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Daihatsu Terios J102 2000 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Generation Code: J100/J102/J122 Model Year: 2000 Chassis Code: J102 👋 Introduction Market Position Vehicle Segment: Compact SUV / Mini SUV Target Audience: Individuals and families seeking an affordable, capable, and compact off-road-oriented vehicle. Competitive Analysis Key Competitors Era: Suzuki Vitara, Toyota RAV4 (early models), Honda CR-V (early models), Mitsubishi Pajero Mini. Key Features Off Road Capability: Available with permanent 4-wheel drive (4WD) and low-range gearing, distinguishing it from many front-wheel-drive-biased compact SUVs of the era. Compact Size: Maneuverable for urban environments and capable off-road. Reliability: Known for Daihatsu's reputation for building robust and reliable smaller vehicles. 📋 Manual Details Coverage Areas Covered Models: All Daihatsu Terios J102 models, engines, trims, and transmissions for the 2000 model year. Specific Regions: Global market variations (e.g., Japanese Domestic Market (JDM), export models where applicable). Page Count Estimated Pages: Comprehensive (Exact page count not provided, but typical for a full workshop manual). Manual Type Type: Workshop Service Repair Manual Language Language: English (Typical for downloaded service manuals, though original may vary). Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, overhaul, cooling system, lubrication system, fuel system, exhaust system, intake system. Engine Electrical: Ignition system, starting system, charging system, engine control unit (ECU) and sensors, emissions control systems. Transmission Manual: Manual transmission removal, disassembly, assembly, repair, clutch system. Transmission Automatic: Automatic transmission removal, disassembly, assembly, repair, torque converter, shift control systems. Drivetrain: Transfer case, differentials (front and rear), driveshafts, constant velocity (CV) joints, hubs. Suspension: Front suspension (struts, control arms, ball joints), rear suspension (multi-link, trailing arms), shock absorbers, springs. Steering: Power steering system, steering column, steering gear/rack and pinion, tie rods, alignment specifications. Brakes: Front disc brakes, rear drum brakes (or discs depending on specific configuration), hydraulic system, parking brake, ABS system (if equipped). Electrical Body: Lighting system (headlights, taillights, interior), power windows, central locking, wipers and washers, horn, accessory circuits. Climate Control: Air conditioning system, heater, ventilation. Body Exterior: Body panels, doors, hood, tailgate, bumpers, glass, seals, trim. Body Interior: Seats, dashboard, console, upholstery, interior trim panels. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement. Troubleshooting: Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting charts, electrical diagnostic aids. Repair Procedures: Step-by-step instructions for component replacement, rebuilds, and adjustments across all major systems. Diagnostic Charts: Schematic diagrams and flowcharts for identifying faults in various vehicle systems. Torques Specifications: Precise torque values for all critical fasteners. Wiring Diagrams: Complete electrical wiring schematics for all vehicle circuits. Technical Depth Depth Level: Comprehensive from basic maintenance to advanced component overhaul and diagnostics. Diagnostic Tools: Information on using specialized diagnostic tools and equipment. Rebuild Procedures: Detailed instructions for rebuilding engines, transmissions, and other major components. 📊 Manual Specifications File Format Format Type: PDF (Portable Document Format) Searchability: Likely searchable text within the PDF, allowing for quick keyword lookups. Print Quality Printability: Designed for clear printing of diagrams, schematics, and text. Binding Type Binding: N/A (Digital format - PDF) Paper Type Paper: N/A (Digital format - PDF) ⚙️ Engine Specifications Primary Engine Engine Code: K3-VE (common for this generation/model year, though others may exist). Engine Type: Inline 4-cylinder, DOHC, 16-valve, Naturally Aspirated. Displacement: 1.3 Liters (1298 cc) Performance Horsepower: Approximately 80-86 hp @ 5500-6000 rpm (specific output varies by market and exact engine variant). Torque: Approximately 115-120 Nm (85-89 lb-ft) @ 3500-4000 rpm. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline (RON 91 or higher recommended). Cooling System Coolant Type: Ethylene Glycol based coolant (e.g., Toyota Super Long Life Coolant or equivalent). Coolant Capacity: Approximately 4.5 - 5.0 Liters (refer to manual for exact specification). Lubrication System Engine Oil Type: API SG/SH/SJ or ILSAC GF-II/GF-III; SAE 10W-30 or 5W-30 depending on climate. Engine Oil Capacity: Approximately 3.7 Liters (with filter change) (refer to manual for exact specification). Oil Filter Part Number: Example: Daihatsu 90047-89003, Bosch 3323, Fram PH3500 (verify compatibility). 🔧 Transmission Standard Transmission Type Std: 5-speed Manual Transmission Optional Transmission Type Opt: 4-speed Automatic Transmission Features Drivetrain Options: Available in 2WD (Rear-Wheel Drive) and 4WD (Four-Wheel Drive with center differential and optional low-range gear). Manual Transmission Fluid Mtf Type: API GL-4 SAE 75W-90 or SAE 80W-90 gear oil. Mtf Capacity: Approximately 1.5 - 2.0 Liters (refer to manual). Automatic Transmission Fluid Atf Type: Dexron II/III or equivalent (e.g., Toyota Type T-II/T-III). Atf Capacity: Approximately 3.0 - 3.5 Liters (for initial fill, refer to manual). 📐 Dimensions Exterior Length: Approx. 3,750 mm (147.6 in) Width: Approx. 1,600 mm (63.0 in) Height: Approx. 1,705 mm (67.1 in) Wheelbase: Approx. 2,430 mm (95.7 in) Ground Clearance: Approx. 190-200 mm (7.5-7.9 in) (Varies by suspension/tire setup). Weights Curb Weight: Approx. 1,100 - 1,250 kg (2,425 - 2,756 lbs) (Depending on drivetrain and...
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Daihatsu Terios J102 2000 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Terios
Generation Code:
J100/J102/J122
Model Year:
2000
Chassis Code:
J102
👋 Introduction
Market Position
Vehicle Segment:
Compact SUV / Mini SUV
Target Audience:
Individuals and families seeking an affordable, capable, and compact off-road-oriented vehicle.
Competitive Analysis
Key Competitors Era:
Suzuki Vitara, Toyota RAV4 (early models), Honda CR-V (early models), Mitsubishi Pajero Mini.
Key Features
Off Road Capability:
Available with permanent 4-wheel drive (4WD) and low-range gearing, distinguishing it from many front-wheel-drive-biased compact SUVs of the era.
Compact Size:
Maneuverable for urban environments and capable off-road.
Reliability:
Known for Daihatsu's reputation for building robust and reliable smaller vehicles.
📋 Manual Details
Coverage Areas
Covered Models:
All Daihatsu Terios J102 models, engines, trims, and transmissions for the 2000 model year.
Specific Regions:
Global market variations (e.g., Japanese Domestic Market (JDM), export models where applicable).
Page Count
Estimated Pages:
Comprehensive (Exact page count not provided, but typical for a full workshop manual).
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English (Typical for downloaded service manuals, though original may vary).
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, overhaul, cooling system, lubrication system, fuel system, exhaust system, intake system.
Engine Electrical:
Ignition system, starting system, charging system, engine control unit (ECU) and sensors, emissions control systems.
Transmission Manual:
Manual transmission removal, disassembly, assembly, repair, clutch system.
Transmission Automatic:
Automatic transmission removal, disassembly, assembly, repair, torque converter, shift control systems.
Drivetrain:
Transfer case, differentials (front and rear), driveshafts, constant velocity (CV) joints, hubs.
Suspension:
Front suspension (struts, control arms, ball joints), rear suspension (multi-link, trailing arms), shock absorbers, springs.
