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Daihatsu Terios J102 J200 J210 & J211 Series Engine Chassis Wiring Transmission 2000-2012 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Terios Codes Chassis Codes: J102, J200, J210, J211 Engine Codes: K3-VE (1.3L), 3SZ-VE (1.5L) 👋 Introduction Market Position Vehicle Segment: Compact SUV/Crossover Key Selling Points: Affordability, reliability, compact size for urban maneuverability, available 4WD for light off-road capability, fuel efficiency. Competitive Analysis Direct Competitors: Suzuki Vitara, Mitsubishi Pajero/Montero io, Toyota RAV4 (older generations), Honda CR-V (older generations), Nissan X-Trail (older generations). Key Features Body Styles: 3-door and 5-door SUV. Drivetrain Options: 2WD (Rear-Wheel Drive) and 4WD (Four-Wheel Drive, often with a selectable transfer case). 📋 Manual Details Coverage Areas Primary Systems: Engine, Chassis, Wiring Harness, Transmission Secondary Systems: Brakes, Suspension, Steering, HVAC, Body Electrical, Fuel System, Exhaust System, Cooling System, Drivetrain Page Count Estimated Pages: 1500+ Manual Type Type: Factory Service Repair Workshop Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Disassembly, assembly, inspection, repair of all engine components (cylinder head, block, pistons, crankshaft, camshaft, valves, timing system, lubrication system, cooling system). Engine Management: Fuel injection system (EFI), ignition system, emissions control systems (EGR, EVAP), engine sensors, ECU diagnostics, troubleshooting. Includes specific details for K3-VE and 3SZ-VE variants. Transmission Manual: Service and repair procedures for manual transmissions (RWD/4WD). Clutch system, gearbox internal components, shift mechanisms, maintenance. Transmission Automatic: Service and repair procedures for automatic transmissions (if applicable to specific models covered). Torque converter, transmission fluid, valve body, planetary gear sets, electronic control unit (ECU) integration. Drivetrain 4Wd: Transfer case operation and repair, front and rear differentials, driveshafts, CV joints, hub locking mechanisms (if applicable). Chassis Suspension: Front suspension (MacPherson struts), rear suspension (Multi-link beam axle or independent), shock absorbers, springs, bushings, alignment specifications. Chassis Steering: Power steering system (hydraulic or electric), steering rack, tie rods, steering column, alignment. Brakes: Front disc brakes, rear drum or disc brakes, ABS system, brake fluid specifications, bleeding procedures, parking brake. Electrical Wiring: Comprehensive wiring diagrams for all vehicle systems, component locations, connector pinouts, diagnostic procedures for electrical faults, fuse and relay information. Body Exterior: Body panel removal and installation, door mechanisms, tailgate, bumpers, mirrors, glass replacement, rust prevention. Body Interior: Dashboard removal, seat removal and installation, trim panels, headliner, carpet, HVAC ducting. HVAC: Air conditioning system (refrigerant types, charging procedures), heater core, blower motor, climate control unit, diagnostics. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug replacement, coolant flushes, brake fluid changes, differential and transmission fluid changes. Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting for engine, transmission, electrical, and chassis issues. Diagnostic Trouble Codes (DTCs). Repair And Rebuild: Detailed instructions for component repair and complete rebuilds of engine, transmission, suspension, and braking systems. Diagnostics: On-Board Diagnostics (OBD-II) system, scan tool usage, sensor data interpretation, electrical circuit testing with multimeters. Specifications Data: Torque specifications for all fasteners, engine clearances, alignment angles, fluid capacities, electrical resistance values. Technical Depth Depth: Comprehensive: Covers everything from basic scheduled maintenance to complete engine and transmission rebuilds, including detailed electrical diagnostics and troubleshooting. 