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DAIHATSU SIRION BOON 2004-10 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Sirion / Boon Model Code: M3 Generation: 2nd Generation (M300 series) Production Years Covered By Manual: 2004, 2005, 2006, 2007, 2008, 2009, 2010 👋 Introduction Market Position Vehicle Segment: Subcompact hatchback, often marketed as a city car or small family vehicle. Competed with models like the Toyota Yaris, Honda Fit/Jazz, and Ford Fiesta. Competitive Analysis Key Differentiators: Known for its compact exterior dimensions, surprisingly spacious interior (especially in the M3 platform which prioritized interior packaging), fuel efficiency, and Daihatsu's reputation for reliability in smaller vehicles. Key Features Manual Value Proposition: An essential resource for owners and independent mechanics seeking in-depth, accurate repair and maintenance information, offering significant cost savings over dealership service. Manual Usability: Combines detailed text with clear illustrations, diagrams, and step-by-step instructions for ease of understanding and execution. Target Audience: Suitable for DIY mechanics, home enthusiasts, and professional repair technicians. 📋 Manual Details Coverage Areas Primary Regions Of Coverage: Global (based on shared platform and common specifications) Specific Market Notes: The Daihatsu Sirion and Toyota bB/Racer (which shares the M3 platform) are closely related. This manual provides comprehensive data for the M3 platform vehicles. Engine Variants Covered: Includes both 1.0L 1KR-FE and 1.3L K3-VE engine variants. Transmission Variants Covered: Includes both 4-Speed Automatic (4A/T) and 5-Speed Manual (5M/T) transmissions. Page Count Estimated Page Count: Likely exceeding 1500 pages (typical for comprehensive workshop manuals of this era) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Delivery Format: Electronic (PDF) Distribution Method: Digital Download (ZIP archive) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, intake, exhaust, lubrication, cooling, fuel, engine control, emission control, ignition, starting, charging, engine mounting, clutch, manual transmission, automatic transmission, transmission control. Chassis: Front suspension, rear suspension, wheel and tire, drive shaft/axle, brake system, parking brake, brake control. Body And Electrical: Body construction, body panel replacement, rust preventive treatment, body dimensional diagrams, wiring diagrams. Electrical System: Comprehensive coverage including lighting, power accessories, engine management sensors and actuators, body control modules, and detailed wiring diagrams for all circuits. Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, lubrication, inspection procedures. Repair And Overhaul: Complete engine disassembly and reassembly, transmission repair, suspension component replacement, brake system overhaul, body panel repair, electrical component diagnostics and replacement. Diagnostics: Troubleshooting guides, diagnostic trouble codes (DTCs) interpretation, symptom-based diagnostics, circuit testing. Performance Tuning: While primarily a repair manual, it provides the foundational technical data (engine specs, ECU function) necessary for understanding performance parameters and potential tuning considerations. Technical Depth Depth: Comprehensive. Covers everything from routine maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and electrical schematics. 📊 Manual Specifications File Format Digital Format: PDF Software Requirements: Adobe Acrobat Reader (free download), WinZip/WinRAR (for extraction, free download available). Searchability: PDF format is typically searchable by keywords, allowing for quick access to specific information within the manual. Print Quality Printability: All pages are printable. Binding Type Binding: Not applicable (Digital format) Paper Type Paper Quality: Not applicable (Digital format) ⚙️ Engine Specifications Primary Engine 1.0L Engine: 1KR-FE, DOHC, 12-valve, 3-cylinder, naturally aspirated. 1.3L Engine: K3-VE, DOHC, 16-valve, 4-cylinder, naturally aspirated. Performance 1.0L Power Output (Estimated): Approximately 65-70 PS (48-51 kW) @ 6000 rpm. 1.0L Torque Output (Estimated): Approximately 95-100 Nm (70-74 lb-ft) @ 3600 rpm. 1.3L Power Output (Estimated): Approximately 85-90 PS (63-66 kW) @ 6000 rpm. 1.3L Torque Output (Estimated): Approximately 120-125 Nm (89-92 lb-ft) @ 3200 rpm. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI). Fuel Type: Unleaded Gasoline. Cooling System Cooling Method: Water-cooled, pressurized system. Engine Mechanical Valve Train: Both engines feature DOHC (Double Overhead Camshaft) for precise valve timing and control. 🔧 Transmission Standard Standard Transmission: 5-Speed Manual Transmission (5M/T). Optional Optional Transmission: 4-Speed Automatic Transmission (4A/T). Features Automatic Transmission Features: Likely equipped with torque converter lock-up for improved fuel economy. Manual Transmission Features: Standard clutch operation, direct gear engagement. 📐 Dimensions Exterior Overall Length M3 Platform: Approximately 3,600 - 3,750 mm (varies slightly by market and trim). Overall Width M3 Platform: Approximately 1,600 - 1,665 mm. Overall Height M3 Platform: Approximately 1,530 - 1,550 mm. Weights Curb Weight Range: Approximately 900 - 980 kg (depending on engine and transmission). 🛡️ Safety Features Ratings Crash Test Results: Euro NCAP and other regional safety bodies tested early models of the M3 platform. Specific scores vary, but generally provided adequate protection for its class. Manual would contain detailed structural information relevant to safety. Active Features Available Active Safety: Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Traction Control System (TCS) on some higher trims/later models. Passive Features Available Passive Safety: Front airbags, side airbags (optional), pretensioner seatbelts, crumple zones, reinforced passenger safety cell. 💡 Technology Features Infotainment Factory Infotainment Options: Basic radio/CD players, optional navigation systems on higher trims. Manual covers wiring and basic diagnostics for these systems. Driver Assistance...
