Daihatsu Terios 2 J200 2013 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Generation: 2 Chassis Code: J200 Model Year: 2013 👋 Introduction Market Position Vehicle Segment: Subcompact Crossover SUV Key Selling Points: Affordability, compact size, practical interior, and available 4WD. Competitive Analysis Direct Competitors: Suzuki Jimny (though often smaller), Nissan Juke (segment overlap), Ford EcoSport, Honda HR-V (later generations). Key Features Body Style: Compact SUV with a utility-focused design. Drivetrain Options: Available in both 2WD (rear-wheel drive) and 4WD (four-wheel drive). Target Audience: Urban dwellers, young families, and individuals seeking a capable small SUV for light off-roading or adverse weather conditions. 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Manual Language: English Format: Downloadable PDF Completeness: Complete Official Factory Manual Page Count Page Count: Hundreds of Pages 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed disassembly, assembly, inspection, and repair procedures for engine components, including cylinder head, block, pistons, crankshaft, camshafts, and valve train. Engine Management: Diagnosis and repair of fuel injection systems (EFI), ignition systems, emissions control systems, and engine control unit (ECU) operations. Transmission Manual: Repair and overhaul procedures for the manual transmission, including clutch, gears, synchronizers, and shift mechanisms. Transmission Automatic: Diagnosis, repair, and maintenance for automatic transmissions, including torque converter, planetary gear sets, valve body, and transmission control module (TCM). Drivetrain 4Wd: Service and repair for the 4WD system, including transfer case, propeller shafts, differential gears, and engagement mechanisms. Suspension Front: Repair and alignment procedures for the independent front suspension system, including shock absorbers, springs, control arms, and steering knuckles. Suspension Rear: Service and repair for the rear suspension, detailing axle components, shock absorbers, springs, and trailing arms. Steering: Diagnosis and repair of the power steering system (hydraulic or electric), steering column, and steering linkage. Brakes Front: Inspection, replacement, and adjustment of front disc brake components, including pads, rotors, calipers, and brake lines. Brakes Rear: Service and repair for rear drum or disc brake systems, including shoes, drums, cylinders, and parking brake mechanisms. Anti Lock Braking System ABS: Diagnosis, testing, and repair of the ABS system, including wheel speed sensors, hydraulic control unit (HCU), and warning lights. Electrical System Charging: Troubleshooting and repair of the charging system, including battery, alternator, and voltage regulator. Electrical System Starting: Diagnosis and repair of the starting system, including starter motor, ignition switch, and related circuits. Lighting System: Repair and maintenance of headlights, taillights, interior lighting, and auxiliary lighting systems. Instrument Panel Gauges: Diagnosis and repair of instrument cluster components, warning lights, and gauges. Body Electrical: Wiring diagrams and troubleshooting for power windows, door locks, mirrors, wipers, and other body electrical components. Climate Control HVAC: Repair and maintenance of the heating, ventilation, and air conditioning (HVAC) system, including refrigerant recharge and component replacement. Audio System: Installation, troubleshooting, and repair of the car audio system. Airbags Srs: Diagnosis, inspection, and replacement procedures for the Supplemental Restraint System (SRS), including airbags, control module, and sensors. Fuel System: Service and repair of the fuel tank, fuel pump, fuel lines, fuel filter, and fuel injectors. Exhaust System: Inspection, repair, and replacement of exhaust pipes, muffler, catalytic converter, and oxygen sensors. Body Exterior: Repair procedures for body panels, bumpers, doors, hood, trunk, and glass. Body Interior: Removal, installation, and repair of interior trim panels, seats, dashboard, and headliner. Procedures Included Routine Maintenance: Oil changes, filter replacements (oil, air, cabin, fuel), spark plug replacement, fluid level checks and top-offs. Troubleshooting Guides: Systematic diagnostic procedures for common and complex issues, including symptom-based troubleshooting charts. Component Removal Installation: Step-by-step instructions for removing and reinstalling virtually all mechanical and electrical components. Engine Rebuild: Detailed procedures for complete engine disassembly, inspection, measurement, part replacement, and reassembly for engine overhauls. Transmission Overhaul: Comprehensive steps for the complete disassembly, inspection, repair, and reassembly of both manual and automatic transmissions. Brake System Overhaul: Procedures for brake bleeding, caliper rebuilding, master cylinder replacement, and ABS component servicing. Electrical Diagnostics: Guidance on using multimeters, oscilloscopes, and diagnostic scan tools; detailed wiring diagrams for all electrical circuits. Suspension Alignment: Specifications and procedures for front and rear wheel alignment. Air Conditioning Servicing: Refrigerant handling, leak testing, component replacement (compressor, condenser, evaporator), and system evacuation/charging. Torque Specifications: Precise torque values for all critical fasteners throughout the vehicle. Tightening Sequences: Specific order and method for tightening critical components like cylinder heads and wheel nuts. Special Tool Requirements: Identification and usage instructions for specialized tools required for specific repairs. Diagnostic Trouble Codes DTC: Explanation of DTCs, their meaning, and troubleshooting steps. Technical Depth Depth Level: Comprehensive factory-level repair information. Diagnostic Capability: Advanced diagnostic procedures, including wiring schematics and sensor data interpretation. Repair Complexity: Covers everything from basic fluid changes to complete powertrain overhauls and body repairs. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Print Quality Print Quality: High-resolution for clear text and diagrams; suitable for printing. Binding Type Binding...