Steering:
Power steering system, steering column, steering gear/rack and pinion, tie rods, alignment specifications.
Brakes:
Front disc brakes, rear drum brakes (or discs depending on specific configuration), hydraulic system, parking brake, ABS system (if equipped).
Electrical Body:
Lighting system (headlights, taillights, interior), power windows, central locking, wipers and washers, horn, accessory circuits.
Climate Control:
Air conditioning system, heater, ventilation.
Body Exterior:
Body panels, doors, hood, tailgate, bumpers, glass, seals, trim.
Body Interior:
Seats, dashboard, console, upholstery, interior trim panels.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting charts, electrical diagnostic aids.
Repair Procedures:
Step-by-step instructions for component replacement, rebuilds, and adjustments across all major systems.
Diagnostic Charts:
Schematic diagrams and flowcharts for identifying faults in various vehicle systems.
Torques Specifications:
Precise torque values for all critical fasteners.
Wiring Diagrams:
Complete electrical wiring schematics for all vehicle circuits.
Technical Depth
Depth Level:
Comprehensive from basic maintenance to advanced component overhaul and diagnostics.
Diagnostic Tools:
Information on using specialized diagnostic tools and equipment.
Rebuild Procedures:
Detailed instructions for rebuilding engines, transmissions, and other major components.
📊 Manual Specifications
File Format
Format Type:
PDF (Portable Document Format)
Searchability:
Likely searchable text within the PDF, allowing for quick keyword lookups.
Print Quality
Printability:
Designed for clear printing of diagrams, schematics, and text.
Binding Type
Binding:
N/A (Digital format - PDF)
Paper Type
Paper:
N/A (Digital format - PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code:
K3-VE (common for this generation/model year, though others may exist).
Engine Type:
Inline 4-cylinder, DOHC, 16-valve, Naturally Aspirated.
Displacement:
1.3 Liters (1298 cc)
Performance
Horsepower:
Approximately 80-86 hp @ 5500-6000 rpm (specific output varies by market and exact engine variant).
Torque:
Approximately 115-120 Nm (85-89 lb-ft) @ 3500-4000 rpm.
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline (RON 91 or higher recommended).
Cooling System
Coolant Type:
Ethylene Glycol based coolant (e.g., Toyota Super Long Life Coolant or equivalent).
Coolant Capacity:
Approximately 4.5 - 5.0 Liters (refer to manual for exact specification).
Lubrication System
Engine Oil Type:
API SG/SH/SJ or ILSAC GF-II/GF-III; SAE 10W-30 or 5W-30 depending on climate.
Engine Oil Capacity:
Approximately 3.7 Liters (with filter change) (refer to manual for exact specification).
Oil Filter Part Number:
Example: Daihatsu 90047-89003, Bosch 3323, Fram PH3500 (verify compatibility).
🔧 Transmission
Standard
Transmission Type Std:
5-speed Manual Transmission
Optional
Transmission Type Opt:
4-speed Automatic Transmission
Features
Drivetrain Options:
Available in 2WD (Rear-Wheel Drive) and 4WD (Four-Wheel Drive with center differential and optional low-range gear).
Manual Transmission Fluid
Mtf Type:
API GL-4 SAE 75W-90 or SAE 80W-90 gear oil.
Mtf Capacity:
Approximately 1.5 - 2.0 Liters (refer to manual).
Automatic Transmission Fluid
Atf Type:
Dexron II/III or equivalent (e.g., Toyota Type T-II/T-III).
Atf Capacity:
Approximately 3.0 - 3.5 Liters (for initial fill, refer to manual).
📐 Dimensions
Exterior
Length:
Approx. 3,750 mm (147.6 in)
Width:
Approx. 1,600 mm (63.0 in)
Height:
Approx. 1,705 mm (67.1 in)
Wheelbase:
Approx. 2,430 mm (95.7 in)
Ground Clearance:
Approx. 190-200 mm (7.5-7.9 in) (Varies by suspension/tire setup).