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DAIHATSU SIRION BOON 2004-10 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Sirion / Boon
Model Code:
M3
Generation:
2nd Generation (M300 series)
Production Years Covered By Manual:
2004, 2005, 2006, 2007, 2008, 2009, 2010
👋 Introduction
Market Position
Vehicle Segment:
Subcompact hatchback, often marketed as a city car or small family vehicle. Competed with models like the Toyota Yaris, Honda Fit/Jazz, and Ford Fiesta.
Competitive Analysis
Key Differentiators:
Known for its compact exterior dimensions, surprisingly spacious interior (especially in the M3 platform which prioritized interior packaging), fuel efficiency, and Daihatsu's reputation for reliability in smaller vehicles.
Key Features
Manual Value Proposition:
An essential resource for owners and independent mechanics seeking in-depth, accurate repair and maintenance information, offering significant cost savings over dealership service.
Manual Usability:
Combines detailed text with clear illustrations, diagrams, and step-by-step instructions for ease of understanding and execution.
Target Audience:
Suitable for DIY mechanics, home enthusiasts, and professional repair technicians.
📋 Manual Details
Coverage Areas
Primary Regions Of Coverage:
Global (based on shared platform and common specifications)
Specific Market Notes:
The Daihatsu Sirion and Toyota bB/Racer (which shares the M3 platform) are closely related. This manual provides comprehensive data for the M3 platform vehicles.
Engine Variants Covered:
Includes both 1.0L 1KR-FE and 1.3L K3-VE engine variants.
Transmission Variants Covered:
Includes both 4-Speed Automatic (4A/T) and 5-Speed Manual (5M/T) transmissions.
Page Count
Estimated Page Count:
Likely exceeding 1500 pages (typical for comprehensive workshop manuals of this era)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Delivery Format:
Electronic (PDF)
Distribution Method:
Digital Download (ZIP archive)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, intake, exhaust, lubrication, cooling, fuel, engine control, emission control, ignition, starting, charging, engine mounting, clutch, manual transmission, automatic transmission, transmission control.
Chassis:
Front suspension, rear suspension, wheel and tire, drive shaft/axle, brake system, parking brake, brake control.
Body And Electrical:
Body construction, body panel replacement, rust preventive treatment, body dimensional diagrams, wiring diagrams.
Electrical System:
Comprehensive coverage including lighting, power accessories, engine management sensors and actuators, body control modules, and detailed wiring diagrams for all circuits.
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, lubrication, inspection procedures.
Repair And Overhaul:
Complete engine disassembly and reassembly, transmission repair, suspension component replacement, brake system overhaul, body panel repair, electrical component diagnostics and replacement.
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs) interpretation, symptom-based diagnostics, circuit testing.
Performance Tuning:
While primarily a repair manual, it provides the foundational technical data (engine specs, ECU function) necessary for understanding performance parameters and potential tuning considerations.
Technical Depth
Depth:
Comprehensive. Covers everything from routine maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and electrical schematics.
📊 Manual Specifications
File Format
Digital Format:
PDF
Software Requirements:
Adobe Acrobat Reader (free download), WinZip/WinRAR (for extraction, free download available).
Searchability:
PDF format is typically searchable by keywords, allowing for quick access to specific information within the manual.
Print Quality
Printability:
All pages are printable.
Binding Type
Binding:
Not applicable (Digital format)
Paper Type
Paper Quality:
Not applicable (Digital format)
⚙️ Engine Specifications
Primary Engine
1.0L Engine:
1KR-FE, DOHC, 12-valve, 3-cylinder, naturally aspirated.
1.3L Engine:
K3-VE, DOHC, 16-valve, 4-cylinder, naturally aspirated.
Performance
1.0L Power Output (Estimated):
Approximately 65-70 PS (48-51 kW) @ 6000 rpm.
1.0L Torque Output (Estimated):
Approximately 95-100 Nm (70-74 lb-ft) @ 3600 rpm.
1.3L Power Output (Estimated):
Approximately 85-90 PS (63-66 kW) @ 6000 rpm.