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Description

🏷️ Basic Information

Identification

Make:

Daihatsu

Model:

Terios

Generation:

Chassis Code:

Model Year:

👋 Introduction

Market Position

Vehicle Segment:

Subcompact Crossover SUV

Key Selling Points:

Affordability, compact size, practical interior, and available 4WD.

Competitive Analysis

Direct Competitors:

Suzuki Jimny (though often smaller), Nissan Juke (segment overlap), Ford EcoSport, Honda HR-V (later generations).

Key Features

Body Style:

Compact SUV with a utility-focused design.

Drivetrain Options:

Available in both 2WD (rear-wheel drive) and 4WD (four-wheel drive).

Target Audience:

Urban dwellers, young families, and individuals seeking a capable small SUV for light off-roading or adverse weather conditions.

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Repair Manual

Language:

English

Format:

Downloadable PDF

Completeness:

Complete Official Factory Manual

Page Count

Page Count:

Hundreds of Pages

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed disassembly, assembly, inspection, and repair procedures for engine components, including cylinder head, block, pistons, crankshaft, camshafts, and valve train.

Engine Management:

Diagnosis and repair of fuel injection systems (EFI), ignition systems, emissions control systems, and engine control unit (ECU) operations.

Transmission Manual:

Repair and overhaul procedures for the manual transmission, including clutch, gears, synchronizers, and shift mechanisms.

Transmission Automatic:

Diagnosis, repair, and maintenance for automatic transmissions, including torque converter, planetary gear sets, valve body, and transmission control module (TCM).

Drivetrain 4Wd:

Service and repair for the 4WD system, including transfer case, propeller shafts, differential gears, and engagement mechanisms.

Suspension Front:

Repair and alignment procedures for the independent front suspension system, including shock absorbers, springs, control arms, and steering knuckles.

Suspension Rear:

Service and repair for the rear suspension, detailing axle components, shock absorbers, springs, and trailing arms.

Steering:

Diagnosis and repair of the power steering system (hydraulic or electric), steering column, and steering linkage.

Brakes Front:

Inspection, replacement, and adjustment of front disc brake components, including pads, rotors, calipers, and brake lines.

Brakes Rear:

Service and repair for rear drum or disc brake systems, including shoes, drums, cylinders, and parking brake mechanisms.

Anti Lock Braking System ABS:

Diagnosis, testing, and repair of the ABS system, including wheel speed sensors, hydraulic control unit (HCU), and warning lights.

Electrical System Charging:

Troubleshooting and repair of the charging system, including battery, alternator, and voltage regulator.

Electrical System Starting:

Diagnosis and repair of the starting system, including starter motor, ignition switch, and related circuits.

Lighting System:

Repair and maintenance of headlights, taillights, interior lighting, and auxiliary lighting systems.

