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Daihatsu Terios J100 1998 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Model Generation: J100 Model Year: 1998 Codes Chassis Code: J100G Engine Code Primary: HDE, HD-E 👋 Introduction Market Position Vehicle Segment: Compact SUV / Kei SUV. Target Audience: Individuals seeking a capable, compact, and often affordable 4x4 vehicle for light off-roading, city driving, and utility. Competitive Analysis Key Competitors Circa 1998: Suzuki Jimny/Samurai, Mitsubishi Pajero Mini, Toyota RAV4 (early models), Honda CR-V (early models). Key Features Off Road Capability: Body-on-frame construction, four-wheel drive system (often with selectable modes), relatively short wheelbase contributing to approach/departure angles. Compact Size: Maneuverability in urban environments and ease of parking. Simplicity Reliability: Often praised for straightforward mechanicals and robust, if basic, construction. 📋 Manual Details Coverage Areas Supported Regions: Global (with regional variations noted where applicable) Page Count Total Pages: Hundreds of pages (exact count not specified in product description, indicating a comprehensive manual) Manual Type Type: Factory Service Repair Manual Language Language: English (assumed based on typical availability for international markets) Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, lubrication, cooling, fuel, ignition, exhaust, emissions control, engine management systems (ECU). Transmission Drivetrain: Manual transmission, automatic transmission (if applicable), transfer case, differentials (front and rear), driveshafts, axles, hubs. Chassis Suspension: Front suspension (independent), rear suspension (solid axle or multi-link, depending on configuration), steering system, wheels, tires. Brakes: Front brakes (disc), rear brakes (drum or disc), parking brake, hydraulic system, ABS (if equipped). Electrical: Battery, charging system, starting system, lighting (headlights, taillights, interior), instrument cluster, wiring diagrams, fuses, relays, body control modules. Body Interior: Body panels, doors, windows, locks, seats, dashboard, trim, climate control (HVAC), safety restraints (seatbelts, airbags). Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement, brake pad replacement, tire rotation. Diagnostics Troubleshooting: System-specific diagnostic trouble codes (DTCs), symptom-based troubleshooting charts, electrical system fault finding. Repair Rebuild: Engine overhaul, transmission overhaul, suspension component replacement, brake system repair, electrical component replacement, body panel repair. Special Tools: Identification and usage of specialized tools required for specific repair and maintenance procedures. Technical Depth Level Of Detail: Comprehensive factory-level detail suitable for professional technicians and advanced DIY enthusiasts. Diagnostic Capabilities: Detailed diagnostic procedures, including symptom analysis, component testing, and troubleshooting flowcharts. Specifications Tolerances: Precise torque specifications, clearances, fluid capacities, electrical specifications, and material properties. 📊 Manual Specifications File Format Type: PDF (Portable Document Format) Searchability: Likely text-searchable (as is common for factory manuals), allowing for quick navigation to specific topics. Print Quality Resolution: High-resolution digital reproduction of original factory documentation, suitable for clear printing. Illustrations: Includes detailed diagrams, schematics, and photographic illustrations for clarity. Binding Type Type: N/A (Downloadable PDF, no physical binding) Paper Type Type: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Type: Inline-4 Cylinder, SOHC Displacement: 1.3 Liters (1298 cc) Engine Code: HD-E Performance Horsepower Net Approx: 83-85 HP (at 6000 rpm, depending on market calibration) Torque Net Approx: 100-105 Nm (at 3500-4000 rpm, depending on market calibration) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline (Octane rating typically 91 or higher) Emission Control: Catalytic converter, EGR (Exhaust Gas Recirculation), O2 sensors. 🔧 Transmission Standard Type: 5-speed Manual Transmission Optional Type: 4-speed Automatic Transmission (with lock-up torque converter) Features Drive System: Part-time Four-Wheel Drive (4WD) with selectable 2WD/4WD High/4WD Low range. Clutch Type: Dry single plate diaphragm spring clutch (for manual transmission) 📐 Dimensions Exterior Overall Length Approx: 3715 mm Overall Width Approx: 1695 mm Overall Height Approx: 1690 mm Wheelbase Approx: 2480 mm Ground Clearance Approx: 195 mm Weights Curb Weight Approx: 1150 kg - 1250 kg (depending on transmission and trim) Gross Vehicle Weight Rating Approx: 1600 kg 🛡️ Safety Features Ratings Crash Test Ratings: Specific ratings for the 1998 J100 are not widely documented, but it predates many modern mandated safety standards. Focus is on passive systems. Active Features ABS: Available on higher trim levels or optional. Traction Control: Not typically available on this generation. Passive Features Airbags: Driver's airbag standard, passenger airbag optional or not available on all models. Seatbelts: 3-point front seatbelts with pretensioners, 2-point or 3-point rear seatbelts depending on seating position. Body Structure: Reinforced body structure with crumple zones (basic for the era). 💡 Technology Features Infotainment Audio System: Factory fitted AM/FM radio with cassette player or single CD player. Optional premium sound systems may exist. Display: Basic digital clock display, instrument cluster lighting. Driver Assistance Cruise Control: Optional on higher trim levels, not standard. Parking Sensors: Not available. Connectivity Bluetooth: Not available. Usb Port: Not available. 🔧 Maintenance Service Intervals Engine Oil Change: Every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, whichever comes first. Oil Filter Replacement: With every oil change. Air Filter Replacement: Every 15,000 - 30,000 miles (24,000 - 48,000 km), or sooner if driven...
