Daihatsu Terios J100 1998 Service Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Generation: J100 Model Year: 1998 👋 Introduction Market Position Vehicle Segment: Compact SUV/Mini SUV Key Competitors Era: Suzuki Vitara, Honda CR-V (earlier models), Toyota RAV4 (earlier models), Mitsubishi Pajero Mini. Competitive Analysis Daihatsu Advantage: Known for affordability, compact size, and a surprisingly capable 4WD system for its class, often appealing to buyers seeking utility without the size and cost of larger SUVs. Key Features Body Style: Three-door and Five-door body styles available. Drivetrain: Available in rear-wheel drive (2WD) and four-wheel drive (4WD) configurations, with the 4WD system being a significant selling point for its off-road capability. Target Demographic: Young drivers, small families, individuals seeking a practical and economical light off-roader. 📋 Manual Details Coverage Areas Engine: Yes Transmission: Yes Brakes: Yes Suspension: Yes Electrical System: Yes Bodywork: Yes Cooling System: Yes Fuel System: Yes Exhaust System: Yes Steering: Yes HVAC: Yes Diagnostic Troubleshooting: Yes Page Count Estimated Pages: Likely over 1000 pages (typical for a comprehensive factory service manual) Manual Type Type: Service and Repair Manual Language Primary Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed disassembly, inspection, assembly, and adjustment of engine components (pistons, rings, bearings, crankshaft, camshaft, valves, cylinder head, block). Engine Management: EFI system operation, fuel injectors, fuel pump, sensors (MAP, TPS, O2, coolant temp), actuators, ignition system (spark plugs, coils, timing). Transmission Manual: Clutch system, gearbox disassembly and assembly, gear ratios, shift mechanisms, lubrication. Transmission Automatic: Torque converter, planetary gear sets, hydraulic control system, valve body, solenoid operation, fluid specifications, cooler lines, disassembly and assembly. Drivetrain 4Wd: Transfer case operation and maintenance, front and rear differentials, drive shafts, CV joints, wheel hubs. Suspension Front: MacPherson strut design, control arms, ball joints, bushings, coil springs, shock absorber replacement, alignment specifications. Suspension Rear: Multi-link or coil spring/shock absorber setup, control arm bushings, trailing arms, alignment specifications. Steering System: Power steering pump, steering rack/gearbox, tie rods, power steering fluid, hydraulic system troubleshooting. Brake System: Front disc brakes (calipers, rotors, pads), rear drum brakes (cylinders, shoes, drums), parking brake system, hydraulic lines, ABS system (if equipped), brake fluid specifications and bleeding procedures. Electrical Charging: Alternator operation, testing, and replacement; battery specifications and maintenance. Electrical Starting: Starter motor operation, testing, and replacement; ignition switch. Lighting System: Headlights, taillights, brake lights, turn signals, interior lighting, bulb types and replacement. Instrument Panel: Gauges, warning lights, indicator functions, cluster removal and repair. HVAC System: Air conditioning compressor, condenser, evaporator, refrigerant types and capacities, heater core, blower motor, controls, cabin air filter. Body And Chassis: Frame construction, body panel removal and installation, door mechanisms, glass replacement, interior trim removal. Safety Systems: Seatbelts, airbags (if equipped, though unlikely for 1998 base models), structural safety components. Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, spark plug replacement, coolant checks and flushes, brake fluid changes, lubrication points. Troubleshooting Diagnostics: Step-by-step diagnostic flowcharts for common problems (e.g., no-start conditions, poor performance, braking issues, electrical faults). Engine Repair: Major engine overhauls, head gasket replacement, timing belt/chain replacement (depending on engine variant), oil pan removal, valve adjustments. Transmission Repair: Clutch replacement, gearbox rebuild (manual), transmission fluid and filter replacement (automatic), seal replacements. Brake Service: Brake pad and rotor replacement, brake shoe and drum relining, caliper rebuild, brake line replacement, bleeding procedures. Suspension And Steering Repair: Shock absorber and strut replacement, ball joint and tie rod end replacement, power steering pump and rack repair/replacement, wheel bearing replacement. Electrical System Diagnosis: Wiring diagrams, fuse and relay identification, component testing using multimeters, troubleshooting lighting, starting, charging, and accessory circuits. HVAC System Service: Refrigerant recharge, component replacement (compressor, condenser, etc.), leak detection, heater core replacement. Body And Trim Repair: Door panel removal, window regulator repair, exterior trim replacement, bumper repair/replacement. Technical Depth Depth: Comprehensive; covers everything from routine maintenance to complete engine and transmission overhauls, electrical system diagnostics, and body repairs. Target Audience: Professional technicians and advanced DIY enthusiasts. 📊 Manual Specifications File Format PDF Quality: Likely high-resolution scans or digital originals, ensuring clarity of diagrams and text. Searchability: PDF format typically allows for text searching, enhancing efficiency. Print Quality Diagram Clarity: Essential for accurate repair; expectation of clear, legible diagrams and schematics. Binding Type Physical Manual: N/A (Digital Download) Paper Type Physical Manual: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code Common: HE-EG (1.3L) Engine Displacement Cc: 1296 cc Engine Type: Inline 4-cylinder, SOHC, 16-valve Performance Horsepower Ps: Approximately 85-88 PS (varies by market and tuning) Torque Nm: Approximately 105-110 Nm (varies by market and tuning) Fuel System Injection Type: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline Engine Management Timing Belt Chain: Timing Belt (critical maintenance item) 🔧 Transmission Standard Transmission Type Std: 5-speed Manual Transmission Optional Transmission Type Opt: 4-speed Automatic Transmission Features 4Wd Engagement: Part-time 4WD with selectable 2WD/4WD/4-Low modes, often operated...

