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Daihatsu TERIOS J100, Service Manual

The Daihatsu TERIOS J100 Maintenance Manual is essential for every owner. This comprehensive guide provides all you need for servicing and preserving your vehicle's reliability and performance. Ensure your TERIOS J100 operates flawlessly by downloading the free manual directly from manualshive.com. Get your copy today for optimal vehicle maintenance!

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BO–94

ENGINE MOUNTING INSULATOR

COMPONENTS

REAR

7 

±

 3 mm

5.3

 mm

+1.5 –1.0

RH 7.5

 mm

+2

–2.5

LH 5.5

 mm

+2

–2.5 

34.3 - 61.8

(3.5 - 6.3)

34.3 - 61.8

(3.5 - 6.3)

21.6 - 39.2

(2.2 - 4.0)

21.6 - 39.2

(2.2 - 4.0)

21.6 - 39.2

(2.2 - 4.0)

JBO00253-00218

: Tightening torque

Unit : N·m (kgf-m)

Summary of Contents for TERIOS J100

Page 1: ...FRONT SEAT BO 37 REAR SEAT BO 39 SEAT BELT BO 40 FRONT DOOR BO 44 REAR DOOR BO 52 BACK DOOR BO 59 TRIM GARNISH BO 64 WINDOWS BO 70 FUEL TANK BO 82 ACCELERATOR PEDAL BO 91 EXHAUST PIPE BO 93 ENGINE MO...

Page 2: ...to exceed 2 0 mm Difference in height 2 9 1 5 mm r Specified value Gap 5 5 1 5 mm Lateral deviation Not to exceed 1 5 mm Difference in height 0 1 5 mm t Specified value Gap 4 7 1 5 mm Lateral deviatio...

Page 3: ...ro and the height at the right and left sides may become the same Specified Value of Difference in Height Not more than 1 5 mm ADJUSTMENT OF FRONT DOOR AND REAR DOOR 1 Gap adjustment 1 Front door q Lo...

Page 4: ...to the door hinges e Tighten the bolts attaching the door to the door hinge BO 4 2 Front Rear door lock striker side q Loosen the screws of the lock striker w Perform the adjustment of the lock strik...

Page 5: ...l not soil or bend the roof head lining during the loosening of the nuts attaching the hinge to the vehicle shell 3 Tighten the attaching bolts of the hinge to the back door BO 5 100 mm 100 mm q w e t...

Page 6: ...the lock striker 2 Perform the adjustment of the lock striker by tapping it lightly with a hammer to change the attaching position of the striker 3 Tighten the attaching bolts of the striker 4 Adjust...

Page 7: ...t bracket r Front bumper guard left bracket t No 1 clip y Radiator grill assembly u Retainer i Grill retainer o Front bumper guard garnish subassembly 0 Front turn signal lamp assembly 1 Front turn si...

Page 8: ...clips at the upper side of the radiator grill 2 Remove the radiator grill assembly while unlocking the locking section of the four clips and one retainer 4 Removal of front turn signal lamps On model...

Page 9: ...t given in this installation procedure Refer to the illustrations in the removal procedure in cases where any difficulty is encountered 1 Install the front bumper guard base brackets with the attachin...

Page 10: ...ting the retainer and four clips 3 Lock the clips by turning the head section of the clip using a phillips screwdriver Four portions 8 Install the under fender bracket by installing the attaching tapp...

Page 11: ...Remove the front fender liner attaching screw grommets Refer to the front fender liner section BO 11 q w y i i e e r t o 1 0 u JBO00024 00023 JBO00025 00024 q Hood subassembly w Hood silencer e Clip r...

Page 12: ...in cases where any difficulty is encountered 1 Install the front fender subassembly with the attaching bolts and tighten them properly 2 Install the side turn signal lamp 3 Installation of over fender...

Page 13: ...aching screw 2 Remove the back up lamp assembly s and rear fog lamp when equipped by disconnecting their connec tor BO 13 w y y u q t t r r e o 0 1 i JBO00028 00026 JBO00029 00027 JBO00030 00028 q Rea...

Page 14: ...acket base when equipped by removing the eight attaching bolts 7 Remove the lower back panel cover and air vent If necessary 8 Removal of rear combination lamp 1 Remove the two attaching bolts and one...

Page 15: ...4 Install the rear bumper cover and license plate bracket base when equipped with the eight attaching bolts 5 Install the rear bumper cover attaching screws to the fender covers and body panel at bot...

Page 16: ...assembly by re moving the three attaching bolts 2 Remove the under fender bracket by removing the grom met and tapping bolt q w t r e JBO00037 00034 JBO00038 00035 JBO00039 00036 q Front fender liner...

Page 17: ...strations in the removal procedure in cases where any difficulty is encountered 1 Install the front fender liner with the ten screw grommets NOTE Insert the fender liner into between the fender panel...

