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Daihatsu Terios J100 Service Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Chassis Code: J100 Generation: First Generation (J100) 👋 Introduction Market Position Vehicle Segment: Compact SUV / Mini SUV Target Audience: DIY mechanics, independent workshops, Terios owners seeking to understand and maintain their vehicle Competitive Analysis Key Competitors J100: Suzuki Vitara, Mitsubishi Pajero/Montero (smaller variants), Toyota RAV4 (early models) Key Features Manual Value Proposition: Provides comprehensive DIY repair and maintenance guidance, reducing reliance on professional service and lowering ownership costs. 📋 Manual Details Coverage Applicable Years: 1997-2007 (Primary focus on J100 generation) Coverage Areas: Comprehensive service, repair, and preventative maintenance Format File Format: PDF Compatibility: Windows/macOS Language Language: English Type Manual Type: Service and Repair Manual 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed breakdown of engine components, cylinder head, block, crankshaft, camshaft, timing, etc. Emission Control: Catalytic converter, oxygen sensors, exhaust gas recirculation (EGR) system Efi System: Electronic Fuel Injection system diagnostics, components (injectors, fuel pump, sensors), and operation Lubrication System: Oil pump, oil filter, oil pressure, oil capacity and specifications Cooling System: Radiator, water pump, thermostat, coolant types and capacity, cooling fan operation Ignition System: Spark plugs, ignition coils, ignition timing, distributor (if applicable) Starting System: Starter motor, battery, ignition switch operation Charging System: Alternator, voltage regulator, battery charging diagnostics Clutch: Clutch disc, pressure plate, release bearing, hydraulic system, adjustments Manual Transmission: Gearbox components, shift mechanism, fluid types and capacity, repair procedures Automatic Transmission: Transmission operation, fluid specifications, service, and repair (if applicable to specific models covered) Transmission And Transfer: Transfer case operation, maintenance, and repair, 4WD system components Propeller Shaft: Driveshaft inspection, U-joints, balancing Front And Rear Differential: Differential gear inspection, fluid types and capacity, servicing Front Axle And Suspension: Front suspension components (struts, shocks, bushings, ball joints), alignment, steering knuckles Rear Axle And Suspension: Rear suspension components (leaf springs, shocks, trailing arms), axle housing inspection Brake Including ABS: Brake system diagnostics, disc brakes (pads, rotors), drum brakes, brake fluid specifications and bleeding procedures, ABS system components and troubleshooting Steering: Steering column, power steering system (pump, rack/box), tie rods, steering wheel removal Body: Body panel repair, door mechanisms, interior trim, glass replacement, rust prevention Body Electrical: Lighting system, power windows, central locking, wipers, horn, fuses, relays Harness And Wiring Diagram: Detailed wiring diagrams for all electrical systems, troubleshooting using wiring schematics Procedures Included Maintenance: Regular servicing, fluid changes, filter replacements, inspections Repair: Component-level repair and replacement for all major systems Diagnostics: Troubleshooting common issues, diagnostic procedures for EFI and electrical systems Rebuilds: Overhaul and rebuild procedures for engine, transmission, and differentials Technical Depth Depth: Detailed technical specifications, torque values, tolerances, diagnostic trouble codes (DTCs) if applicable, repair procedures from basic to advanced 📊 Manual Specifications File Characteristics Page Count: Not specified, but implies a comprehensive manual Printability: All pages printable Physical Characteristics Binding Type: Digital (PDF) - Not applicable to physical binding Paper Type: Digital (PDF) - Not applicable to physical paper type ⚙️ Engine Specifications Primary Engine Engine Code Common: G13BA (1.3L SOHC), G15A (1.5L SOHC), G16A (1.6L SOHC - less common on J100) Displacement 1.3L: 1300 cc 1.5L: 1500 cc Performance Horsepower 1.3L: Approx. 70-75 hp Torque 1.3L: Approx. 100-105 Nm Horsepower 1.5L: Approx. 80-85 hp Torque 1.5L: Approx. 115-120 Nm Fuel System Induction: Multi-point Fuel Injection (MPI) Fuel Type Fuel Recommendation: Unleaded gasoline 🔧 Transmission Standard Manual Transmission: 5-speed manual Optional Automatic Transmission: 3-speed automatic (less common) Features Drivetrain: Part-time 4WD (selectable high/low range) 📐 Dimensions Exterior Length Mm: Approx. 