimensions Exterior Length: Approx. 3,715 mm (146.3 in) Width: Approx. 1,620 mm (63.8 in) Height: Approx. 1,725 mm (67.9 in) (with roof rails) Wheelbase: Approx. 2,430 mm (95.7 in) Weights Curb Weight: Approx. 1000-1150 kg (2200-2535 lbs) depending on configuration. Gross Vehicle Weight Rating: Typically around 1500-1600 kg. Tire Size Standard Tire Size: Typically 205/70R15 or 205/65R16 (refer to manual for exact specification by trim and market). Wheel Specifications Bolt Pattern: 5x114.3 (5x4.5 inch) Center Bore: 67.1 mm 🛡️ Safety Features Ratings Safety Certifications: Varies by market. Primarily developed for Japanese Domestic Market (JDM) standards. Likely no extensive North American (NHTSA/IIHS) or European (Euro NCAP) crash test data available for this generation and market. Active Features Antilock Braking System: Optional ABS (Anti-lock Braking System) available on higher trims or specific markets. Four Wheel Drive System: Available 4WD system enhances traction and stability. Passive Features Airbags: Driver airbag standard. Passenger airbag optional or market-dependent. Seatbelts: 3-point seatbelts with pretensioners for front occupants; 2-point or 3-point for rear occupants depending on seating position. 💡 Technology Features Infotainment Audio System: Factory-fitted radio/cassette player or radio/CD player, with basic speaker configuration. Driver Assistance Traction Control: Not...
Panel removal/installation, interior trim, door mechanisms, glass replacement, and structural component information.
Heating Ventilation And Air Conditioning:
HVAC system component testing, refrigerant handling (with safety warnings), and diagnostics.
Fuel System:
Fuel pump, injectors, fuel filter replacement, and fuel tank service.
Cooling System:
Radiator, thermostat, water pump service, and coolant flush procedures.
Exhaust System:
Muffler, catalytic converter, and exhaust pipe replacement and repair.
Procedures Included
Maintenance Procedures:
Routine maintenance tasks such as oil changes, filter replacements, spark plug service, and belt inspections.
Diagnostic Procedures:
Troubleshooting guides, symptom-based diagnostics, and specific repair procedures for common faults.
Repair Procedures:
Step-by-step instructions for component removal, installation, and adjustment.
Rebuild Procedures:
Detailed instructions for engine and transmission overhauls, including specifications for critical components.
Tightening Specifications:
Torque values for critical fasteners across all vehicle systems.
Technical Depth
Diagnostic Capabilities:
Covers both basic visual inspections and more advanced electrical testing and component diagnosis.
Rebuild Level:
Suitable for complete engine and transmission rebuilds, including detailed measurements and tolerances.
Wiring Diagrams Detail:
Comprehensive, often color-coded wiring diagrams for all electrical circuits.
⚙️ Engine Specifications
Primary Engine
Engine Code:
G13B (for 1.3L), G15A (for 1.5L)
Engine Type:
Inline 4-cylinder, SOHC, 16-valve
Displacement:
1298cc (1.3L) or 1498cc (1.5L)
Performance
Horsepower 1.3L:
Approx. 70-75 PS (51-55 kW) at around 5500 rpm
Torque 1.3L:
Approx. 100-105 Nm (74-77 lb-ft) at around 3500 rpm
Horsepower 1.5L:
Approx. 90-95 PS (66-70 kW) at around 5500 rpm
Torque 1.5L:
Approx. 120-125 Nm (89-92 lb-ft) at around 3500 rpm
Fuel System
Induction:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Cooling System
Coolant Type:
Ethylene Glycol based coolant (e.g., Toyota Super Long Life Coolant or equivalent Japanese coolant specification).
Lubrication
Oil Viscosity:
Typically 10W-30 or 5W-30 depending on climate (refer to manual for exact specification).
🔧 Transmission
Standard
Type:
5-speed Manual Transmission
Optional
Type:
4-speed Automatic Transmission
Features
Drive System:
Available in Rear-Wheel Drive (RWD) and 4-Wheel Drive (4WD).