Page 18: ...amps of the engine hood and clamp 2 Remove the window washer nozzles from the engine hood by retracting the lock sections of the window washer noz zles q r w e e y t JBO00043 00039 JBO00044 00040 JBO0...

Page 19: ...re in cases where any difficulty is encountered 1 Installation of engine hood hinge 1 Install the engine hood hinge with the attaching bolts 2 Install the front fender Refer to the front fender sectio...

Page 20: ...he cowl side trim board subassembly Refer to the BO section 8 Remove the hood lock control cable assembly from the vehicle NOTE For easier operation to reinstall the hood lock control cable connect a...

Page 21: ...all the cowl side trim board assembly Refer to the trim garnish section 4 Connect the hood lock control cable to the clamps provided in the fender liner as shown 5 Connect the hood lock control cable...

Page 22: ...ectional view E sectional view G sectional view Up Center pillar lower garnish Up Inside Harness Harness w Floor carpet Up Up Front Front Front Right Right Up Front Right Harness w e w q JBO00054 0004...

Page 23: ...ure is reverse to the removal procedure Therefore illustrations are not given in this installation procedure Refer to the illustrations in the removal procedure in cases where any difficulty is encoun...

Page 24: ...d roof drip molding INSTALLATION NOTE Do not reuse the removed roof drip molding 1 Connect the retainer on the roof drip molding to the pin on the roof panel and insert the front end of the roof drip...

Page 25: ...event the painted surface of the roof panel from being scratched by inserting a piece of cloth into between the clip remover and the roof panel as shown BO 25 q w e y r r w t u i Hexagon wrench Clip J...

Page 26: ...e roof rear rack from the rear spoiler subassembly by removing the attaching nuts Model equipped with rear spoiler NOTE Do not damage the harness of the high mount stop lamp during the removal 11 Remo...

Page 27: ...rear spoiler 4 Install the each side of roof rack assembly with the five or three attaching nuts 5 Install the rear spoiler with the roof racks to the roof panel with the attaching nuts Model equippe...

Page 28: ...rim molding and removable roof inner weatherstrip 9 Remove the roof headlining Refer to the trim garnish section 10 Remove the roof window deflector panel assembly by removing the two attaching nuts 1...

Page 29: ...e trim garnish section 4 Install the sunroof opening trim molding and removable roof inner weatherstrip 5 Install the removable roof outer weatherstrip to the roof panel 6 Install the removable roof h...

Page 30: ...3 Instrument cluster finish center panel as sembly 4 Glove compartment subassembly 5 Glove compartment door hinge 6 Glove compartment cushion 7 Shifting hole cover 8 Shifting hole flame 9 Console pane...

Page 31: ...ing column assembly Refer to the SR section for more details of the removal and installation of the column assembly 1 Disconnect the steering column assembly related con nectors 2 Remove the four atta...

Page 32: ...12 Removal of instrument cluster finish center panel assem bly 1 Pull out the cigarette lighter heater 2 Remove the two attaching screws of the instrument cluster finish center panel 3 Remove the fron...

Page 33: ...rnish by disengaging the retainers using a clip remover or the like 3 Remove the front pillar garnish from the front pillar 19 Remove the instrument panel hole covers No 1 No 2 and No 3 from the instr...

Page 34: ...move the heater to register center duct subassembly by removing the five attaching screws 24 Removal of airbag at front passenger seat side Only for model equipped with front passenger seat side airba...

Page 35: ...e assembly and side defroster duct subassembly with the attaching screws right and left to the cowl panel and bracket 3 Install the register assembly No 2 of the instrument panel to the instrument pan...

Page 36: ...the instrument cluster assembly 2 Insert the instrument cluster panel assembly into the instrument panel and ensure that the retainers are locked properly 3 Insert the cigarette lighter heater 18 Inst...

Page 37: ...attaching bolts of the front seat BO 37 25 4 4 9 2 5 0 5 Right side JBO00094 00082 JBO00095 00083 4 Move the front seat to the most forward position 5 Remove the attaching bolts of the front seat 6 R...

Page 38: ...m 2 6 0 5 kgf m 6 Tighten the inner side attaching bolts to the specified tightening torque Tightening Torque 25 4 4 9 N m 2 6 0 5 kgf m 7 Move the front seat to the most forward position 8 Tighten th...

Page 39: ...ecified tight ening torque Tightening Torque 5 5 1 5 N m 0 56 0 15 kgf m 2 Install the rear seatback with the three attaching bolts and tighten the attaching bolts to the specified tightening torque T...

Page 40: ...elt retractor by removing the attaching bolt and screw 6 Removal of inner seat belt 1 Remove the front seat Refer to the front seat section 2 Remove the inner seat belt by removing its attaching bolts...