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Description

🏷️ Basic Information

Identification

Make:

Daihatsu

Model:

Terios

Generation:

Model Year:

👋 Introduction

Market Position

Vehicle Segment:

Compact SUV/Mini SUV

Key Competitors Era:

Suzuki Vitara, Honda CR-V (earlier models), Toyota RAV4 (earlier models), Mitsubishi Pajero Mini.

Competitive Analysis

Daihatsu Advantage:

Known for affordability, compact size, and a surprisingly capable 4WD system for its class, often appealing to buyers seeking utility without the size and cost of larger SUVs.

Key Features

Body Style:

Three-door and Five-door body styles available.

Drivetrain:

Available in rear-wheel drive (2WD) and four-wheel drive (4WD) configurations, with the 4WD system being a significant selling point for its off-road capability.

Target Demographic:

Young drivers, small families, individuals seeking a practical and economical light off-roader.

📋 Manual Details

Coverage Areas

Engine:

Transmission:

Brakes:

Suspension:

Electrical System:

Bodywork:

Cooling System:

Fuel System:

Exhaust System:

Steering:

HVAC:

Diagnostic Troubleshooting:

Page Count

Estimated Pages:

Likely over 1000 pages (typical for a comprehensive factory service manual)

Manual Type

Type:

Service and Repair Manual

Language

Primary Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed disassembly, inspection, assembly, and adjustment of engine components (pistons, rings, bearings, crankshaft, camshaft, valves, cylinder head, block).

Engine Management:

EFI system operation, fuel injectors, fuel pump, sensors (MAP, TPS, O2, coolant temp), actuators, ignition system (spark plugs, coils, timing).

Transmission Manual:

Clutch system, gearbox disassembly and assembly, gear ratios, shift mechanisms, lubrication.

Transmission Automatic:

Torque converter, planetary gear sets, hydraulic control system, valve body, solenoid operation, fluid specifications, cooler lines, disassembly and assembly.

Drivetrain 4Wd:

Transfer case operation and maintenance, front and rear differentials, drive shafts, CV joints, wheel hubs.

