2008 Daihatsu Terios (2nd gen) Service and Repair Manual
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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Year: 2008 Generation Generation: 2nd Generation (J200 Series) Codes Chassis Codes: J200, J210 👋 Introduction Market Position Market Segment: Compact SUV / Crossover, often appealing to budget-conscious buyers and those seeking a small, versatile all-wheel-drive vehicle. Competitive Analysis Key Competitors: Suzuki Vitara, Honda CR-V (early models), Toyota RAV4 (early models), Nissan X-Trail (early models). Key Features Vehicle Strengths: Compact size, available 4WD, fuel efficiency, affordability, practicality for urban and light off-road use. Manual Value Proposition Target Audience: Dealership technicians, independent repair shops, experienced DIY enthusiasts who perform their own maintenance and repairs. 📋 Manual Details Coverage Areas Coverage Summary: Comprehensive A-Z coverage for all models and repairs, vehicle-specific for technicians. Page Count Estimated Page Count: Over 1500 pages (typical for a complete factory service manual) Manual Type Manual Type: Factory Service and Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, diagnosis, repair, cylinder head, pistons, crankshaft, timing system, lubrication system, cooling system. Engine Performance: Fuel system (injection, pump, injectors), ignition system, emission control system, engine control module (ECM) diagnosis. Transmission Manual: Manual transmission removal, disassembly, inspection, assembly, repair, clutch system. Transmission Automatic: Automatic transmission removal, disassembly, inspection, assembly, repair, torque converter, valve body, planetary gear sets. Drivetrain: Four-wheel drive (4WD) system, transfer case, front and rear differentials, drive shafts, CV joints, axle shafts. Suspension: Front and rear suspension systems, shock absorbers, struts, coil springs, control arms, bushings, ball joints, wheel bearings. Steering: Power steering system, steering column, steering gear, tie rods, power steering pump, fluid. Brakes: Front and rear disc brakes, brake calipers, rotors, pads, master cylinder, brake booster, parking brake, ABS system. Electrical System: Battery, charging system (alternator), starting system (starter motor), lighting system, horn, wiper system, power windows, power locks. Body Exterior: Body panels, doors, hood, tailgate, bumpers, glass, mirrors, trim, rust prevention, corrosion repair. Body Interior: Seats, dashboard, interior trim panels, carpeting, headliner, airbags, seat belts, HVAC controls. HVAC: Heating, ventilation, and air conditioning (HVAC) system, refrigerant, compressor, evaporator, condenser, blower motor, controls. Chassis Electrical: Instrument cluster, warning lights, sensors, relays, fuses, wiring diagrams. Procedures Included Maintenance Procedures: Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, brake pad replacement. Diagnostic Procedures: Troubleshooting guides, symptom-based diagnostics, error code interpretation, wiring diagram usage. Repair Procedures: Step-by-step instructions for component removal, installation, and repair for all major systems. Calibration Procedures: Wheel alignment, steering angle sensor calibration, ABS sensor calibration (where applicable). Specification Updates: Torque specifications, diagnostic parameters, component tolerances. Technical Depth Depth Of Coverage: Complete factory-level detail, suitable for professional technicians and advanced DIYers. Includes disassembly, assembly, component testing, and diagnostics. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Print Quality Print Quality: High-resolution scans ensuring clear text, diagrams, and images for printing. Binding Type Binding Type: N/A (Digital format) Paper Type Paper Type: N/A (Digital format) Searchability Searchability: Fully searchable text content for quick access to information. ⚙️ Engine Specifications Primary Engine Engine Code And Type: 3SZ-VE (1.5L Inline-4, DOHC, VVT-i) Performance Horsepower: Approximately 106-109 PS (78-80 kW) @ 6000 rpm Torque: Approximately 14.4 kg⋅m (141 Nm; 104 lb⋅ft) @ 4400 rpm Fuel System Fuel System Type: Electronic Fuel Injection (EFI) Engine Details Bore X Stroke: 72.0 mm x 84.7 mm Compression Ratio: 10.2:1 Cylinder Block Material: Aluminum Cylinder Head Material: Aluminum 🔧 Transmission Standard Standard Transmission: 5-speed Manual Transmission Optional Optional Transmission: 4-speed Automatic Transmission Features Drivetrain Options: Front-Wheel Drive (FWD) and All-Wheel Drive (AWD) 📐 Dimensions Exterior Length: Approx. 4,195 mm (165.2 in) Width: Approx. 1,690 mm (66.5 in) Height: Approx. 1,705 mm (67.1 in) Wheelbase: Approx. 2,580 mm (101.6 in) Ground Clearance: Approx. 190 mm (7.5 in) Interior Seating Capacity: 5 Passengers Cargo Cargo Volume: Approx. 350 liters (12.4 cu ft) with rear seats up, expandable Weights Curb Weight: Approx. 1,200 - 1,350 kg (2,646 - 2,976 lbs) 🛡️ Safety Features Ratings NHTSA Safety Rating: Varied by market and specific configuration, generally good for its class and era. Active Features Active Safety Features: Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD). Passive Features Passive Safety Features: Front airbags, side airbags (optional on some trims), seatbelt pretensioners, reinforced body structure. 💡 Technology Features Infotainment Infotainment System: Factory-installed AM/FM stereo with CD player, some models may have MP3 compatibility or an auxiliary input. Optional navigation systems were available. Driver Assistance Driver Assistance Features: Limited by era; primarily ABS and EBD. Stability control (VSC) became more common in later model years or higher trims. Connectivity Connectivity Options: Auxiliary audio input jack (on some models), power outlets for charging devices. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 miles (8,000 km) or 6 months, whichever comes first (severe conditions) / Every 10,000 miles (16,000 km) or 12 months (normal conditions), consult manual...
