Daihatsu Terios 2006-2009 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Generation: Second Generation (J200) Codes Chassis Code: J200 Series (J200G, J210G, J200E, J210E) Engine Code Primary: K3-VE (1.5L) Engine Code Secondary: 3SZ-VE (1.5L VVT-i) 👋 Introduction Market Position Segment: Compact Crossover SUV / Small SUV Target Audience: Budget-conscious consumers seeking a practical, versatile, and capable small SUV for urban driving and light off-roading. Competitive Analysis Key Competitors: Suzuki Vitara, Honda CR-V (earlier generations), Toyota RAV4 (earlier generations), Nissan X-Trail (earlier generations), Mitsubishi Outlander Sport. Key Features Versatility: Compact dimensions for urban maneuverability combined with available 4WD for light off-road capability and all-weather traction. Practicality: Spacious interior for its class, foldable rear seats for cargo flexibility, elevated driving position. Reliability: Generally regarded as a reliable vehicle, particularly with regular maintenance, leveraging Daihatsu's reputation for dependable small engines. 📋 Manual Details Coverage Areas Regions Covered: Global (with variations for specific markets) Page Count Estimated Pages: 1000+ Manual Type Type: Factory Service Repair Workshop Manual Language Language: English Format Format: Downloadable PDF File Format File Type: PDF Print Quality Quality: High-resolution scans, clear text and diagrams, suitable for printing. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) 📖 Manual Coverage Systems Covered Engine: Full disassembly, assembly, troubleshooting, repair, specifications for K3-VE and 3SZ-VE engines (including timing belt/chain, lubrication, cooling, fuel injection, emissions). Transmission: Manual Transmission (5-speed), Automatic Transmission (4-speed) repair, overhaul, troubleshooting, fluid specifications, and control systems. Drivetrain: Four-wheel Drive (4WD) system operation, maintenance, repair of transfer case and differentials. Rear-wheel drive (RWD) specifications. Brakes: Front disc brakes, rear drum brakes (or optional rear discs depending on market/trim), ABS system diagnosis and repair, parking brake. Suspension: Front MacPherson strut, Rear multi-link independent suspension. Shock absorbers, springs, control arms, bushings, wheel alignment specifications. Steering: Power assisted steering system (hydraulic or electric depending on specific model/market), steering rack, tie rods, pump. Electrical: Comprehensive wiring diagrams, starter system, charging system, ignition system, lighting, instrumentation, power windows, door locks, HVAC controls, body control modules (BCM), fuse box diagrams. Bodywork: Body panel removal and installation, door mechanisms, glass replacement, bumper repair, interior trim, chassis component identification. HVAC: Air conditioning system service, refrigerant types, compressor, condenser, evaporator, heater core, blower motor, controls. Procedures Included Maintenance: Scheduled maintenance items (oil changes, filter replacements, spark plugs, belt inspection/replacement), fluid level checks and top-ups, tire rotation. Troubleshooting: Diagnostic flowcharts for common starting, running, electrical, and mechanical issues. DTC code interpretation and resolution. Repair: Step-by-step guides for major component overhauls, component replacements (e.g., alternator, starter, fuel pump, radiator, brake calipers), suspension and steering linkage repair. Diagnostics: OBD-II system, sensor testing, actuator testing, ECU diagnosis, power balance testing, fuel pressure testing. Specifications: Torque specifications for all fasteners, valve clearances, engine build data, wheel alignment angles, fluid capacities, electrical resistance values. Technical Depth Depth: Comprehensive, covering from basic maintenance procedures to full engine and transmission rebuilds, complex electrical diagnostics, and chassis work. ⚙️ Engine Specifications Primary Engine Engine Name 1: K3-VE Configuration 1: Inline 4-cylinder, DOHC, 16-valve Displacement 1: 1495 cc (1.5 Liters) Bore X Stroke 1: 72.0 mm x 77.3 mm Compression Ratio 1: 9.0:1 or 9.5:1 (market dependent) Horsepower 1: 91-102 PS (67-75 kW) @ 6000-6400 rpm (approx.) Torque 1: 120-130 Nm (89-96 lb-ft) @ 3000-4400 rpm (approx.) Secondary Engine Engine Name 2: 3SZ-VE Configuration 2: Inline 4-cylinder, DOHC, 16-valve, VVT-i (Variable Valve Timing with intelligence) Displacement 2: 1495 cc (1.5 Liters) Bore X Stroke 2: 72.0 mm x 77.3 mm Compression Ratio 2: 10.0:1 Horsepower 2: 109 PS (80 kW) @ 6000 rpm (approx.) Torque 2: 140 Nm (103 lb-ft) @ 4400 rpm (approx.) Performance Fuel Type: Unleaded Gasoline Emission Standards: Euro 4 / JDM standards (market dependent) Fuel System Injection Type: Electronic Fuel Injection (EFI), Multi-point injection Fuel Pump Type: Electric in-tank Fuel Octane Rating: 91 RON (minimum recommended) 🔧 Transmission Standard Type Standard: 5-speed Manual Transmission Optional Type Optional: 4-speed Automatic Transmission Features Drivetrain Options: Rear-Wheel Drive (RWD) or Selectable Four-Wheel Drive (4WD) 4Wd System: Center differential with viscous coupling (on some models) for part-time or full-time 4WD operation. Fluid Specification Manual Transmission Fluid: API GL-4, SAE 75W-90 (check manual for exact spec) Automatic Transmission Fluid: Dexron III / MERCON or equivalent (check manual for exact spec) 📐 Dimensions Exterior Length: Approx. 3995 - 4300 mm (depending on market/variant) Width: Approx. 1695 mm Height: Approx. 1705 - 1715 mm Wheelbase: Approx. 2430 mm Ground Clearance: Approx. 190 - 200 mm Interior Seating Capacity: 5 Passengers Cargo Cargo Volume Rear Seats Up: Approx. 310 - 380 Liters (Varies by market and configuration) Weights Curb Weight: Approx. 1150 - 1300 kg (depending on drivetrain and equipment) Gross Vehicle Weight Rating Gvwr: Approx. 1700 kg (check specific model) 🛡️ Safety Features Ratings Ancap Rating: Likely 3-4 Stars (based on contemporary small SUVs in its class, check specific market test results) Active...