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Daihatsu Terios J100 1998 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Terios
Model Generation:
J100
Model Year:
1998
Codes
Chassis Code:
J100G
Engine Code Primary:
HDE, HD-E
👋 Introduction
Market Position
Vehicle Segment:
Compact SUV / Kei SUV.
Target Audience:
Individuals seeking a capable, compact, and often affordable 4x4 vehicle for light off-roading, city driving, and utility.
Competitive Analysis
Key Competitors Circa 1998:
Suzuki Jimny/Samurai, Mitsubishi Pajero Mini, Toyota RAV4 (early models), Honda CR-V (early models).
Key Features
Off Road Capability:
Body-on-frame construction, four-wheel drive system (often with selectable modes), relatively short wheelbase contributing to approach/departure angles.
Compact Size:
Maneuverability in urban environments and ease of parking.
Simplicity Reliability:
Often praised for straightforward mechanicals and robust, if basic, construction.
📋 Manual Details
Coverage Areas
Supported Regions:
Global (with regional variations noted where applicable)
Page Count
Total Pages:
Hundreds of pages (exact count not specified in product description, indicating a comprehensive manual)
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English (assumed based on typical availability for international markets)
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, lubrication, cooling, fuel, ignition, exhaust, emissions control, engine management systems (ECU).
Transmission Drivetrain:
Manual transmission, automatic transmission (if applicable), transfer case, differentials (front and rear), driveshafts, axles, hubs.
Chassis Suspension:
Front suspension (independent), rear suspension (solid axle or multi-link, depending on configuration), steering system, wheels, tires.
Brakes:
Front brakes (disc), rear brakes (drum or disc), parking brake, hydraulic system, ABS (if equipped).
Electrical:
Battery, charging system, starting system, lighting (headlights, taillights, interior), instrument cluster, wiring diagrams, fuses, relays, body control modules.
Body Interior:
Body panels, doors, windows, locks, seats, dashboard, trim, climate control (HVAC), safety restraints (seatbelts, airbags).
Procedures Included
Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement, brake pad replacement, tire rotation.
Diagnostics Troubleshooting:
System-specific diagnostic trouble codes (DTCs), symptom-based troubleshooting charts, electrical system fault finding.
Repair Rebuild:
Engine overhaul, transmission overhaul, suspension component replacement, brake system repair, electrical component replacement, body panel repair.
Special Tools:
Identification and usage of specialized tools required for specific repair and maintenance procedures.
Technical Depth
Level Of Detail:
Comprehensive factory-level detail suitable for professional technicians and advanced DIY enthusiasts.
Diagnostic Capabilities:
Detailed diagnostic procedures, including symptom analysis, component testing, and troubleshooting flowcharts.
Specifications Tolerances:
Precise torque specifications, clearances, fluid capacities, electrical specifications, and material properties.
📊 Manual Specifications
File Format
Type:
PDF (Portable Document Format)
Searchability:
Likely text-searchable (as is common for factory manuals), allowing for quick navigation to specific topics.
Print Quality
Resolution:
High-resolution digital reproduction of original factory documentation, suitable for clear printing.
Illustrations:
Includes detailed diagrams, schematics, and photographic illustrations for clarity.
Binding Type
Type:
N/A (Downloadable PDF, no physical binding)
Paper Type
Type:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline-4 Cylinder, SOHC
Displacement:
1.3 Liters (1298 cc)
Engine Code:
HD-E
Performance
Horsepower Net Approx:
83-85 HP (at 6000 rpm, depending on market calibration)
Torque Net Approx:
100-105 Nm (at 3500-4000 rpm, depending on market calibration)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (Octane rating typically 91 or higher)
Emission Control:
Catalytic converter, EGR (Exhaust Gas Recirculation), O2 sensors.
