Daihatsu TERIOS J100 Maintenance Manual
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Daihatsu TERIOS J100 Maintenance Manual

Daihatsu TERIOS J100 Maintenance Manual

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MAINTENANCE SCHEDULE ............ MA- 3
MAINTENANCE OPERATION ........... MA- 6
ENGINE ............................................. MA- 6
COLD ENGINE OPERATION ........ MA- 6
HOT ENGINE OPERATION .......... MA-13
CHASSIS ........................................... MA-26
BRAKE FLUID .............................. MA-26
BRAKE PEDAL ............................. MA-27
PARKING BRAKE HANDLE .......... MA-27
FRONT BRAKE ............................. MA-29
REAR BRAKE ............................... MA-32
BRAKE BOOSTER HOSE ............. MA-34
DAIHATSU
J100
TO INDEX
MAINTENANCE
BRAKE MASTER CYLINDER ........ MA-35
CLUTCH ....................................... MA-38
PROPELLER SHAFT ..................... MA-40
DRIVE SHAFT ............................... MA-40
WHEEL HUB NUT ........................ MA-40
WHEEL BEARING ........................ MA-40
STEERING SYSTEM ..................... MA-41
WHEEL ALIGNMENT .................... MA-42
SHOCK ABSORBER ..................... MA-43
NO. 9710-JE
MA
JMA00001-00000

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Summary of Contents for Daihatsu TERIOS J100

  • Page 1: Table Of Contents

    DAIHATSU J100 TO INDEX MAINTENANCE MAINTENANCE REQUIREMENTS ... MA– 2 BRAKE MASTER CYLINDER ..MA–35 MAINTENANCE SCHEDULE .... MA– 3 MUFFLER AND EXHAUST PIPE ... MA–37 SCHEDULE FOR SEVERE AUTOMATIC TRANSMISSION ..MA–37 DRIVING ........MA– 5 CLUTCH ........MA–38 MAINTENANCE OPERATION ...

  • Page 2: Maintenance Requirements

    Consequently, potential vehicle damage can be prevented or the degree of the damage can be minimized. Therefore, all of the persons who are concerned with servicing the Daihatsu vehicles should offer the peri- odical maintenance service to Daihatsu car owners in order that they may be protected from accidents or unexpected problems.

  • Page 3: Maintenance Schedule

    • This maintenance schedule prepared based on requirements mentioned in the owner’s manual which are to be performed by the Daihatsu owner thoroughly. ™ ¡ ···Check or inspect.
  • Page 4 MA–4 ™ ¡ ···Check or inspect. ···Change or replace. ×1000 km 1 10 20 30 40 50 60 70 80 90 100 ×1000 miles Section Item What to do Inspection interval 0.6 6 12 18 24 30 36 42 48 54 60 page Years —...

  • Page 5: Schedule For Severe Driving

    MA–5 ™ ¡ ···Check or inspect. ···Change or replace. ×1000 km 1 10 20 30 40 50 60 70 80 90 100 ×1000 miles Section Item What to do Inspection interval 0.6 6 12 18 24 30 36 42 48 54 60 page Years —...