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Tipo: Car

Fabricante:

Sku: 36375

Coleções: ALL Daihatsu

Disponibilidade: Em estoque

Tag: 2006 2007 2008 2009 Car Daihatsu Terios

Variantes do produto

Description

🏷️ Basic Information

Identification

Make:

Daihatsu

Model:

Terios

Generation:

Second Generation (J200)

Codes

Chassis Code:

J200 Series (J200G, J210G, J200E, J210E)

Engine Code Primary:

K3-VE (1.5L)

Engine Code Secondary:

3SZ-VE (1.5L VVT-i)

👋 Introduction

Market Position

Segment:

Compact Crossover SUV / Small SUV

Target Audience:

Budget-conscious consumers seeking a practical, versatile, and capable small SUV for urban driving and light off-roading.

Competitive Analysis

Key Competitors:

Suzuki Vitara, Honda CR-V (earlier generations), Toyota RAV4 (earlier generations), Nissan X-Trail (earlier generations), Mitsubishi Outlander Sport.

Key Features

Versatility:

Compact dimensions for urban maneuverability combined with available 4WD for light off-road capability and all-weather traction.

Practicality:

Spacious interior for its class, foldable rear seats for cargo flexibility, elevated driving position.

Reliability:

Generally regarded as a reliable vehicle, particularly with regular maintenance, leveraging Daihatsu's reputation for dependable small engines.

📋 Manual Details

Coverage Areas

Regions Covered:

Global (with variations for specific markets)

Page Count

Estimated Pages:

1000+

Manual Type

Type:

Factory Service Repair Workshop Manual

Language

Language:

English

Format

Format:

Downloadable PDF

File Format

File Type:

Print Quality

Quality:

High-resolution scans, clear text and diagrams, suitable for printing.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

📖 Manual Coverage

Systems Covered

Engine:

Full disassembly, assembly, troubleshooting, repair, specifications for K3-VE and 3SZ-VE engines (including timing belt/chain, lubrication, cooling, fuel injection, emissions).

Transmission:

Manual Transmission (5-speed), Automatic Transmission (4-speed) repair, overhaul, troubleshooting, fluid specifications, and control systems.