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable for quick access to information Printability: Printable for workshop use Print Quality Image Resolution: High-resolution diagrams and illustrations Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine 1: Daihatsu K3-VE (1.3L DOHC VVT-i) Engine 2: Daihatsu 3SZ-VE (1.5L DOHC VVT-i) Performance K3 Ve Horsepower: Approx. 86-91 HP (depending on market/tuning) K3 Ve Torque: Approx. 120-125 Nm (depending on market/tuning) 3Sz Ve Horsepower: Approx. 109 HP 3Sz Ve Torque: Approx. 145 Nm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline Engine Features Valvetrain: DOHC, 16 valves with VVT-i (Variable Valve Timing with intelligence) Engine Maintenance Oil Type: API SG/SH or SF/SG, ACEA A2-96 or B2-96 (Refer to manual for specific viscosity recommendations like 5W-30 or 10W-30) Oil Capacity: Approx. 3.4 Liters (with filter change) Spark Plugs: Denso K20TXR or NGK BKR6EGP (or equivalent, refer to manual for exact part number based on engine code) 🔧 Transmission Standard Transmission Type 1: 5-speed Manual Transmission Optional Transmission Type 2: 4-speed Automatic Transmission Features 4Wd System: Part-time 4WD system, often with a center differential and transfer case allowing for 2WD, 4WD High, and sometimes 4WD Low range (depending on specific J-series model and trim). Maintenance Manual Trans Fluid: API GL-4, SAE 75W-90 (Refer to manual for exact specifications and capacity) Auto Trans Fluid: Dexron II or equivalent (Refer to manual for exact specifications and capacity) 📐 Dimensions Exterior Overall Length: J102: ~3.6-3.7 m; J200/J210/J211: ~3.9-4.0 m (varies by body style) Overall Width: ~1.6-1.7 m Overall Height: ~1.7-1.8 m Wheelbase: J102: ~2.35 m; J200/J210/J211: ~2.43 m Weights Curb Weight: Approx. 1100-1300 kg (depending on configuration) Gross Vehicle Weight Rating: Approx. 1600-1700 kg (Refer to vehicle VIN plate for exact GVM) Cargo Cargo Volume Rear Seats Up: Approx. 300-350 Liters (estimated, varies by model year...
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Daihatsu Terios J102 J200 J210 & J211 Series Engine Chassis Wiring Transmission 2000-2012 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Terios
Codes
Chassis Codes:
J102, J200, J210, J211
Engine Codes:
K3-VE (1.3L), 3SZ-VE (1.5L)
👋 Introduction
Market Position
Vehicle Segment:
Compact SUV/Crossover
Key Selling Points:
Affordability, reliability, compact size for urban maneuverability, available 4WD for light off-road capability, fuel efficiency.
Competitive Analysis
Direct Competitors:
Suzuki Vitara, Mitsubishi Pajero/Montero io, Toyota RAV4 (older generations), Honda CR-V (older generations), Nissan X-Trail (older generations).
Key Features
Body Styles:
3-door and 5-door SUV.
Drivetrain Options:
2WD (Rear-Wheel Drive) and 4WD (Four-Wheel Drive, often with a selectable transfer case).
📋 Manual Details
Coverage Areas
Primary Systems:
Engine, Chassis, Wiring Harness, Transmission
Secondary Systems:
Brakes, Suspension, Steering, HVAC, Body Electrical, Fuel System, Exhaust System, Cooling System, Drivetrain
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Factory Service Repair Workshop Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Disassembly, assembly, inspection, repair of all engine components (cylinder head, block, pistons, crankshaft, camshaft, valves, timing system, lubrication system, cooling system).
Engine Management:
Fuel injection system (EFI), ignition system, emissions control systems (EGR, EVAP), engine sensors, ECU diagnostics, troubleshooting. Includes specific details for K3-VE and 3SZ-VE variants.
Transmission Manual:
Service and repair procedures for manual transmissions (RWD/4WD). Clutch system, gearbox internal components, shift mechanisms, maintenance.
Transmission Automatic:
Service and repair procedures for automatic transmissions (if applicable to specific models covered). Torque converter, transmission fluid, valve body, planetary gear sets, electronic control unit (ECU) integration.
Drivetrain 4Wd:
Transfer case operation and repair, front and rear differentials, driveshafts, CV joints, hub locking mechanisms (if applicable).