  • Page 6: Maintenance Operation

    MA–6 MAINTENANCE OPERATION ENGINE COLD ENGINE OPERATION 1. Inspection of drive belt (1) Visual inspection of drive belt Visually check the belt for separation of the adhesive rubber above and below the core, core separation from the belt side, severed core, separation of the rib from the adhesive rubber, cracks or separation of the JMA00005-00001 ribs, torn or worn ribs or cracks in the inner ridges of...
  • Page 7 MA–7 (4) Cleaning of air filter element Clean the air filter element with compressed air. First, blow compressed air from the back side of the element thoroughly. Then, blow off the upper side of the element. WARNING: · Protect your eyes with safety goggles during the clean- ing operation.
  • Page 8 MA–8 4. Inspection of fuel line and connection (1) Visually inspect the fuel line including the fuel hose for connecting condition, cracks, tightness, leakage and damage. If cracks or any other damage exists, repair or replace the part as required. (2) Check the connecting section of the fuel line for loose- ness and leakage.
  • Page 9 MA–9 (10) Remove the wire from the fuel pump relay terminal in the relay box. CAUTION: · Never deform or damage the terminals during opera- tion. · Never make connection between terminals except for those specified. Fuel pump relay Even slight contact of the other terminal causes serious trouble.
  • Page 10 MA–10 (4) Start the engine and wait for a little while until the engine stops. (5) Turn off the ignition switch. (6) Jack-up the vehicle and support it with safety stands. (Refer to the GI section.) (7) Detach the fuel hose clips. WARNING: ·...
  • Page 11 MA–11 e Remove the engine undercover by removing the six attaching bolts. JMA00020-00015 r Disconnect the atmosphere side hose from the frame. t Remove the charcoal canister from the vehicle by pulling up the charcoal canister case to unlock it from the bracket.
  • Page 12 MA–12 t Cleaning of charcoal canister Clean the charcoal canister by blowing com- pressed air of 294.2kPa (3.0 kg/cm ) into the fuel tank side pipe B while holding the purge side of the canister pipes A closed. CAUTION: · Never attempt to wash the charcoal canister.

  • Page 13: Hot Engine Operation

    MA–13 HOT ENGINE OPERATION 1. Change of engine oil and oil filter WARNING: · Protect your eyes by wearing safety goggles. · Never burn yourself with hot engine oil or hot engine components during operation. (1) Park the vehicle on a level surface. (2) Check the oil level.
  • Page 14 MA–14 (17) Pull out the oil level gauge and wipe off the engine oil. ˚C –29 –18 –7 TEMP. –20 ˚F (18) Reinsert the oil level gauge as far as it will go. Engine oil (19) Pull out the oil level gauge again. (4 stroke) *10W-30, 10W-40, 10W-50 (20) Ensure that the engine oil level is between the “L”...
  • Page 15 Remove the No. 1 and No. 3 resistive cords by dis- connecting the connectors from the ignition coils and spark plugs. CAUTION: DAIHATSU · Never disconnect the resistive cords by holding the 16VALVE cord section of the resistive cords.
  • Page 16 MA–16 (4) Removal of spark plug (Refer to the step (3)–6 above.) (5) Visual inspection of spark plug Visually inspect the spark plug for electrode wear, damage in threads or insulation. Replace the spark plug if it exhibits any damage. Recommended Spark Plug: DENSO K20TNR-S...
  • Page 17 (12) Connect the resistive cords to the spark plugs and ig- nition coils properly as shown in the figure. NOTE: DAIHATSU · Never interfere the resistive cord with the ignition coils 16VALVE and attaching nuts of the ignition coils.
  • Page 18 MA–18 3. Inspection and adjustment of valve clearance The measurement and adjustment of the valve clearance are carried out when each piston of the No. 1 and No. 4 cylinders is set to the top dead center at the end of com- pression stroke.
  • Page 19 MA–19 e Check to see if the valve rocker arms of the No. 1 cylinder are free or are being pushed. According to the table below, check and adjust the valve clearance, using a thickness gauge. JMA00051-00042 Pistion position Inkate When valve rocker arms of No.
  • Page 20 MA–20 t Apply the Three Bond ® 1104 to the four points on the cylinder head, as indicated in the figure. JMA00054-00044 y Install the cylinder head cover on the cylinder head. NOTE: • Never damage the rubber grommets for the spark plug tubes during the installation of the cylinder head cover.
  • Page 21 MA–21 CAUTION: • Never allow the tachometer terminal to touch ground. It could result in damage of the ignition system. • As some tachometer are not compatible with this igni- tion system, it is recommended to confirm the compati- bility with your unit before its use. •...
  • Page 22 MA–22 5. Inspection of dashpot (For automatic transmission-equipped model only) Preparation to be made prior to idle speed adjustment · Check and adjust the ignition timing. · Check and adjust the idle speed. · Apply the parking brake fully. · Warm up the engine thoroughly.
  • Page 23 MA–23 6. Change of engine coolant WARNING: · Never open the radiator cap when the engine is still hot. CAUTION: · As regards water to be used as cooling water, use soft water which does not contain salts of minerals, calci- um, magnesium, and so forth.
  • Page 24 MA–24 (27) Slowly pour a proper amount of antifreeze solution into the radiator in accordance with the instruction of the manufacturer of antifreeze solution. CAUTION: · Use a good brand of ethylene-glycol base antifreeze solution. Coolant Capacity: Automatic Transmission: 5.3 liters Manual Transmission: 5.4 liters NOTE:...
  • Page 25 MA–25 (38) Remove the radiator cap. (39) Ensure that the concentration of antifreeze solution in the radiator meets the instruction of the manufacturer of antifreeze solution by a densitometer. Adjust the concentration of the antifreeze solution in the radiator according to the instruction of the manu- facturer of the antifreeze solution, if the concentration does not meet the instruction of the manufacturer of the antifreeze solution.