Drivetrain:

Four-wheel Drive (4WD) system operation, maintenance, repair of transfer case and differentials. Rear-wheel drive (RWD) specifications.

Brakes:

Front disc brakes, rear drum brakes (or optional rear discs depending on market/trim), ABS system diagnosis and repair, parking brake.

Suspension:

Front MacPherson strut, Rear multi-link independent suspension. Shock absorbers, springs, control arms, bushings, wheel alignment specifications.

Steering:

Power assisted steering system (hydraulic or electric depending on specific model/market), steering rack, tie rods, pump.

Electrical:

Comprehensive wiring diagrams, starter system, charging system, ignition system, lighting, instrumentation, power windows, door locks, HVAC controls, body control modules (BCM), fuse box diagrams.

Bodywork:

Body panel removal and installation, door mechanisms, glass replacement, bumper repair, interior trim, chassis component identification.

HVAC:

Air conditioning system service, refrigerant types, compressor, condenser, evaporator, heater core, blower motor, controls.

Procedures Included

Maintenance:

Scheduled maintenance items (oil changes, filter replacements, spark plugs, belt inspection/replacement), fluid level checks and top-ups, tire rotation.

Troubleshooting:

Diagnostic flowcharts for common starting, running, electrical, and mechanical issues. DTC code interpretation and resolution.

Repair:

Step-by-step guides for major component overhauls, component replacements (e.g., alternator, starter, fuel pump, radiator, brake calipers), suspension and steering linkage repair.

Diagnostics:

OBD-II system, sensor testing, actuator testing, ECU diagnosis, power balance testing, fuel pressure testing.

Specifications:

Torque specifications for all fasteners, valve clearances, engine build data, wheel alignment angles, fluid capacities, electrical resistance values.

Technical Depth

Depth:

Comprehensive, covering from basic maintenance procedures to full engine and transmission rebuilds, complex electrical diagnostics, and chassis work.

⚙️ Engine Specifications

Primary Engine

Engine Name 1:

K3-VE

Configuration 1:

Inline 4-cylinder, DOHC, 16-valve

Displacement 1:

1495 cc (1.5 Liters)

Bore X Stroke 1:

72.0 mm x 77.3 mm

Compression Ratio 1:

9.0:1 or 9.5:1 (market dependent)

Horsepower 1:

91-102 PS (67-75 kW) @ 6000-6400 rpm (approx.)

Torque 1:

120-130 Nm (89-96 lb-ft) @ 3000-4400 rpm (approx.)

Secondary Engine

Engine Name 2:

3SZ-VE

Configuration 2:

Inline 4-cylinder, DOHC, 16-valve, VVT-i (Variable Valve Timing with intelligence)

Displacement 2:

1495 cc (1.5 Liters)

Bore X Stroke 2:

72.0 mm x 77.3 mm

Compression Ratio 2:

10.0:1

Horsepower 2:

109 PS (80 kW) @ 6000 rpm (approx.)

Torque 2:

140 Nm (103 lb-ft) @ 4400 rpm (approx.)

Performance

Fuel Type:

Unleaded Gasoline

Emission Standards:

Euro 4 / JDM standards (market dependent)

Fuel System

Injection Type:

Electronic Fuel Injection (EFI), Multi-point injection

Fuel Pump Type:

Electric in-tank

Fuel Octane Rating:

91 RON (minimum recommended)

🔧 Transmission

Standard

Type Standard:

5-speed Manual Transmission

Optional

Type Optional:

4-speed Automatic Transmission

Features

Drivetrain Options:

Rear-Wheel Drive (RWD) or Selectable Four-Wheel Drive (4WD)

4Wd System:

Center differential with viscous coupling (on some models) for part-time or full-time 4WD operation.

Fluid Specification

Manual Transmission Fluid:

API GL-4, SAE 75W-90 (check manual for exact spec)

Automatic Transmission Fluid:

Dexron III / MERCON or equivalent (check manual for exact spec)

📐 Dimensions

Exterior

Length:

Approx. 3995 - 4300 mm (depending on market/variant)

Width:

Approx. 1695 mm

Height:

Approx. 1705 - 1715 mm

Wheelbase:

Approx. 2430 mm

Ground Clearance:

Approx. 190 - 200 mm

Interior

Seating Capacity:

5 Passengers

Cargo

Cargo Volume Rear Seats Up:

Approx. 310 - 380 Liters (Varies by market and configuration)

Weights

Curb Weight:

Approx. 1150 - 1300 kg (depending on drivetrain and equipment)

Gross Vehicle Weight Rating Gvwr:

Approx. 1700 kg (check specific model)

🛡️ Safety Features

Ratings

Ancap Rating:

Likely 3-4 Stars (based on contemporary small SUVs in its class, check specific market test results)

Active Features

Standard on most models, often with EBD (Electronic Brakeforce Distribution) and Brake Assist.