🔧 Transmission
Standard
Type:
5-speed Manual Transmission
Optional
Type:
4-speed Automatic Transmission (with lock-up torque converter)
Features
Drive System:
Part-time Four-Wheel Drive (4WD) with selectable 2WD/4WD High/4WD Low range.
Clutch Type:
Dry single plate diaphragm spring clutch (for manual transmission)
📐 Dimensions
Exterior
Overall Length Approx:
3715 mm
Overall Width Approx:
1695 mm
Overall Height Approx:
1690 mm
Wheelbase Approx:
2480 mm
Ground Clearance Approx:
195 mm
Weights
Curb Weight Approx:
1150 kg - 1250 kg (depending on transmission and trim)
Gross Vehicle Weight Rating Approx:
1600 kg
🛡️ Safety Features
Ratings
Crash Test Ratings:
Specific ratings for the 1998 J100 are not widely documented, but it predates many modern mandated safety standards. Focus is on passive systems.
Active Features
ABS:
Available on higher trim levels or optional.
Traction Control:
Not typically available on this generation.
Passive Features
Airbags:
Driver's airbag standard, passenger airbag optional or not available on all models.
Seatbelts:
3-point front seatbelts with pretensioners, 2-point or 3-point rear seatbelts depending on seating position.
Body Structure:
Reinforced body structure with crumple zones (basic for the era).
💡 Technology Features
Infotainment
Audio System:
Factory fitted AM/FM radio with cassette player or single CD player. Optional premium sound systems may exist.
Display:
Basic digital clock display, instrument cluster lighting.
Driver Assistance
Cruise Control:
Optional on higher trim levels, not standard.
Parking Sensors:
Not available.
Connectivity
Bluetooth:
Not available.
Usb Port:
Not available.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, whichever comes first.
Oil Filter Replacement:
With every oil change.
Air Filter Replacement:
Every 15,000 - 30,000 miles (24,000 - 48,000 km), or sooner if driven in dusty conditions.
Spark Plug Replacement:
Every 30,000 - 60,000 miles (48,000 - 96,000 km), depending on plug type (copper vs. platinum).
Coolant Flush:
Every 24,000 - 36,000 miles (40,000 - 60,000 km) or 2-3 years.
Fluid Specifications
Engine Oil Type:
API SG or higher, SAE 10W-30 or 10W-40 (check owner's manual for specific climate recommendations).
Engine Oil Capacity:
Approx. 3.7 Liters (3.9 US Quarts) with filter change.
Transmission Fluid Manual:
API GL-4, SAE 75W-90 or 80W-90 gear oil.
Transmission Fluid Automatic:
Dexron III (or equivalent) automatic transmission fluid.
Coolant Type:
Ethylene glycol-based coolant (pink or green, non-silicate additive type).
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Engine Minor:
Occasional oil leaks from valve cover or oil pan gaskets. Spark plug and distributor cap/rotor wear.
Suspension Wear:
Wear in ball joints, tie rod ends, and bushings due to off-road use or age.
Rust Corrosion:
Areas prone to rust, particularly on the undercarriage, wheel arches, and body seams, especially in regions with road salt.
Transfer Case Issues:
Potential for worn bearings or seals in the transfer case, especially with high mileage or aggressive 4WD use.
Clutch Wear:
Clutch wear on manual transmission models is dependent on driving style.
📚 Vehicle History
Brand Heritage
Manufacturer:
Daihatsu Motor Co., Ltd. (Japan), a subsidiary of Toyota Motor Corporation.
Model Evolution
First Generation Start:
The first generation of the Terios (J100 series) was introduced in 1997.
J100 Key Characteristics:
Positioned as a smaller, more affordable alternative to larger SUVs, emphasizing its compact dimensions and off-road capability due to its body-on-frame construction and 4WD system.
Facelifts Updates:
The J100 received minor updates and facelifts during its production run, including styling revisions and feature additions.
Production
Production Period J100:
1997-2006 (globally, with variations by market)
Manufacturing Location:
Primarily Japan, with potential assembly in other countries under license or joint ventures.
🏆 Awards & Recognition
Recognitions
Off Road Acclaim:
While not winning specific major awards, the Terios J100 gained a reputation in enthusiast circles for its surprising off-road prowess relative to its size and price point.
Ratings
Fuel Economy Approx:
Urban: ~10-12 L/100km; Highway: ~8-10 L/100km (Varies significantly with driving conditions and 4WD usage).
Certifications
Emissions Standards:
Compliant with Japanese emission standards of the late 1990s (e.g., JCCA standards) and applicable international standards where sold.
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