Page 41: ...stallation of inner seat belt 1 Install the inner seat belt with the attaching bolt and tighten the attaching bolt to the specified tight ening torque Tightening Torque 40 5 12 5 N m 4 1 1 3 kgf m 2 I...

Page 42: ...trim garnish section for the removal procedure 5 Open the rear seat belt upper anchor bolt cover 6 Remove the attaching bolt of the seat belt upper anchor 7 Remove the rear seat belt retractor by rem...

Page 43: ...ng Torque 40 5 12 5 N m 4 1 1 3 kgf m 2 Install the rear seat belt retractor with the attaching bolt and tighten it to the specified tightening torque Tightening Torque 40 5 12 5 N m 4 1 1 3 kgf m 3 I...

Page 44: ...r 6 Front door trim panel assembly 7 Front door glass outer weatherstrip 8 Front door rear lower frame subassembly 9 Retainer 0 Front door glass outer weatherstrip 1 Front door outside handle assembly...

Page 45: ...t to disengage the retainers provided on the bracket using a clip remover 8 Unlock the nail section of the front door inside handle sub assembly from the front door panel and insert it into the front...

Page 46: ...on sections on the front door glass weatherstrip assembly 21 Remove the attaching bolts of the front door front lower frame assembly Then remove the front lower frame as sembly 22 Removal of front doo...

Page 47: ...ct the front door open control link assembly from the front door lock assembly 3 Remove the front door lock cylinder and lock cylinder pad by removing the lock retainer 4 Remove the front door outside...

Page 48: ...by retracting the mushroom section of the retainers CAUTION The front part of the garnish is affixed with a two faced adhesive tape Therefore be very careful not to bend the garnish dur ing the remov...

Page 49: ...the front door glass run 8 Install the front door glass outer weatherstrip to the front door panel and ensure that the front door glass weatherstrip grips are engaged with the front door panel secure...

Page 50: ...tion of the butyl tape may come at the upper section If the joint section of the tape comes at the lower side of the door it may cause water leakage The butyl tape should be routed just under the wate...

Page 51: ...nel 28 Connect the front door trim panel assembly to the front door panel by connecting the retainers on the front door trim panel assembly 29 Connect the front door inside handle to the front door pa...

Page 52: ...frame seal 3 Rear door outside handle assembly 4 Rear door check assembly 5 Rear door locking button 6 Door lock control knob holder 7 Rear door locking control link subassembly 8 Rear door locking li...

Page 53: ...el assembly 7 Unlock the nail section of the rear door inside handle sub assembly from the rear door panel Then insert it into the rear door trim panel assembly 8 Remove the rear door trim panel assem...

Page 54: ...using a clip remover or the like 17 Remove the rear door window guide subassembly by re moving the attaching bolts 18 Removal of rear door glass subassembly 1 Install the rear door window handle assem...

Page 55: ...r door open control link assembly from the rear door lock assembly 26 Remove the rear door lock assembly 27 Remove the rear door lock assembly by removing the three attaching screws and one bolt For d...

Page 56: ...he rear door check assembly by installing the attaching bolts 4 Install the rear door wire harness to the rear door through the body shell and rear door panel and set the rubber grommets to the body s...

Page 57: ...r door panel assembly 24 Connect the connector of the rear door wire to the door control motor assembly 25 Install the rear door glass weatherstrip assembly to the rear door trim panel assembly by ben...

Page 58: ...ndle subassembly to the rear door panel and secure the attaching screws NOTE An oversize screw is available 34 Install the attaching screw of the door lock control knob holder securely 35 Screw in the...

Page 59: ...assembly 3 Upper hinge assembly 4 Door check pin 5 Back door check base 6 Back door check assembly 7 Back door handle assembly 8 Back door lock assembly 9 Door lock striker plate assembly 0 Back door...

Page 60: ...er arm by removing the attaching nut Only for rear wiper equipped model Refer to the BE sec tion for the removal procedure 3 Remove the back door trim board by disengaging the re tainers provided on t...

Page 61: ...ect the connector of the central door lock Only for central door lock equipped model 10 Remove the back door lock assembly by removing the three attaching bolts 11 Remove the back door lower male stop...

Page 62: ...e rear bumper section 3 Install the rubber grommets of the back door wire harness to the back door panel and body shell 4 Connect the connector of the rear door wire harness to the connector of the wi...

Page 63: ...door and ensure that the retainers are connected to the rear door panel properly 20 Install the rear wiper arm with the attaching nut Only for rear wiper equipped model Refer to the BE section for th...

Page 64: ...ish R L t Clip y Rear floor rear carpet u Cowl side trim right board assembly i Cowl side trim left board assembly o Rear floor front carpet 0 Front door scuff plate R L 1 Center pillar lower garnish...