Suspension Front:

MacPherson strut design, control arms, ball joints, bushings, coil springs, shock absorber replacement, alignment specifications.

Suspension Rear:

Multi-link or coil spring/shock absorber setup, control arm bushings, trailing arms, alignment specifications.

Steering System:

Power steering pump, steering rack/gearbox, tie rods, power steering fluid, hydraulic system troubleshooting.

Brake System:

Front disc brakes (calipers, rotors, pads), rear drum brakes (cylinders, shoes, drums), parking brake system, hydraulic lines, ABS system (if equipped), brake fluid specifications and bleeding procedures.

Electrical Charging:

Alternator operation, testing, and replacement; battery specifications and maintenance.

Electrical Starting:

Starter motor operation, testing, and replacement; ignition switch.

Lighting System:

Headlights, taillights, brake lights, turn signals, interior lighting, bulb types and replacement.

Instrument Panel:

Gauges, warning lights, indicator functions, cluster removal and repair.

HVAC System:

Air conditioning compressor, condenser, evaporator, refrigerant types and capacities, heater core, blower motor, controls, cabin air filter.

Body And Chassis:

Frame construction, body panel removal and installation, door mechanisms, glass replacement, interior trim removal.

Safety Systems:

Seatbelts, airbags (if equipped, though unlikely for 1998 base models), structural safety components.

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter replacement, spark plug replacement, coolant checks and flushes, brake fluid changes, lubrication points.

Troubleshooting Diagnostics:

Step-by-step diagnostic flowcharts for common problems (e.g., no-start conditions, poor performance, braking issues, electrical faults).

Engine Repair:

Major engine overhauls, head gasket replacement, timing belt/chain replacement (depending on engine variant), oil pan removal, valve adjustments.

Transmission Repair:

Clutch replacement, gearbox rebuild (manual), transmission fluid and filter replacement (automatic), seal replacements.

Brake Service:

Brake pad and rotor replacement, brake shoe and drum relining, caliper rebuild, brake line replacement, bleeding procedures.

Suspension And Steering Repair:

Shock absorber and strut replacement, ball joint and tie rod end replacement, power steering pump and rack repair/replacement, wheel bearing replacement.

Electrical System Diagnosis:

Wiring diagrams, fuse and relay identification, component testing using multimeters, troubleshooting lighting, starting, charging, and accessory circuits.

HVAC System Service:

Refrigerant recharge, component replacement (compressor, condenser, etc.), leak detection, heater core replacement.

Body And Trim Repair:

Door panel removal, window regulator repair, exterior trim replacement, bumper repair/replacement.

Technical Depth

Depth:

Comprehensive; covers everything from routine maintenance to complete engine and transmission overhauls, electrical system diagnostics, and body repairs.

Target Audience:

Professional technicians and advanced DIY enthusiasts.

📊 Manual Specifications

File Format

PDF Quality:

Likely high-resolution scans or digital originals, ensuring clarity of diagrams and text.

Searchability:

PDF format typically allows for text searching, enhancing efficiency.

Print Quality

Diagram Clarity:

Essential for accurate repair; expectation of clear, legible diagrams and schematics.

Binding Type

Physical Manual:

N/A (Digital Download)

Paper Type

Physical Manual:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code Common:

HE-EG (1.3L)

Engine Displacement Cc:

1296 cc

Engine Type:

Inline 4-cylinder, SOHC, 16-valve

Performance

Horsepower Ps:

Approximately 85-88 PS (varies by market and tuning)

Torque Nm:

Approximately 105-110 Nm (varies by market and tuning)

Fuel System

Injection Type:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline

Engine Management

Timing Belt Chain:

Timing Belt (critical maintenance item)

🔧 Transmission

Standard

Transmission Type Std:

5-speed Manual Transmission

Optional

Transmission Type Opt:

4-speed Automatic Transmission

Features

4Wd Engagement:

Part-time 4WD with selectable 2WD/4WD/4-Low modes, often operated via a lever or electronic button.