3695-3735 mm Width Mm: Approx. 1600-1620 mm Height Mm: Approx. 1690-1705 mm Wheelbase Mm Wheelbase: Approx. 2280 mm Weights Curb Weight Kg: Approx. 1050-1150 kg 🛡️ Safety Features Ratings Crash Test Ratings: Varies by region and testing agency; generally basic for the era. NCAP ratings may be available for specific markets. Active Features ABS: Optional or standard depending on trim level and market. Passive Features Airbags: Driver airbag standard on later models and higher trims; passenger airbag optional. Seatbelts: Front and rear seatbelts, pre-tensioners for front seats on some models. 💡 Technology Features Infotainment Head Unit: Basic AM/FM/CD or cassette players were common. Aftermarket upgrades are frequent. Speakers: Typically 2 or 4 speakers. Driver Assistance ABS: Optional, as mentioned in safety features. Connectivity Connectivity Options: Limited to basic power accessories. No integrated Bluetooth or USB on original units. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 5,000-10,000 km or 6-12 months, depending on driving conditions and oil type. Consult manual for specifics. Transmission Fluid Interval: Manual: Check periodically, change every 40,000-60,000 km. Automatic: Check regularly, change every 40,000-50,000 km. Coolant Change Interval: Every 2-3 years or 40,000-60,000 km. Fluid Specifications Engine Oil Type: API SG/SH/SJ or higher, viscosity typically 10W-30 or 5W-30 depending on climate. Check manual for exact specification. Transmission Fluid Manual: GL-4 gear oil, viscosity 75W-90 or 80W-90. Transmission Fluid Automatic: Dexron III equivalent...
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Daihatsu Terios J100 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Terios
Chassis Code:
J100
Generation:
First Generation (J100)
👋 Introduction
Market Position
Vehicle Segment:
Compact SUV / Mini SUV
Target Audience:
DIY mechanics, independent workshops, Terios owners seeking to understand and maintain their vehicle
Competitive Analysis
Key Competitors J100:
Suzuki Vitara, Mitsubishi Pajero/Montero (smaller variants), Toyota RAV4 (early models)
Key Features
Manual Value Proposition:
Provides comprehensive DIY repair and maintenance guidance, reducing reliance on professional service and lowering ownership costs.
📋 Manual Details
Coverage
Applicable Years:
1997-2007 (Primary focus on J100 generation)
Coverage Areas:
Comprehensive service, repair, and preventative maintenance
Format
File Format:
PDF
Compatibility:
Windows/macOS
Language
Language:
English
Type
Manual Type:
Service and Repair Manual
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed breakdown of engine components, cylinder head, block, crankshaft, camshaft, timing, etc.
Emission Control:
Catalytic converter, oxygen sensors, exhaust gas recirculation (EGR) system
Efi System:
Electronic Fuel Injection system diagnostics, components (injectors, fuel pump, sensors), and operation
Lubrication System:
Oil pump, oil filter, oil pressure, oil capacity and specifications
Cooling System:
Radiator, water pump, thermostat, coolant types and capacity, cooling fan operation
Ignition System:
Spark plugs, ignition coils, ignition timing, distributor (if applicable)
Starting System:
Starter motor, battery, ignition switch operation
Charging System:
Alternator, voltage regulator, battery charging diagnostics
Clutch:
Clutch disc, pressure plate, release bearing, hydraulic system, adjustments
Manual Transmission:
Gearbox components, shift mechanism, fluid types and capacity, repair procedures
Automatic Transmission:
Transmission operation, fluid specifications, service, and repair (if applicable to specific models covered)
Transmission And Transfer:
Transfer case operation, maintenance, and repair, 4WD system components
Propeller Shaft:
Driveshaft inspection, U-joints, balancing
Front And Rear Differential:
Differential gear inspection, fluid types and capacity, servicing
Front Axle And Suspension:
Front suspension components (struts, shocks, bushings, ball joints), alignment, steering knuckles
Rear Axle And Suspension:
Rear suspension components (leaf springs, shocks, trailing arms), axle housing inspection
Brake Including ABS:
Brake system diagnostics, disc brakes (pads, rotors), drum brakes, brake fluid specifications and bleeding procedures, ABS system components and troubleshooting
Steering:
Steering column, power steering system (pump, rack/box), tie rods, steering wheel removal
