Daihatsu Terios J100 1999 All Service Repair Manual
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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Generation: J100 Year: 1999 Codes Chassis Code: J100G, J102G, J122G 👋 Introduction Market Position Vehicle Class: Mini SUV / Compact SUV / Kei SUV (in some markets) Target Audience: Consumers seeking a compact, capable, and affordable 4WD vehicle for light off-roading, urban driving, and general utility. Competitive Analysis Key Competitors 1999: Suzuki Vitara, Mitsubishi Pajero Mini, Toyota RAV4 (older generation), Honda CR-V (older generation) Key Features Offroad Capability: Part-time 4WD system with low-range gearing (on some variants), compact dimensions, and good ground clearance for its class. Versatility: Practical interior with foldable rear seats for cargo, suitable for light utility and outdoor activities. Affordability: Known for its economical price point and relatively low running costs. 📋 Manual Details Coverage Areas Engine Coverage: 1.3L (1300cc) K3-VE, K3-VET (Turbocharged) Transmission Coverage: 5-Speed Manual, 4-Speed Automatic Drivetrain Coverage: 4WD (Part-time) Body Style Coverage: 3-Door Hardtop SUV Page Count Estimated Pages: Approximately 800-1200 (typical for comprehensive service manuals of this era) Manual Type Manual Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical (K3-VE, K3-VET), Fuel system, Ignition system, Exhaust system, Cooling system, Lubrication system, Turbocharger system (K3-VET) Transmission Drivetrain: Manual transmission, Automatic transmission, Transfer case, Driveshafts, Differentials (Front, Center, Rear) Chassis Suspension: Front suspension (MacPherson strut), Rear suspension (3-link live axle), Steering system (Power assisted rack and pinion), Wheel bearings, Hubs Brakes: Front disc brakes, Rear drum brakes, Parking brake system, Brake hydraulics, ABS (if equipped) Electrical: Battery, Charging system (Alternator), Starting system (Starter motor), Lighting system (Headlights, taillights, interior), Fuses, Relays, Wiring diagrams, Engine Control Unit (ECU), Sensors, Actuators Body Interior Exterior: Body panels, Doors, Hood, Tailgate, Bumpers, Seats, Trim, Dashboard, HVAC (Heating, Ventilation, Air Conditioning) system Procedures Included Maintenance Procedures: Oil and filter changes, Air filter replacement, Spark plug replacement, Coolant flush and replacement, Brake fluid replacement, Transmission fluid changes, Differential oil changes, Belt inspection and replacement Repair Procedures: Engine overhaul, Cylinder head removal/installation, Piston and connecting rod service, Crankshaft service, Turbocharger repair/replacement, Transmission overhaul, Clutch replacement, Differential rebuild, Suspension component replacement, Brake caliper and drum service, Power steering system repair, Starter and alternator testing/replacement, ECU diagnostics and replacement Troubleshooting Guides: Diagnostic flowcharts for common symptoms (e.g., no-start, rough running, poor performance), Fault code interpretation, Electrical system diagnosis Technical Specifications: Torque specifications for all fasteners, Engine timing procedures, Valve clearance adjustments, Diagnostic trouble codes (DTCs), Electrical resistance values, Fluid capacities and types Technical Depth Depth: Comprehensive: Covers routine maintenance, scheduled servicing, diagnostics, component removal, installation, rebuilding, and troubleshooting for all major vehicle systems. 📊 Manual Specifications File Format File Format: PDF Searchable Text: Yes (typically, depending on original scan quality) Print Quality Printability: Printable (designed for home or shop printing) Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code 1: K3-VE Engine Type 1: Inline 4-cylinder, DOHC, 16-valve Displacement 1: 1298 cc (1.3 Liters) Bore X Stroke 1: 72.0 mm x 79.7 mm Compression Ratio 1: 9.5:1 Horsepower 1: 88 hp @ 6000 rpm (approx.) Torque 1: 115 Nm @ 3200 rpm (approx.) Optional Engine Engine Code 2: K3-VET (Turbocharged) Engine Type 2: Inline 4-cylinder, DOHC, 16-valve, Turbocharged Displacement 2: 1298 cc (1.3 Liters) Horsepower 2: 105 hp @ 6000 rpm (approx.) Torque 2: 135 Nm @ 3200 rpm (approx.) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (RON 91 or higher recommended) Engine Management ECU Type: Electronic Control Unit (ECU) with OBD-II interface (specific implementation may vary by market) 🔧 Transmission Standard Transmission Type Standard: 5-Speed Manual Transmission Optional Transmission Type Optional: 4-Speed Automatic Transmission Features Drivetrain Layout: Part-time 4WD with selectable 2WD/4WD High/4WD Low Clutch Type: Single dry plate diaphragm spring clutch (Manual) Fluid Specifications Manual Transmission Fluid: API GL-4, SAE 75W-90 (Check manual for specific part number/recommendation) Automatic Transmission Fluid: Dexron III or equivalent (Check manual for specific part number/recommendation) 📐 Dimensions Exterior Length: 3,675 mm (approx.) Width: 1,580 mm (approx.) Height: 1,695 mm (approx.) Wheelbase: 2,235 mm (approx.) Ground Clearance: 195 mm (approx.) Weights Curb Weight: 1,050 - 1,150 kg (depending on transmission and options) Gross Vehicle Weight Rating Gvwr: Approx. 1,550 kg Cargo Cargo Volume: Varies with rear seats up/down. Adequate for its class. 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Vehicle is from an era where standardized global ratings were less common, especially for smaller, niche vehicles. Refer to specific market reports if available.) Active Features ABS: Available on some higher trims/markets Passive Features Airbags: Driver airbag standard, Passenger airbag optional on some variants. Seatbelts: 3-point seatbelts with pretensioners (front), 2-point or 3-point rear seatbelts. Construction Body On Frame: Body-on-frame construction, typical for robust small SUVs of the era. 💡 Technology Features Infotainment Audio System: Factory fitted...
Battery, Charging system (Alternator), Starting system (Starter motor), Lighting system (Headlights, taillights, interior), Fuses, Relays, Wiring diagrams, Engine Control Unit (ECU), Sensors, Actuators
Body Interior Exterior:
Body panels, Doors, Hood, Tailgate, Bumpers, Seats, Trim, Dashboard, HVAC (Heating, Ventilation, Air Conditioning) system
Procedures Included
Maintenance Procedures:
Oil and filter changes, Air filter replacement, Spark plug replacement, Coolant flush and replacement, Brake fluid replacement, Transmission fluid changes, Differential oil changes, Belt inspection and replacement
Repair Procedures:
Engine overhaul, Cylinder head removal/installation, Piston and connecting rod service, Crankshaft service, Turbocharger repair/replacement, Transmission overhaul, Clutch replacement, Differential rebuild, Suspension component replacement, Brake caliper and drum service, Power steering system repair, Starter and alternator testing/replacement, ECU diagnostics and replacement
Troubleshooting Guides:
Diagnostic flowcharts for common symptoms (e.g., no-start, rough running, poor performance), Fault code interpretation, Electrical system diagnosis
Technical Specifications:
Torque specifications for all fasteners, Engine timing procedures, Valve clearance adjustments, Diagnostic trouble codes (DTCs), Electrical resistance values, Fluid capacities and types
Technical Depth
Depth:
Comprehensive: Covers routine maintenance, scheduled servicing, diagnostics, component removal, installation, rebuilding, and troubleshooting for all major vehicle systems.
📊 Manual Specifications
File Format
File Format:
PDF
Searchable Text:
Yes (typically, depending on original scan quality)
Print Quality
Printability:
Printable (designed for home or shop printing)
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
K3-VE
Engine Type 1:
Inline 4-cylinder, DOHC, 16-valve
Displacement 1:
1298 cc (1.3 Liters)
Bore X Stroke 1:
72.0 mm x 79.7 mm
Compression Ratio 1:
9.5:1
Horsepower 1:
88 hp @ 6000 rpm (approx.)
Torque 1:
115 Nm @ 3200 rpm (approx.)
Optional Engine
Engine Code 2:
K3-VET (Turbocharged)
Engine Type 2:
Inline 4-cylinder, DOHC, 16-valve, Turbocharged
Displacement 2:
1298 cc (1.3 Liters)
Horsepower 2:
105 hp @ 6000 rpm (approx.)