📐 Dimensions

Exterior

Length Mm:

Approx. 3745 mm (3-door)

Width Mm:

Approx. 1600 mm

Height Mm:

Approx. 1695 mm

Wheelbase Mm:

Approx. 2295 mm

Weights

Curb Weight Kg:

Approx. 960-1050 kg (depending on configuration)

🛡️ Safety Features

Ratings

Crash Test Data:

Limited publicly available formal crash test data for this specific era and model from major agencies like NHTSA/Euro NCAP. Early compact SUVs often had less rigorous testing standards compared to modern vehicles.

Active Features

Optional or standard on higher trims/specific markets.

Passive Features

Airbags:

Driver airbag standard, passenger airbag often optional or absent on base models.

Seatbelts:

Three-point seatbelts in the front, likely two-point in the rear on base models or three-point on higher trims.

💡 Technology Features

Infotainment

Audio System:

Likely a basic AM/FM radio with CD or cassette player. Aftermarket head units are common upgrades.

Driver Assistance

Traction Control:

Not typically featured on base models of this era; some higher trims might have basic systems or be absent.

Connectivity

Bluetooth Usb:

Not factory equipped; requires aftermarket installation.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 5,000-7,500 km or 6 months, whichever comes first (refer to manual for specific oil type).

Timing Belt Replacement:

Crucial: Typically 80,000 - 100,000 km or 5-7 years. Failure can cause severe engine damage.

Spark Plugs:

Every 30,000 - 40,000 km, depending on plug type (standard vs. platinum).

Coolant Flush:

Every 40,000 - 60,000 km or 2-3 years.

Fluid Specifications

Engine Oil Grade:

API SG or higher, SAE 10W-30 or 10W-40 recommended (verify in manual).

Engine Oil Capacity:

Approx. 3.0 - 3.5 liters (with filter change).

Coolant Type:

Ethylene Glycol based, typically a 50/50 mix with distilled water. Check manual for specific color/type.

Brake Fluid Type:

DOT 3 or DOT 4.

Transmission Fluid Type Manual:

GL-4 Gear Oil, SAE 75W-90 or 80W-90.

Transmission Fluid Type Automatic:

Dexron II or Dexron III compatible ATF (Automatic Transmission Fluid).

Known Issues

Timing Belt Wear:

Critical wear item. Regular replacement is paramount to avoid catastrophic engine failure. Always replace tensioner and idler pulleys with the belt.

Rust Corrosion:

As with many vehicles of this age, particularly those used in areas with salt on roads, chassis and body rust can be an issue. Check wheel wells, rocker panels, and frame rails.

Suspension Bushings:

Wear and tear on suspension bushings can lead to knocking noises, poor handling, and alignment issues.

Cv Joint Boots:

Torn CV joint boots can lead to premature wear of the joints, especially on 4WD models due to their angle of operation.

Exhaust System:

Corrosion and eventual failure of mufflers and exhaust pipes is common with age.

📚 Vehicle History

Brand Heritage

Daihatsu Focus:

Daihatsu, a subsidiary of Toyota, is renowned for producing small, fuel-efficient, and reliable vehicles, particularly Kei cars and compact SUVs.

Model Evolution

First Generation Start:

First generation Terios (J100 series) launched globally in 1997.

J100 Era:

The J100 represents the initial design philosophy, focusing on a compact, body-on-frame chassis for durability and off-road capability, unlike the monocoque construction of some rivals.

Production

Manufacturing Locations:

Primarily manufactured in Japan, with licensed production and variations in other countries (e.g., Toyota Cami in Japan).

🏆 Awards & Recognition

Recognitions

Specific Awards:

While the Terios J100 itself may not have garnered numerous widely publicized individual awards, Daihatsu vehicles in general are often recognized for their value, practicality, and reliability within their respective segments.