Chassis Suspension:
Front suspension (MacPherson struts), rear suspension (Multi-link beam axle or independent), shock absorbers, springs, bushings, alignment specifications.
Chassis Steering:
Power steering system (hydraulic or electric), steering rack, tie rods, steering column, alignment.
Brakes:
Front disc brakes, rear drum or disc brakes, ABS system, brake fluid specifications, bleeding procedures, parking brake.
Electrical Wiring:
Comprehensive wiring diagrams for all vehicle systems, component locations, connector pinouts, diagnostic procedures for electrical faults, fuse and relay information.
Body Exterior:
Body panel removal and installation, door mechanisms, tailgate, bumpers, mirrors, glass replacement, rust prevention.
Body Interior:
Dashboard removal, seat removal and installation, trim panels, headliner, carpet, HVAC ducting.
HVAC:
Air conditioning system (refrigerant types, charging procedures), heater core, blower motor, climate control unit, diagnostics.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug replacement, coolant flushes, brake fluid changes, differential and transmission fluid changes.
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting for engine, transmission, electrical, and chassis issues. Diagnostic Trouble Codes (DTCs).
Repair And Rebuild:
Detailed instructions for component repair and complete rebuilds of engine, transmission, suspension, and braking systems.
Diagnostics:
On-Board Diagnostics (OBD-II) system, scan tool usage, sensor data interpretation, electrical circuit testing with multimeters.
Specifications Data:
Torque specifications for all fasteners, engine clearances, alignment angles, fluid capacities, electrical resistance values.
Technical Depth
Depth:
Comprehensive: Covers everything from basic scheduled maintenance to complete engine and transmission rebuilds, including detailed electrical diagnostics and troubleshooting.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable for quick access to information
Printability:
Printable for workshop use
Print Quality
Image Resolution:
High-resolution diagrams and illustrations
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine 1:
Daihatsu K3-VE (1.3L DOHC VVT-i)
Engine 2:
Daihatsu 3SZ-VE (1.5L DOHC VVT-i)
Performance
K3 Ve Horsepower:
Approx. 86-91 HP (depending on market/tuning)
K3 Ve Torque:
Approx. 120-125 Nm (depending on market/tuning)
3Sz Ve Horsepower:
Approx. 109 HP
3Sz Ve Torque:
Approx. 145 Nm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Engine Features
Valvetrain:
DOHC, 16 valves with VVT-i (Variable Valve Timing with intelligence)
Engine Maintenance
Oil Type:
API SG/SH or SF/SG, ACEA A2-96 or B2-96 (Refer to manual for specific viscosity recommendations like 5W-30 or 10W-30)
Oil Capacity:
Approx. 3.4 Liters (with filter change)
Spark Plugs:
Denso K20TXR or NGK BKR6EGP (or equivalent, refer to manual for exact part number based on engine code)
🔧 Transmission
Standard
Transmission Type 1:
5-speed Manual Transmission
Optional
Transmission Type 2:
4-speed Automatic Transmission
Features
4Wd System:
Part-time 4WD system, often with a center differential and transfer case allowing for 2WD, 4WD High, and sometimes 4WD Low range (depending on specific J-series model and trim).
Maintenance
Manual Trans Fluid:
API GL-4, SAE 75W-90 (Refer to manual for exact specifications and capacity)
Auto Trans Fluid:
Dexron II or equivalent (Refer to manual for exact specifications and capacity)
📐 Dimensions
Exterior
Overall Length:
J102: ~3.6-3.7 m; J200/J210/J211: ~3.9-4.0 m (varies by body style)
Overall Width:
~1.6-1.7 m
Overall Height:
~1.7-1.8 m
Wheelbase:
J102: ~2.35 m; J200/J210/J211: ~2.43 m
Weights
Curb Weight:
Approx. 1100-1300 kg (depending on configuration)
Gross Vehicle Weight Rating:
Approx. 1600-1700 kg (Refer to vehicle VIN plate for exact GVM)
Cargo
Cargo Volume Rear Seats Up:
Approx. 300-350 Liters (estimated, varies by model year and body style)
Cargo Volume Rear Seats Down:
Approx. 800-900 Liters (estimated, varies by model year and body style)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Varies significantly by market and specific year. Early models may not have undergone extensive modern crash testing. Later models sold in regions with stricter safety standards would have more data. Manual provides safety system information.
