Daihatsu Terios J100 1999 Full Service Repair Manual
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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Generation: J100 Year: 1999 Codes Chassis Code: J100 👋 Introduction Market Position Vehicle Segment: Compact SUV / Off-road vehicle Target Audience: Enthusiasts, DIY mechanics, owners seeking to maintain or repair their Terios. Competitive Analysis Competitors 1999: Suzuki Vitara, Honda CR-V (early models), Toyota RAV4 (early models), Mitsubishi Pajero Mini. Key Features Vehicle Appeal: Compact size, genuine off-road capability (often with selectable 4WD), affordability, reliability. 📋 Manual Details Coverage Areas Primary Focus: Service, Repair, Maintenance, Restoration Page Count Estimated Pages: Variable (often 500+ for full service manuals) Manual Type Type: Full Service Repair Manual Language Language: English Format Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine overhaul, fuel system, ignition system, exhaust system, cooling system, lubrication system. Drivetrain: Transmission (manual/automatic), clutch, drive shafts, differentials, transfer case (if applicable for 4WD). Suspension And Steering: Front suspension (MacPherson struts, control arms), rear suspension (multi-link, coil springs), steering gear, power steering system. Brakes: Front disc brakes, rear drum brakes (common for this era), ABS system (if equipped), hydraulic lines, parking brake. Electrical System: Battery, charging system (alternator), starting system, lighting, wiring diagrams, fuses, relays, ignition coils, ECU. Body And Chassis: Body panels, doors, interior trim, glass, chassis components, structural integrity, rust repair. Procedures Included Maintenance: Routine checks, fluid changes (oil, coolant, brake fluid), filter replacements, spark plug replacement, belt tensioning. Troubleshooting: Diagnostic fault codes, common symptoms and their causes, step-by-step diagnostic guides. Repair And Rebuild: Engine component replacement, transmission overhaul, brake caliper rebuilding, suspension part replacement, electrical component repair. Restoration: Guidance on refurbishing older components, bodywork restoration techniques, interior refurbishment. Specifications And Tolerances: Torque specifications, clearance measurements, timing settings, diagnostic parameters. Technical Depth Depth: Comprehensive, covering basic maintenance to complete engine and transmission rebuilds. Includes detailed diagnostic procedures and wiring diagrams. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Likely text-searchable, allowing quick access to specific information. Print Quality Print Readability: Designed for clear reproduction, with legible text and diagrams. Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code: H20A Engine Type: Inline 4-cylinder, DOHC (Dual Overhead Camshaft) Displacement: 1.6 Liters (1590 cc) Bore X Stroke: 76.0 mm x 87.5 mm Compression Ratio: 9.7:1 (approximate) Performance Horsepower: 90-93 HP (depending on market/tuning) Torque: 132-135 Nm (depending on market/tuning) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Fuel Octane Rating: 91 RON (Research Octane Number) or higher recommended 🔧 Transmission Standard Type: 5-Speed Manual Transmission Optional Type: 4-Speed Automatic Transmission Features Drivetrain Options: Selectable 4WD with high-range (4H) and low-range (4L) gears, or 2WD (RWD). Transmission Fluid Type Manual: API GL-4 SAE 75W-90 (or equivalent) Transmission Fluid Type Automatic: Dexron III or equivalent 📐 Dimensions Exterior Length: Approx. 3,720 mm Width: Approx. 1,690 mm Height: Approx. 1,705 mm (with roof rails) Wheelbase: Approx. 2,430 mm Ground Clearance: Approx. 190-200 mm Weights Curb Weight: Approx. 1,150 - 1,250 kg Gross Vehicle Weight Rating: Approx. 1,700 kg Towing Capacity: Not specified for most models, generally light duty. 🛡️ Safety Features Ratings Crash Test Results: Limited data available for this specific year/model from major agencies like NHTSA/Euro NCAP. Era of design may not reflect modern safety standards. Active Features ABS: Optional (Anti-lock Braking System) Four Wheel Drive: Often equipped with a robust 4WD system for off-road capability. Passive Features Airbags: Driver airbag standard, passenger airbag optional or market dependent. Seatbelts: 3-point seatbelts with pre-tensioners (front), 2-point lap belts (rear) or 3-point belts depending on configuration. Body Structure: Body-on-frame construction (common for J100) provides good durability and off-road resilience. 💡 Technology Features Infotainment Audio System: Basic AM/FM radio with cassette player or single-CD player. Limited speaker configuration. Display: Simple analog gauges and basic digital displays for odometer/trip meter. Driver Assistance Cruise Control: Optional, often found on higher trim levels. Connectivity Auxiliary Input: Generally not available on factory units of this era. 🔧 Maintenance Service Intervals Engine Oil Change: Every 5,000 - 10,000 km or 6-12 months, depending on driving conditions and oil type used. Air Filter Replacement: Every 20,000 - 30,000 km or as needed based on inspection. Spark Plug Replacement: Every 40,000 - 60,000 km (iridium plugs may last longer). Coolant Replacement: Every 2-4 years or 40,000-80,000 km. Timing Belt Replacement: Critical: Every 80,000 - 100,000 km or 5-7 years. Failure can cause catastrophic engine damage. Fluid Specifications Engine Oil Type: API SJ or SL, SAE 10W-30 or 5W-30 (check owner's manual for precise grade). Engine Oil Capacity: Approx. 3.8 - 4.0 Liters (with filter change). Coolant Type: Ethylene glycol based coolant, color may vary (e.g., green, pink). Use a 50/50 mix with distilled water. Brake Fluid Type: DOT 3 or DOT 4. Known Issues Timing Belt Wear: Premature wear or failure of the timing belt is a...