Torque 2:
135 Nm @ 3200 rpm (approx.)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (RON 91 or higher recommended)
Engine Management
ECU Type:
Electronic Control Unit (ECU) with OBD-II interface (specific implementation may vary by market)
🔧 Transmission
Standard
Transmission Type Standard:
5-Speed Manual Transmission
Optional
Transmission Type Optional:
4-Speed Automatic Transmission
Features
Drivetrain Layout:
Part-time 4WD with selectable 2WD/4WD High/4WD Low
Clutch Type:
Single dry plate diaphragm spring clutch (Manual)
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-90 (Check manual for specific part number/recommendation)
Automatic Transmission Fluid:
Dexron III or equivalent (Check manual for specific part number/recommendation)
📐 Dimensions
Exterior
Length:
3,675 mm (approx.)
Width:
1,580 mm (approx.)
Height:
1,695 mm (approx.)
Wheelbase:
2,235 mm (approx.)
Ground Clearance:
195 mm (approx.)
Weights
Curb Weight:
1,050 - 1,150 kg (depending on transmission and options)
Gross Vehicle Weight Rating Gvwr:
Approx. 1,550 kg
Cargo
Cargo Volume:
Varies with rear seats up/down. Adequate for its class.
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Vehicle is from an era where standardized global ratings were less common, especially for smaller, niche vehicles. Refer to specific market reports if available.)
Active Features
ABS:
Available on some higher trims/markets
Passive Features
Airbags:
Driver airbag standard, Passenger airbag optional on some variants.
Seatbelts:
3-point seatbelts with pretensioners (front), 2-point or 3-point rear seatbelts.
Construction
Body On Frame:
Body-on-frame construction, typical for robust small SUVs of the era.
💡 Technology Features
Infotainment
Audio System:
Factory fitted AM/FM radio with CD player or cassette player (depending on trim and market). Speaker configuration typically 2-4 speakers.
Dashboard Controls:
Basic analog gauges for speedometer, tachometer, fuel, and temperature. Manual climate controls.
Driver Assistance
ABS Availability:
Optional on certain models/markets.
Connectivity
Auxiliary Inputs:
Not standard; may be aftermarket additions.
🔧 Maintenance
Service Intervals
Engine Oil Filter Change:
Every 7,500 - 10,000 km or 6-12 months (whichever comes first, check manual)
Air Filter Replacement:
Every 20,000 - 30,000 km or 12-24 months (check manual)
Spark Plug Replacement:
Every 30,000 - 40,000 km (depending on plug type, check manual)
Coolant Replacement:
Every 40,000 - 60,000 km or 2-3 years (check manual)
5W-30 or 5W-40 (API SG or higher recommended, check manual)
Coolant Type:
Ethylene Glycol-based coolant (50/50 mix with distilled water), refer to manual for specific Daihatsu/Toyota spec.
Known Issues
Common Problems Engine:
Potential for carbon buildup on intake valves, particularly if driven gently. Timing belt (if applicable to K3-VE variant) needs regular replacement. Turbocharger on K3-VET can be a failure point if maintenance is neglected.
Common Problems Suspension:
Worn ball joints, tie rod ends, and bushings due to age and potential off-road use. Struts can weaken over time.
Common Problems Electrical:
Corrosion on electrical connectors, particularly in areas exposed to moisture. Alternator and starter motor reliability can vary.
Common Problems Body:
Rust formation, especially on the chassis, wheel arches, and lower body panels, depending on climate and care.
📚 Vehicle History
Brand Heritage
Daihatsu Legacy:
Daihatsu, a subsidiary of Toyota, has a long history of producing small, economical, and practical vehicles, particularly kei cars and compact SUVs.
Model Evolution
Terios Introduction:
The first generation Terios (J100 series) was launched in 1997, designed as a compact and rugged SUV offering genuine off-road capability.
J100 Series Development:
The J100 series was Daihatsu's answer to the growing demand for small, affordable SUVs. It focused on compact dimensions, a lightweight construction, and a user-friendly 4WD system.
Production
Production Period:
1997-2006 (for J100 series)
Production Locations
Manufacturing:
Primarily Japan, with significant assembly in other countries through joint ventures or licensing.
🏆 Awards & Recognition
Recognitions
Kei Car Awards:
While not strictly a Kei car in all dimensions, it shared characteristics and market appeal with Kei SUVs that were popular in Japan.
Ratings
Consumer Satisfaction:
Generally rated as a reliable and practical vehicle by owners, particularly appreciated for its off-road capability relative to its size and price.
Certifications
Emission Standards:
Meets the emission standards applicable to the model year and market of sale (e.g., Euro 2, J-DM standards).
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