1.3L Torque Output (Estimated):
Approximately 120-125 Nm (89-92 lb-ft) @ 3200 rpm.
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI).
Fuel Type:
Unleaded Gasoline.
Cooling System
Cooling Method:
Water-cooled, pressurized system.
Engine Mechanical
Valve Train:
Both engines feature DOHC (Double Overhead Camshaft) for precise valve timing and control.
🔧 Transmission
Standard
Standard Transmission:
5-Speed Manual Transmission (5M/T).
Optional
Optional Transmission:
4-Speed Automatic Transmission (4A/T).
Features
Automatic Transmission Features:
Likely equipped with torque converter lock-up for improved fuel economy.
Manual Transmission Features:
Standard clutch operation, direct gear engagement.
📐 Dimensions
Exterior
Overall Length M3 Platform:
Approximately 3,600 - 3,750 mm (varies slightly by market and trim).
Overall Width M3 Platform:
Approximately 1,600 - 1,665 mm.
Overall Height M3 Platform:
Approximately 1,530 - 1,550 mm.
Weights
Curb Weight Range:
Approximately 900 - 980 kg (depending on engine and transmission).
🛡️ Safety Features
Ratings
Crash Test Results:
Euro NCAP and other regional safety bodies tested early models of the M3 platform. Specific scores vary, but generally provided adequate protection for its class. Manual would contain detailed structural information relevant to safety.
Active Features
Available Active Safety:
Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Traction Control System (TCS) on some higher trims/later models.
Passive Features
Available Passive Safety:
Front airbags, side airbags (optional), pretensioner seatbelts, crumple zones, reinforced passenger safety cell.
💡 Technology Features
Infotainment
Factory Infotainment Options:
Basic radio/CD players, optional navigation systems on higher trims. Manual covers wiring and basic diagnostics for these systems.
Driver Assistance
Driver Assistance Features:
Limited in base models. ABS, EBD, and optional traction control were available depending on market and trim level. Manual details operation and troubleshooting.
Connectivity
Wiring Diagrams Importance:
Comprehensive wiring diagrams are provided, essential for diagnosing and repairing any electrical issues, including accessory installations or aftermarket upgrades.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000 km (6,000 miles) or 12 months, whichever comes first. Manual will confirm exact intervals and conditions.
Air Filter Replacement:
Recommended every 20,000 - 30,000 km (12,000 - 18,000 miles) or as needed based on driving conditions. Manual will provide specific checks.
Spark Plug Replacement:
Depends on spark plug type (e.g., standard, iridium). Iridium plugs can last up to 100,000 km (60,000 miles). Manual will specify type and interval.
Fluid Specifications
Engine Oil Type:
API SG, SH, SJ or ACEA A1/B1 or A3/B3 compatible. Viscosity typically 5W-30 or 10W-30. Manual will provide exact specification (e.g., 08880-80373 for Toyota Genuine Motor Oil).
Coolant Type:
Ethylene glycol-based antifreeze coolant. Toyota Super Long Life Coolant (SLLC) or equivalent (e.g., pink coolant) is often recommended. Manual will specify with part numbers.
Transmission Fluid Automatic:
Dexron III or equivalent. Toyota Genuine ATF WS (if specified for later models/specific variants) or Dexron II/III for earlier. Manual will list exact part numbers and specifications (e.g., 08886-01705 for ATF T-IV).
Transmission Fluid Manual:
GL-4 gear oil. Viscosity typically 75W-90 or 80W-90. Manual will specify exact API rating and viscosity grade.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid. Manual will specify exact requirement.
Power Steering Fluid:
Typically uses a specific power steering fluid. Manual will list the required type and part number (often Dexron III or a proprietary fluid).
Known Issues
Common Wear Items:
Front control arm bushings, sway bar links, brake pads/rotors due to typical urban driving conditions. The manual details wear checks and replacement procedures for these.
Engine Specific Considerations:
The 1KR-FE (3-cylinder) can be sensitive to oil levels and quality. The K3-VE (4-cylinder) is generally robust. Manual provides detailed engine internal inspection and repair guidance.
📚 Vehicle History
Brand Heritage
Daihatsu Specialty:
Daihatsu has a long-standing reputation as a manufacturer of small, efficient, and reliable cars and Kei cars, particularly known for its engineering prowess in this segment.
Model Evolution
M3 Platform Introduction:
The M3 platform debuted in 2004 and was a significant modernization for Daihatsu's small car offerings, designed for global markets and sharing components with Toyota's subcompact models.
Production
Manufacturing Locations:
Primarily manufactured in Japan by Daihatsu Motor Co., Ltd.
🏆 Awards & Recognition
Recognitions
Safety Awards:
While specific awards for the Sirion/Boon are varied by region, the M3 platform was generally well-received for its safety advancements in the subcompact segment at the time of its release.
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