Transmission Fluid
Manual Fluid Type:
API GL-4 Gear Oil, SAE 75W-90 or 80W-90 (refer to manual for precise specification).
Automatic Fluid Type:
Dexron III / Mercon equivalent automatic transmission fluid.
📐 Dimensions
Exterior
Length:
Approx. 3,715 mm (146.3 in)
Width:
Approx. 1,620 mm (63.8 in)
Height:
Approx. 1,725 mm (67.9 in) (with roof rails)
Wheelbase:
Approx. 2,430 mm (95.7 in)
Weights
Curb Weight:
Approx. 1000-1150 kg (2200-2535 lbs) depending on configuration.
Gross Vehicle Weight Rating:
Typically around 1500-1600 kg.
Tire Size
Standard Tire Size:
Typically 205/70R15 or 205/65R16 (refer to manual for exact specification by trim and market).
Wheel Specifications
Bolt Pattern:
5x114.3 (5x4.5 inch)
Center Bore:
67.1 mm
🛡️ Safety Features
Ratings
Safety Certifications:
Varies by market. Primarily developed for Japanese Domestic Market (JDM) standards. Likely no extensive North American (NHTSA/IIHS) or European (Euro NCAP) crash test data available for this generation and market.
Active Features
Antilock Braking System:
Optional ABS (Anti-lock Braking System) available on higher trims or specific markets.
Four Wheel Drive System:
Available 4WD system enhances traction and stability.
Passive Features
Airbags:
Driver airbag standard. Passenger airbag optional or market-dependent.
Seatbelts:
3-point seatbelts with pretensioners for front occupants; 2-point or 3-point for rear occupants depending on seating position.
💡 Technology Features
Infotainment
Audio System:
Factory-fitted radio/cassette player or radio/CD player, with basic speaker configuration.
Driver Assistance
Traction Control:
Not typically available on this generation.
Connectivity
Auxiliary Input:
Unlikely to have standard auxiliary or USB inputs. Aftermarket upgrades are common.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Typically every 5,000 - 10,000 km (3,000 - 6,000 miles) or 6-12 months, whichever comes first (refer to manual for exact interval based on driving conditions).
Air Filter Replacement:
Every 15,000 - 30,000 km (9,000 - 18,000 miles) or as needed based on driving environment.
Spark Plug Replacement:
Typically every 30,000 - 60,000 km (18,000 - 36,000 miles) depending on spark plug type (standard or platinum).
Transmission Fluid Change:
Manual: Every 40,000 - 80,000 km (25,000 - 50,000 miles). Automatic: Every 30,000 - 60,000 km (18,000 - 36,000 miles).
Fluid Specifications
Engine Oil Capacity:
Approx. 3.5 - 4.0 liters (3.7 - 4.2 US quarts) with filter change (verify with manual).
Coolant Capacity:
Approx. 5.0 - 6.0 liters (5.3 - 6.3 US quarts) (verify with manual).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Common Wear Items:
Clutch wear, suspension bushings and ball joints, exhaust system components, and potential for rust on older models.
Engine Performance:
While generally reliable, some units may experience slight power loss over time or require attention to the ignition system.
Electrical Quirks:
As with many vehicles of this era, minor electrical gremlins can arise, particularly with aged wiring or grounds.
📚 Vehicle History
Brand Heritage
Daihatsu Specialization:
Daihatsu is a Japanese automobile manufacturer with a long history, often specializing in kei cars and small, practical vehicles.
Model Evolution
First Generation:
The Daihatsu Terios (also known as Toyota Cami in some markets) was introduced in 1997 as a compact SUV designed to be nimble and capable for its size.
Development Focus:
Developed as a response to the growing popularity of small SUVs and recreational vehicles, offering a more affordable and fuel-efficient alternative to larger SUVs.
Production
Manufacturing Location:
Primarily manufactured in Japan.
Production Period:
First generation (J100 series) produced from 1997 to 2000.
🏆 Awards & Recognition
Recognitions
Industry Awards:
Specific industry awards for the 1997-1999 Terios generation are not widely documented in major international automotive publications. It was generally well-regarded in its segment for practicality and affordability in its target markets.
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