Traction Control:

Available on some 4WD models.

Stability Control:

Less common in this segment during these years; check specific market specifications.

Passive Features

Airbags:

Front airbags standard, side airbags and curtain airbags often optional or standard on higher trims.

Seatbelts:

3-point seatbelts with pretensioners and load limiters for front occupants, 3-point rear seatbelts.

Child Seat Anchors:

ISOFIX/LATCH anchor points on rear seats.

💡 Technology Features

Infotainment

Head Unit:

Basic AM/FM radio with CD player, often with optional MP3 playback and auxiliary input. Higher trims might have touchscreens.

Speakers:

Typically 4 or 6 speakers.

Driver Assistance

Parking Sensors:

Optional on some models.

Reverse Camera:

Rarely standard, potentially available as an aftermarket upgrade or on very high trim levels in specific markets.

Connectivity

Bluetooth:

Not typically factory standard for this generation; often an aftermarket addition.

Usb Ports:

Not typically factory standard; often an aftermarket addition.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 - 10,000 km or 6-12 months, whichever comes first (refer to manual for exact mileage/time).

Air Filter Replacement:

Every 20,000 - 30,000 km or as needed based on driving conditions.

Spark Plug Replacement:

100,000 km for Iridium-tipped plugs (if fitted), or 30,000-50,000 km for conventional plugs (check manual).

Timing Belt Chain:

K3-VE uses a timing chain (low maintenance, typically lasts engine life). 3SZ-VE uses a timing chain (low maintenance). Check manual for specific inspection intervals.

Fluid Specifications

Engine Oil Capacity:

Approx. 3.7 Liters (with filter) for 1.5L engines (check manual for exact capacity).

Engine Oil Type:

API SN/SP, ILSAC GF-5/GF-6, SAE 0W-20 or 5W-30 (refer to manual for exact specification and viscosity based on climate).

Coolant Type:

Ethylene Glycol based, Toyota Super Long Life Coolant (SLLC) or equivalent (pink coolant recommended).

Brake Fluid Type:

DOT 3 or DOT 4 (check manual for specific recommendation).

Known Issues

Common Wear Items:

Suspension bushings, brake pads/rotors, exhaust components, catalytic converter (higher mileage).

Engine Potential Issues:

Carbon build-up in intake ports (especially on engines with early direct injection, though this model is mostly port injected), potential for oil consumption at very high mileage. Ensure proper cooling system maintenance to prevent overheating.

Transmission Potential Issues:

Automatic transmission may benefit from regular fluid changes to maintain longevity. Manual transmission clutches are generally robust.

📚 Vehicle History

Brand Heritage

Daihatsu Focus:

Daihatsu, a subsidiary of Toyota, has a long history of producing small, reliable, and fuel-efficient vehicles.

Model Evolution

First Generation Terios:

Introduced in 1997, the first generation was a more rugged, ladder-frame SUV. The 2006 model marks the transition to a monocoque (unibody) construction for improved on-road comfort and handling.

Second Generation Terios:

Launched in 2006, featuring a more modern design, enhanced interior space, and improved on-road dynamics. Sold globally under various names including Toyota Rush and Daihatsu Feroza in some markets.

Production

Manufacturing Locations:

Primarily Japan, with significant production in Indonesia for the ASEAN market.

Production Years

Production Period:

2006-2009 (for this specific manual's coverage)

🏆 Awards & Recognition

Recognitions

Market Reception:

Praised for its value proposition, practicality, and fuel efficiency within the compact SUV segment.

Ratings

Reliability Perception:

Consistently receives good reliability ratings from consumer surveys, reflecting Toyota/Daihatsu's engineering.

Certifications

Emission Compliance:

Meets relevant emission standards for its production years and target markets.