Complete factory-level detail, suitable for professional technicians and advanced DIYers. Includes disassembly, assembly, component testing, and diagnostics.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format)
Print Quality
Print Quality:
High-resolution scans ensuring clear text, diagrams, and images for printing.
Binding Type
Binding Type:
N/A (Digital format)
Paper Type
Paper Type:
N/A (Digital format)
Searchability
Searchability:
Fully searchable text content for quick access to information.
⚙️ Engine Specifications
Primary Engine
Engine Code And Type:
3SZ-VE (1.5L Inline-4, DOHC, VVT-i)
Performance
Horsepower:
Approximately 106-109 PS (78-80 kW) @ 6000 rpm
Torque:
Approximately 14.4 kg⋅m (141 Nm; 104 lb⋅ft) @ 4400 rpm
Fuel System
Fuel System Type:
Electronic Fuel Injection (EFI)
Engine Details
Bore X Stroke:
72.0 mm x 84.7 mm
Compression Ratio:
10.2:1
Cylinder Block Material:
Aluminum
Cylinder Head Material:
Aluminum
🔧 Transmission
Standard
Standard Transmission:
5-speed Manual Transmission
Optional
Optional Transmission:
4-speed Automatic Transmission
Features
Drivetrain Options:
Front-Wheel Drive (FWD) and All-Wheel Drive (AWD)
📐 Dimensions
Exterior
Length:
Approx. 4,195 mm (165.2 in)
Width:
Approx. 1,690 mm (66.5 in)
Height:
Approx. 1,705 mm (67.1 in)
Wheelbase:
Approx. 2,580 mm (101.6 in)
Ground Clearance:
Approx. 190 mm (7.5 in)
Interior
Seating Capacity:
5 Passengers
Cargo
Cargo Volume:
Approx. 350 liters (12.4 cu ft) with rear seats up, expandable
Weights
Curb Weight:
Approx. 1,200 - 1,350 kg (2,646 - 2,976 lbs)
🛡️ Safety Features
Ratings
NHTSA Safety Rating:
Varied by market and specific configuration, generally good for its class and era.
Active Features
Active Safety Features:
Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD).
Passive Features
Passive Safety Features:
Front airbags, side airbags (optional on some trims), seatbelt pretensioners, reinforced body structure.
💡 Technology Features
Infotainment
Infotainment System:
Factory-installed AM/FM stereo with CD player, some models may have MP3 compatibility or an auxiliary input. Optional navigation systems were available.
Driver Assistance
Driver Assistance Features:
Limited by era; primarily ABS and EBD. Stability control (VSC) became more common in later model years or higher trims.
Connectivity
Connectivity Options:
Auxiliary audio input jack (on some models), power outlets for charging devices.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles (8,000 km) or 6 months, whichever comes first (severe conditions) / Every 10,000 miles (16,000 km) or 12 months (normal conditions), consult manual for specifics.
Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months.
Spark Plug Replacement:
Every 30,000 miles (48,000 km) or 24 months (using iridium-tipped plugs).
Fluid Specifications
Engine Oil Type:
API SN/SP or ILSAC GF-5/GF-6 certified, SAE 0W-20 or 5W-30 (refer to owner's manual for exact recommendation).
Engine Oil Capacity:
Approx. 3.9 liters (4.1 US quarts) with filter change.
Coolant Type:
Toyota Super Long Life Coolant (Pink) or equivalent ethylene glycol-based antifreeze with demineralized water (50/50 mix).
Transmission Fluid Manual:
API GL-4 SAE 75W-90 gear oil.
Transmission Fluid Automatic:
Toyota ATF WS (World Standard) or equivalent Dexron III compatible fluid.
Power Steering Fluid:
DEXRON II/III or equivalent automatic transmission fluid.
Known Issues
Common Wear Items:
Front sway bar links and bushings, rear shock absorbers, wheel bearings, exhaust system components.
Engine Potential Issues:
While generally reliable, occasional oil consumption or minor oil leaks can occur with high mileage. VVT-i system maintenance is important.
Drivetrain Potential Issues:
CV boots can be prone to cracking and tearing, leading to joint damage. Transfer case and differential fluid changes are crucial for AWD models.
📚 Vehicle History
Brand Heritage
Daihatsu Heritage:
Daihatsu, a subsidiary of Toyota, has a long history of producing small, economical, and durable vehicles, often specializing in kei cars and compact utility vehicles.
Model Evolution
Terios Lineage:
The 2nd generation Terios (J200 series) represented a significant redesign from the first generation, offering a more modern appearance, improved interior space, and enhanced refinement. It continued the tradition of a compact, capable SUV.
Production
Manufacturing Location:
Japan (primarily), also produced under license or rebadged in other markets.
Production Years 2Nd Gen:
2006 - 2017 (Global, with facelifts)
🏆 Awards & Recognition
Recognitions
Awards And Ratings:
While not typically winning major awards, the Daihatsu Terios often received positive mentions for its practicality, affordability, and capability as a small, cost-effective SUV in its segment.
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