Comprehensive, covering basic maintenance to complete engine and transmission rebuilds. Includes detailed diagnostic procedures and wiring diagrams.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Likely text-searchable, allowing quick access to specific information.
Print Quality
Print Readability:
Designed for clear reproduction, with legible text and diagrams.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
H20A
Engine Type:
Inline 4-cylinder, DOHC (Dual Overhead Camshaft)
Displacement:
1.6 Liters (1590 cc)
Bore X Stroke:
76.0 mm x 87.5 mm
Compression Ratio:
9.7:1 (approximate)
Performance
Horsepower:
90-93 HP (depending on market/tuning)
Torque:
132-135 Nm (depending on market/tuning)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Fuel Octane Rating:
91 RON (Research Octane Number) or higher recommended
🔧 Transmission
Standard
Type:
5-Speed Manual Transmission
Optional
Type:
4-Speed Automatic Transmission
Features
Drivetrain Options:
Selectable 4WD with high-range (4H) and low-range (4L) gears, or 2WD (RWD).
Transmission Fluid Type Manual:
API GL-4 SAE 75W-90 (or equivalent)
Transmission Fluid Type Automatic:
Dexron III or equivalent
📐 Dimensions
Exterior
Length:
Approx. 3,720 mm
Width:
Approx. 1,690 mm
Height:
Approx. 1,705 mm (with roof rails)
Wheelbase:
Approx. 2,430 mm
Ground Clearance:
Approx. 190-200 mm
Weights
Curb Weight:
Approx. 1,150 - 1,250 kg
Gross Vehicle Weight Rating:
Approx. 1,700 kg
Towing Capacity:
Not specified for most models, generally light duty.
🛡️ Safety Features
Ratings
Crash Test Results:
Limited data available for this specific year/model from major agencies like NHTSA/Euro NCAP. Era of design may not reflect modern safety standards.
Active Features
ABS:
Optional (Anti-lock Braking System)
Four Wheel Drive:
Often equipped with a robust 4WD system for off-road capability.
Passive Features
Airbags:
Driver airbag standard, passenger airbag optional or market dependent.
Seatbelts:
3-point seatbelts with pre-tensioners (front), 2-point lap belts (rear) or 3-point belts depending on configuration.
Body Structure:
Body-on-frame construction (common for J100) provides good durability and off-road resilience.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with cassette player or single-CD player. Limited speaker configuration.
Display:
Simple analog gauges and basic digital displays for odometer/trip meter.
Driver Assistance
Cruise Control:
Optional, often found on higher trim levels.
Connectivity
Auxiliary Input:
Generally not available on factory units of this era.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000 - 10,000 km or 6-12 months, depending on driving conditions and oil type used.
Air Filter Replacement:
Every 20,000 - 30,000 km or as needed based on inspection.
Spark Plug Replacement:
Every 40,000 - 60,000 km (iridium plugs may last longer).
Coolant Replacement:
Every 2-4 years or 40,000-80,000 km.
Timing Belt Replacement:
Critical: Every 80,000 - 100,000 km or 5-7 years. Failure can cause catastrophic engine damage.
Fluid Specifications
Engine Oil Type:
API SJ or SL, SAE 10W-30 or 5W-30 (check owner's manual for precise grade).
Engine Oil Capacity:
Approx. 3.8 - 4.0 Liters (with filter change).
Coolant Type:
Ethylene glycol based coolant, color may vary (e.g., green, pink). Use a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Timing Belt Wear:
Premature wear or failure of the timing belt is a significant concern if maintenance is neglected.
Suspension Bushings:
Wear and tear on suspension bushings can lead to knocking noises and poor handling over time.
Rust And Corrosion:
As with many vehicles of this era, especially those used in regions with salt on roads, rust can be an issue on the undercarriage and body panels.
Clutch Wear:
The clutch can wear out over time, especially with frequent off-road use or stop-and-go traffic.
📚 Vehicle History
Brand Heritage
Daihatsu Focus:
Daihatsu, a subsidiary of Toyota, has a long history of producing compact, efficient, and often rugged vehicles.
Model Evolution
Terios J100 Introduction:
The J100 generation was introduced in 1997 and was designed as a compact, affordable, and capable off-road vehicle.
Terios J100 Facelifts:
Minor styling updates and feature enhancements occurred during its production run.
Production
Production Period:
1997-2006 (J100 generation)
Manufacturing Location:
Japan (primarily)
🏆 Awards & Recognition
Recognitions
Automotive Awards:
While specific awards for the 1999 Terios are not widely publicized, the model was recognized for its value, affordability, and compact off-road capability in various markets.
Ratings
Consumer Reports:
Consumer reports data from this era may be limited or vary by region. Focus tends to be on reliability and functionality over luxury or advanced features.
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