Active Features
ABS:
Anti-lock Braking System (ABS) commonly available, especially on higher trims and later models.
Traction Control:
Traction Control System (TCS) may be available on some higher-spec models or later production years.
Passive Features
Airbags:
Driver and front passenger airbags standard on most models. Side airbags and curtain airbags may be optional or standard on later/higher trim levels.
Seat Belts:
3-point seatbelts with pretensioners for front occupants.
Child Seat Anchors:
ISOFIX/LATCH child seat anchor points in rear seats on applicable models.
💡 Technology Features
Infotainment
Infotainment System:
Basic to moderate infotainment systems depending on trim and market. Typically includes AM/FM radio, CD player, and optional navigation. Speaker system details and wiring are covered.
Driver Assistance
Driver Assistance Features:
Limited by modern standards. Primarily includes ABS and potentially TCS. The manual details the operation and diagnostics of these systems.
Connectivity
Connectivity Features:
Basic connectivity, often with auxiliary audio input. Power outlet (cigarette lighter socket) for charging devices.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-10,000 km or 6-12 months, whichever comes first (depending on driving conditions and oil quality – refer to manual).
Air Filter Replacement:
Every 20,000-40,000 km or annually.
Spark Plug Replacement:
Every 40,000-80,000 km (depending on spark plug type - standard vs. iridium).
Coolant Flush:
Every 40,000-60,000 km or 2-4 years.
Brake Fluid Change:
Every 2-3 years.
Fluid Specifications
Coolant Type:
Ethylene glycol based, anti-freeze/anti-corrosion coolant (e.g., Toyota Super Long Life Coolant or equivalent, typically 50/50 mix with distilled water).
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Engine Mounts:
Wear and tear on engine mounts can lead to increased vibration and noise, especially at idle or during acceleration. The manual covers inspection and replacement.
Suspension Bushings:
Rubber bushings in the suspension and steering can degrade over time, leading to clunking noises, poor handling, and uneven tire wear. Detailed replacement procedures are in the manual.
ABS Sensors:
Wheel speed sensors for the ABS system can become faulty due to corrosion or damage, triggering ABS warning lights. The manual provides diagnostic steps and replacement instructions.
Ignition Coils:
Coil-on-plug ignition systems can experience failures, leading to misfires and rough running. Diagnosis and replacement are covered.
Water Pump Leaks:
Although generally reliable, water pumps can develop leaks over time, requiring replacement as part of major engine service. The manual details removal and installation.
📚 Vehicle History
Brand Heritage
Daihatsu Focus:
Daihatsu, a subsidiary of Toyota, is renowned for producing small, efficient, and reliable vehicles, particularly kei cars and compact SUVs.
Model Evolution
J100 Series:
The first generation Terios (J100 series) debuted in 1997, featuring a compact, body-on-frame SUV design. The J102 refers to updated models within this first generation.
J200 Series:
The second generation (J200 series, including J200, J210, J211) was launched in 2005/2006. It adopted a unibody construction, offering a more car-like ride and improved interior space and efficiency. This generation is the primary focus for the 2000-2012 range covered by the manual, particularly the latter half of this period.
Production
Manufacturing Locations:
Primarily Japan, with significant production and assembly in other countries through joint ventures and licensing, particularly for various international markets (e.g., India, Indonesia, Philippines, Brazil - where it was often sold as the Toyota Rush).
🏆 Awards & Recognition
Recognitions
Industry Awards:
While specific major awards are uncommon for this segment, the Terios has historically been recognized for its value, affordability, and practicality in various emerging markets. Its strong sales and widespread adoption in regions like Southeast Asia and Latin America indicate market success.
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