  • Page 26: Chassis

    MA–26 CHASSIS BRAKE FLUID CHANGE WARNING: · Do not mix the different kind and manufacture of brake fluid. Recommended brake fluid: FMVSS116 DOT3 or SAE J1703 CAUTION: · If the brake fluid is spilled inadvertently over the paint finish surface of the vehicle or the resin made part, immediately wipe off the brake fluid and flush with fresh water.

  • Page 27: Brake Pedal

    MA–27 BRAKE PEDAL FREE PLAY Ensure that the ignition switch is turned OFF. Depress the brake pedal more than five times to release the vacuum saved in the brake booster. Ensure that the specified free play exists on the brake pedal by pushing the brake pedal lightly by hand.

  • Page 28: Brake Hose & Tube

    MA–28 INSPECTION OF EFFECTIVENESS Check to see if the vehicle can be retained in a stationary state on a dry slope with a grade of 1/5 when the parking brake is applied fully. If not, check and repair the rear brake system. JMA00080-00000 BRAKE HOSE &...

  • Page 29: Front Brake

    MA–29 FRONT BRAKE COMPONENTS 83.4 ± 4.9 : Tightening torque (8.5 ± 0.5) Unit : N·m (kgf-m) : Non-reusable parts 49.0 ± 4.9 (5.0 ± 0.5) q Cylinder slide main pin w Cylinder slide sub-pin e Disc brake No. 1 pad r Disc brake No.
  • Page 30 MA–30 INSPECTION OF FRONT BRAKE RUBBER PARTS AND BRAKE PAD FOR DAMAGE 1. Jack up the vehicle and support the vehicle with safety stands. 2. Remove the front wheel. 3. Remove the sub-cylinder slide pins. JMA00084-00065 4. Turn up the disc brake assembly as shown. CAUTION : ·...
  • Page 31 MA–31 11. Ensure that the brake pads, anti-squeal shims and pad guide plates are installed properly. CAUTION: · Be very careful not to deform or lose the anti-squeal shims. 12. Thinly apply the brake rubber grease to the sub-cylinder slide pin boot. JMA00087-00068 13.

  • Page 32: Rear Brake

    MA–32 REAR BRAKE COMPONENTS : Tightening torque Unit : N·m (kgf-m) 9.8 ± 2 (1.0 ± 0.2) : Non-reusable parts !5 !7 !1 1 61 ± 7 (6.25 ± 0.75) q Brake drum subassembly w Brake shoe hold down spring e Shoe hold down spring pin r Tension No.
  • Page 33 MA–33 INSPECTION OF WHEEL CYLINDER FOR LEAKAGE Jack up the vehicle and support it with safety stands. (Refer to the GI section.) Remove the wheels. Release the parking brake fully. Remove the rear brake drum from the rear axle hub by pulling it out.