Instrument Panel Gauges:

Diagnosis and repair of instrument cluster components, warning lights, and gauges.

Body Electrical:

Wiring diagrams and troubleshooting for power windows, door locks, mirrors, wipers, and other body electrical components.

Climate Control HVAC:

Repair and maintenance of the heating, ventilation, and air conditioning (HVAC) system, including refrigerant recharge and component replacement.

Audio System:

Installation, troubleshooting, and repair of the car audio system.

Airbags Srs:

Diagnosis, inspection, and replacement procedures for the Supplemental Restraint System (SRS), including airbags, control module, and sensors.

Fuel System:

Service and repair of the fuel tank, fuel pump, fuel lines, fuel filter, and fuel injectors.

Exhaust System:

Inspection, repair, and replacement of exhaust pipes, muffler, catalytic converter, and oxygen sensors.

Body Exterior:

Repair procedures for body panels, bumpers, doors, hood, trunk, and glass.

Body Interior:

Removal, installation, and repair of interior trim panels, seats, dashboard, and headliner.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements (oil, air, cabin, fuel), spark plug replacement, fluid level checks and top-offs.

Troubleshooting Guides:

Systematic diagnostic procedures for common and complex issues, including symptom-based troubleshooting charts.

Component Removal Installation:

Step-by-step instructions for removing and reinstalling virtually all mechanical and electrical components.

Engine Rebuild:

Detailed procedures for complete engine disassembly, inspection, measurement, part replacement, and reassembly for engine overhauls.

Transmission Overhaul:

Comprehensive steps for the complete disassembly, inspection, repair, and reassembly of both manual and automatic transmissions.

Brake System Overhaul:

Procedures for brake bleeding, caliper rebuilding, master cylinder replacement, and ABS component servicing.

Electrical Diagnostics:

Guidance on using multimeters, oscilloscopes, and diagnostic scan tools; detailed wiring diagrams for all electrical circuits.

Suspension Alignment:

Specifications and procedures for front and rear wheel alignment.

Air Conditioning Servicing:

Refrigerant handling, leak testing, component replacement (compressor, condenser, evaporator), and system evacuation/charging.

Torque Specifications:

Precise torque values for all critical fasteners throughout the vehicle.

Tightening Sequences:

Specific order and method for tightening critical components like cylinder heads and wheel nuts.

Special Tool Requirements:

Identification and usage instructions for specialized tools required for specific repairs.

Diagnostic Trouble Codes DTC:

Explanation of DTCs, their meaning, and troubleshooting steps.

Technical Depth

Depth Level:

Comprehensive factory-level repair information.

Diagnostic Capability:

Advanced diagnostic procedures, including wiring schematics and sensor data interpretation.

Repair Complexity:

Covers everything from basic fluid changes to complete powertrain overhauls and body repairs.

📊 Manual Specifications

File Format

File Format:

PDF (Portable Document Format)

Print Quality

Print Quality:

High-resolution for clear text and diagrams; suitable for printing.

Binding Type

Binding Type:

Digital Download (Printable)

Paper Type

Paper Type:

N/A (Digital Format)

Searchability

Searchability:

Text-searchable PDF for quick information retrieval.

⚙️ Engine Specifications

Primary Engine

Engine Code:

3SZ-VE

Engine Type:

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

Displacement:

1.5 Liters (1495 cc)

Bore X Stroke:

72.0 mm x 91.8 mm

Compression Ratio:

9.0:1

Fuel Delivery:

Electronic Fuel Injection (EFI)

Performance

Horsepower:

Approximately 109 PS (107 hp / 80 kW) at 6000 rpm

Torque:

Approximately 141 Nm (104 lb-ft) at 4400 rpm

Fuel System

Fuel Type:

Unleaded Gasoline

Fuel Tank Capacity:

Approximately 50 Liters (13.2 US Gallons)

🔧 Transmission

Standard

Transmission Type Standard:

5-Speed Manual Transmission

Optional

Transmission Type Optional:

4-Speed Automatic Transmission

Features

Transfer Case:

Center differential with viscous coupling for 4WD models.