Weights
Curb Weight:
Approx. 1,100 - 1,250 kg (2,425 - 2,756 lbs) (Depending on drivetrain and options).
Gross Vehicle Weight Rating:
Refer to vehicle compliance plate.
Cargo
Cargo Volume:
Configurable with folding rear seats; capacity varies.
Wheels Tires
Wheel Size:
15-inch or 16-inch alloy or steel wheels.
Tire Size:
Commonly 205/70 R15 or 215/65 R16 (Verify based on trim level).
Bolt Pattern:
5x114.3 mm (5x4.5 inches)
🛡️ Safety Features
Ratings
Crash Test Ratings:
NHTSA/Euro NCAP ratings are less common for this specific generation and market; consult local automotive safety archives.
Active Features
ABS:
Anti-lock Braking System (ABS) often optional or standard on higher trims.
Traction Control:
Traction control systems were less common in this segment at the time, likely optional or absent.
Passive Features
Airbags:
Driver and front passenger airbags typically standard or optional.
Seatbelts:
Three-point seatbelts for all occupants, with pre-tensioners for front seats.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with CD player or cassette deck. Often aftermarket upgrades are common.
Speakers:
Typically 2 or 4 speakers.
Driver Assistance
Parking Assistance:
Rear parking sensors are a rare aftermarket addition for this era.
Connectivity
Aux Input:
Rare on original units; typically added via aftermarket head units.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 - 10,000 km (3,000 - 6,000 miles) or 6-12 months, depending on driving conditions (refer to manual).
Air Filter Replacement:
Every 20,000 - 30,000 km (12,000 - 18,000 miles) or as needed based on inspection.
Spark Plug Replacement:
Every 40,000 - 60,000 km (25,000 - 37,000 miles), depending on spark plug type (e.g., standard vs. iridium).
Coolant Flush:
Every 40,000 - 60,000 km (25,000 - 37,000 miles) or 2-3 years.
Transmission Fluid Change Mt:
Every 50,000 - 80,000 km (30,000 - 50,000 miles).
Transmission Fluid Change At:
Every 40,000 - 60,000 km (25,000 - 37,000 miles) or 2-3 years.
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4.
Power Steering Fluid Type:
ATF Dexron II/III or power steering fluid (refer to manual).
Known Issues
Common Wear Items:
Suspension bushings, ball joints, tie rod ends, CV boots due to off-road use. Clutch wear on manual transmissions.
Engine Performance Issues:
Occasional issues with ignition coils, fuel injectors, or catalytic converters can affect performance and fuel economy.
Electrical Gremlins:
As with any vehicle of this age, minor electrical issues like sensor failures or switch malfunctions can occur.
Rust Corrosion:
Check for rust on chassis, body panels, and exhaust components, especially in areas with harsh climates.
📚 Vehicle History
Brand Heritage
Daihatsu Focus:
Daihatsu, a subsidiary of Toyota, has a long history of producing small, reliable, and often niche vehicles, particularly in the kei car and compact segments.
Model Evolution
Terios Generation 1:
The J100/J102/J122 series represents the first generation of the Daihatsu Terios, launched globally in 1997. It was designed as a more compact and affordable alternative to larger SUVs, with a focus on light off-road capability.
Model Facelifts:
This 2000 model year likely reflects a minor update or remains within the initial production run of the first generation.
Production
Manufacturing Locations:
Primarily manufactured in Japan by Daihatsu Motor Co., Ltd. Also produced under license in other countries.
Production Years
First Generation Production:
1997 – 2005
🏆 Awards & Recognition
Recognitions
General Recognition:
The Daihatsu Terios J102 series gained recognition for its compact size, practical utility, and surprising off-road capability, especially within its segment.
Ratings
Reliability Ratings:
Daihatsu vehicles are generally well-regarded for their long-term reliability and low running costs, which contributes to the Terios' appeal.
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