  • Page 34: Brake Booster Hose

    MA–34 BRAKE BOOSTER HOSE COMPONENTS : Tightening torque Unit : N·m (kgf-m) : Non-reusable parts 9.8 - 15.7 (1.0 - 1.6) 25.5 ± 2.9 (2.6 ± 0.3) 25.5 ± 2.9 (2.6 ± 0.3) 9.8 - 15.7 (1.0 - 1.6) q Brake booster assembly w Master cylinder push rod clevis e Brake booster bracket gasket r Union to connector tube...

  • Page 35: Brake Master Cylinder

    MA–35 BRAKE MASTER CYLINDER COMPONENTS : Tightening torque Unit : N·m (kgf-m) : Non-reusable parts 12.7 ± 2.5 (1.3 ± 0.3) 7.9 - 11.7 (0.8 - 1.2) q Brake master cylinder reservoir tank w Reservoir filler cap e Reservoir diagram r Grommet t Brake master cylinder assembly y Tandem master cylinder repair kit...
  • Page 36 MA–36 7. Secure the master cylinder in a vise. 8. Ensure that no brake fluid leakage exists around the pis- ton guide section of the brake master cylinder. If any brake fluid leakage exists, replace the brake master cylinder pistons with piston cups(repair kit) with new ones. (Refer to the BR section.) 9.

  • Page 37: Muffler And Exhaust Pipe

    MA–37 MUFFLER AND EXHAUST PIPE DAMAGE & TIGHTNESS 1. Visually check that the exhaust pipes and mufflers for damage and exhaust gas leakage. Also ensure that there is no possibility of interference with any other parts. WARNING · Never perform this check when the exhaust system is hot.

  • Page 38: Clutch

    MA–38 CHECK OF OIL COOLER HOSE Inspect the following points. If any problem is found, repair them, as required. 1. Hoses and tubes for scratches or cracks. 2. Hoses for aging such as deformation and swelling. 3. Tubes for corrosion or rusting. 4.

  • Page 39: Manual Transmission, Transfer, Front And Rear Differential

    MA–39 MANUAL TRANSMISSION, TRANSFER, FRONT AND REAR DIFFERENTIAL OIL CHANGE 1. Place a suitable container under the drain plug. 2. Drain the oil by removing the drain plug. 3. Remove the filler plug. 4. Reinstall the drain plug with a new gasket interposed and tighten it to the specified tightening torque.

  • Page 40: Propeller Shaft

    MA–40 PROPELLER SHAFT CHECK OF PROPELLER SHAFT 1. Ensure that no looseness exists on the attaching bolts of the universal joint flange yokes which were connected to the front, rear differential and propeller shaft, using a torque wrench. Tightening Torque: 51.0 - 69.6 N·m (5.2 - 7.1 kgf-m) If any looseness exists, retighten the attaching bolts as re- quired.

  • Page 41: Steering System

    MA–41 STEERING SYSTEM STEERING WHEEL FREE PLAY 1. Set the vehicle in a straight-ahead condition. Play 2. Inspect the steering wheel free play by turning it lightly with your fingers. Specified Value: 10 mm MAX. 10 mm MAX. If the free play fails to meet with the specification, adjust the free play to the specified value.

  • Page 42: Wheel Alignment

    MA–42 POWER STEERING FLUID HOSE Inspect the power steering fluid hose for aging, deformation, cracks, scratches, cut, twist and swelling. If any problem is found, replace the fluid hose with a new one. (Refer to the SR section.) CAUTION: · Never reuse the removed hose bands.

  • Page 43: Shock Absorber

    MA–43 SHOCK ABSORBER DAMAGE AND OIL LEAKAGE Visually inspect each shock absorber for damage and oil leakage. If damage or oil leakage exists, replace the damaged part with a new one. (Refer to FS or RS section.) JMA00124-00104 FUNCTION Rock the vehicle in an up-&-down direction. Ensure that the vehicle emits no abnormal noise and the shake will finish with- in a few times.

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