Transmission Fluid Type:

Refer to manual for specific fluid type (e.g., Dexron III or equivalent for automatic, GL-4 for manual).

📐 Dimensions

Exterior

Length:

Approximately 4000 mm (157.5 in)

Width:

Approximately 1695 mm (66.7 in)

Height:

Approximately 1705 mm (67.1 in)

Wheelbase:

Approximately 2580 mm (101.6 in)

Ground Clearance:

Approximately 190 mm (7.5 in)

Weights

Curb Weight:

Approximately 1150 - 1250 kg (2535 - 2756 lbs) depending on configuration.

Cargo

Cargo Volume Seats Up:

Approximately 350 - 400 Liters (12.4 - 14.1 cu ft)

Cargo Volume Seats Down:

Approximately 750 - 800 Liters (26.5 - 28.3 cu ft)

🛡️ Safety Features

Ratings

Latin Ncap Rating:

4 Stars (for models tested with airbags)

Active Features

Standard on most models.

E Brake Assist:

Not commonly featured.

Traction Control:

Optional on some models.

Electronic Stability Control Esc:

Optional on some models.

Passive Features

Airbags Driver:

Standard.

Airbags Passenger:

Standard.

Airbags Side Curtain:

Optional on some models.

Seatbelts Front Pre Tensioners:

Standard.

Child Seat Anchors:

ISOFIX mounts.

💡 Technology Features

Infotainment

Head Unit:

Standard radio with CD player, often with MP3 compatibility and auxiliary input. Optional touchscreen infotainment systems in higher trims.

Speaker System:

Typically 4-6 speakers depending on trim level.

Driver Assistance

Cruise Control:

Available on higher trim levels.

Parking Sensors:

Optional.

Connectivity

Bluetooth:

Optional on later models.

Usb Port:

Optional.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000-10,000 km (3,000-6,000 miles) or 6-12 months, depending on driving conditions.

Air Filter Replacement:

Every 20,000-30,000 km (12,000-18,000 miles) or as needed.

Spark Plug Replacement:

Iridium type plugs typically last 80,000-100,000 km (50,000-60,000 miles).

Coolant Replacement:

Every 40,000-60,000 km (25,000-37,000 miles) or 2-4 years.

Fluid Specifications

Engine Oil Specification:

API SN/SP, ILSAC GF-5/GF-6A, SAE 0W-20 or 5W-30 (check manual for exact specification).

Engine Oil Capacity:

Approximately 3.7 Liters (3.9 US Quarts) with filter change.

Transmission Fluid Manual:

API GL-4 SAE 75W-85 or 75W-90 (check manual).

Transmission Fluid Automatic:

Dexron III H or equivalent (check manual).

Brake Fluid Type:

DOT 3 or DOT 4.

Coolant Type:

Ethylene Glycol based, silicate-free, OAT (Organic Acid Technology) type coolant (typically pink/red).

Known Issues

Catalytic Converter Failure:

Can occur due to engine misfires or fuel contamination over time.

Suspension Wear:

Front control arm bushings and ball joints can wear, leading to knocking noises and alignment issues.

Rear Wheel Bearing Noise:

Rear wheel bearings can become noisy with mileage, especially on 4WD models.

Exhaust Manifold Cracks:

Some reports of exhaust manifold cracks leading to exhaust leaks and ticking sounds.

Automatic Transmission Shifting Issues:

Early signs of transmission wear can manifest as delayed or harsh shifting.

📚 Vehicle History

Brand Heritage

Brand Focus:

Daihatsu is known for producing small, fuel-efficient, and often rugged vehicles.

Model Evolution

First Generation:

The original Terios was launched in 1997, also as a compact SUV.

Second Generation Launch:

The J200 series (second generation) was introduced globally around 2006, with this 2013 model being a facelifted version.

Production

Manufacturing Locations:

Primarily manufactured in Japan and also licensed for production in other regions.

🏆 Awards & Recognition

Recognitions

Latin Ncap:

Achieved a respectable 4-star safety rating in Latin NCAP tests for models equipped with airbags, highlighting its commitment to safety in its segment.