Body:
Body panel repair, door mechanisms, interior trim, glass replacement, rust prevention
Body Electrical:
Lighting system, power windows, central locking, wipers, horn, fuses, relays
Harness And Wiring Diagram:
Detailed wiring diagrams for all electrical systems, troubleshooting using wiring schematics
Procedures Included
Maintenance:
Regular servicing, fluid changes, filter replacements, inspections
Repair:
Component-level repair and replacement for all major systems
Diagnostics:
Troubleshooting common issues, diagnostic procedures for EFI and electrical systems
Rebuilds:
Overhaul and rebuild procedures for engine, transmission, and differentials
Technical Depth
Depth:
Detailed technical specifications, torque values, tolerances, diagnostic trouble codes (DTCs) if applicable, repair procedures from basic to advanced
📊 Manual Specifications
File Characteristics
Page Count:
Not specified, but implies a comprehensive manual
Printability:
All pages printable
Physical Characteristics
Binding Type:
Digital (PDF) - Not applicable to physical binding
Paper Type:
Digital (PDF) - Not applicable to physical paper type
⚙️ Engine Specifications
Primary Engine
Engine Code Common:
G13BA (1.3L SOHC), G15A (1.5L SOHC), G16A (1.6L SOHC - less common on J100)
Displacement
1.3L:
1300 cc
1.5L:
1500 cc
Performance
Horsepower 1.3L:
Approx. 70-75 hp
Torque 1.3L:
Approx. 100-105 Nm
Horsepower 1.5L:
Approx. 80-85 hp
Torque 1.5L:
Approx. 115-120 Nm
Fuel System
Induction:
Multi-point Fuel Injection (MPI)
Fuel Type
Fuel Recommendation:
Unleaded gasoline
🔧 Transmission
Standard
Manual Transmission:
5-speed manual
Optional
Automatic Transmission:
3-speed automatic (less common)
Features
Drivetrain:
Part-time 4WD (selectable high/low range)
📐 Dimensions
Exterior
Length Mm:
Approx. 3695-3735 mm
Width Mm:
Approx. 1600-1620 mm
Height Mm:
Approx. 1690-1705 mm
Wheelbase Mm
Wheelbase:
Approx. 2280 mm
Weights
Curb Weight Kg:
Approx. 1050-1150 kg
🛡️ Safety Features
Ratings
Crash Test Ratings:
Varies by region and testing agency; generally basic for the era. NCAP ratings may be available for specific markets.
Active Features
ABS:
Optional or standard depending on trim level and market.
Passive Features
Airbags:
Driver airbag standard on later models and higher trims; passenger airbag optional.
Seatbelts:
Front and rear seatbelts, pre-tensioners for front seats on some models.
💡 Technology Features
Infotainment
Head Unit:
Basic AM/FM/CD or cassette players were common. Aftermarket upgrades are frequent.
Speakers:
Typically 2 or 4 speakers.
Driver Assistance
ABS:
Optional, as mentioned in safety features.
Connectivity
Connectivity Options:
Limited to basic power accessories. No integrated Bluetooth or USB on original units.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-10,000 km or 6-12 months, depending on driving conditions and oil type. Consult manual for specifics.
Transmission Fluid Interval:
Manual: Check periodically, change every 40,000-60,000 km. Automatic: Check regularly, change every 40,000-50,000 km.
Coolant Change Interval:
Every 2-3 years or 40,000-60,000 km.
Fluid Specifications
Engine Oil Type:
API SG/SH/SJ or higher, viscosity typically 10W-30 or 5W-30 depending on climate. Check manual for exact specification.
Transmission Fluid Manual:
GL-4 gear oil, viscosity 75W-90 or 80W-90.
Transmission Fluid Automatic:
Dexron III equivalent ATF.
Brake Fluid:
DOT 3 or DOT 4.
Coolant:
Ethylene glycol based antifreeze mixed with distilled water (50/50 ratio). Refer to manual for specific type.
Known Issues
Common Wear Items:
Suspension bushings, ball joints, tie rod ends, clutch wear, exhaust system rust, radiator hoses.
Engine Concerns:
Minor oil leaks from gaskets, occasional ignition coil failure on older models.
4Wd System Concerns:
Transfer case bushings, propeller shaft U-joints can wear with high mileage and off-road use.
📚 Vehicle History
Brand Heritage
Daihatsu Specialization:
Daihatsu is known for its expertise in small, compact, and kei-class vehicles, often with a focus on affordability and practicality.
Model Evolution
Terios Purpose:
The Terios J100 was designed as a compact, body-on-frame SUV, offering genuine off-road capability in a small package, a rarity in its segment at the time.
Production
Production Years J100:
1997 - 2007
Manufacturing Locations:
Primarily Japan, with production also occurring in other countries under license or for specific markets.
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