Page 65: ...door scuff plate 5 Removal of center pillar lower garnish 1 Disconnect the retainers of the center pillar lower gar nish using a clip remover or the like 2 Remove the center pillar lower garnish while...

Page 66: ...ide trim by carefully disconnecting the three spring clips installed at the rear door side 4 Remove the luggage room lamp connector Only for luggage room lamp equipped model Refer to the BE section 12...

Page 67: ...the inner rear view mirror by disconnecting its connector 16 Remove the removable roof assembly Refer to the removable roof section 17 Remove the roof headlining assembly by removing the at taching r...

Page 68: ...the two attaching screws 6 Connect the visor assembly to the visor holder 5 Install the assist grip assembly with the attaching screws 6 Place the front floor carpet in position and install the clip...

Page 69: ...properly 3 Install the front seat outer belt shoulder anchor Refer to the seat belt section for the removal proce dure 15 Install the center pillar lower garnish 16 Installation of rear door scuff pla...

Page 70: ...ng 7 Protection of paint surface around windshield glass Protect the paint surface around the windshield glass by applying a protective tape or the like CAUTION To protect the paint surface be sure to...

Page 71: ...nt 4 Hold both ends of the piano wire by pliers or the like and cut off the adhesive by pulling the piano wire one side to the other NOTE Some parts are hard to be cut off because spacers or retainers...

Page 72: ...als remain on the windshield glass frame or windshield glass Be sure to apply the adhesive agent three minutes after the primer has been applied 4 Apply the adhesive agent to the positions shown in th...

Page 73: ...ding 8 Cure the adhesive agent completely NOTE Observe the curing time of the adhesive agent speci fied by its manufacturer CAUTION Do not move the vehicle until the adhesive agent of the windshield c...

Page 74: ...Cut off the window glass adhesive by a cutter knife or the like to make a small hole in order to pass a piano wire through the hole CAUTION Be very careful not to damage the paint surface and window b...

Page 75: ...gent that was cut by the piano wire should be made flat by means of a cutter knife while leaving a thin layer of the adhesive material INSTALLATION 1 Affix clips to the quater window glass as follows...

Page 76: ...e glass by inserting the clips into the holes on the body side Push the entire glass surface lightly so that the glass may fit completely 7 Cure the adhesive agent completely NOTE Observe the curing t...

Page 77: ...E section 4 Disconnect the connectors of the rear window defog ger from the back door window Only for model equipped with the rear window defogger Refer to the back door section 5 Remove the high moun...

Page 78: ...operation make a hole on the adhesive agent with a heated wire CAUTION Be very careful not to get scalded during the operation 3 Pass a piano wire through the adhesive agent 4 Hold the both ends of t...

Page 79: ...cked to the back door window glass 5 Remove the back door window glass from the back door 6 Ensure that the clips are sticked to the correct position of the quater window glass as shown BO 79 A A A A...

Page 80: ...r edge of the back door glass as shown in the figure below BO 80 7 Install the glass by inserting the clips into the holes on the back door side Push the entire glass surface lightly so that the glass...

Page 81: ...r hinge cover by connecting the retainers 13 Install the high mount stop lamp Only for model equipped with the high mount stop lamp 14 Connect the connectors of the rear window defogger to the back do...

Page 82: ...n plug CAUTION Never reuse the used gasket S B B i y o u e r w t 1 q 65 0 66 0 2 5 5 0 0 25 0 5 2 5 5 0 0 25 0 5 2 5 5 0 0 25 0 5 17 0 22 0 1 7 2 2 B JBO00215 00182 JBO00216 00183 JBO00217 00184 q Dra...

Page 83: ...ive terminal of the ground wire from the battery negative terminal 7 Disconnection of fuel tubes 1 Remove the hose bands Then disconnect the fuel hoses form the fuel pipes 2 Disconnect the quick conne...

Page 84: ...l hose again Failure to observe this caution may lead to fuel leakage 2 Remove the fuel main hose from fuel tank by unlocking the main hose from the hose clips 3 Remove the retainer for quick connecto...

Page 85: ...Disconnect the fuel tank sub inlet hose from the fuel tank by loosening the hose clamp 18 Remove the shut valve from the fuel inlet pipe 19 Disconnect the breather hose from the fuel tank breather No...

Page 86: ...gasket interposed Then tighten the attaching screws to specified tightening torque evenly Tightening Torque 2 5 5 0 N m 0 25 0 5 kgf m CAUTION Never reuse the used gasket again BO 86 2 Connect the fue...

Page 87: ...ected properly by pull the connector from the fuel pipe lightly 2 Connect the fuel main tube to the fuel pipe clamps in stalled on the fuel tank securely 3 Connection of the fuel return tube q Ensure...

Page 88: ...o 2 tube and its attaching surface of fuel tank thoroughly 10 Install the fuel tank breather No 2 tube to the fuel tank by the attaching bolts with the new gasket interposed CAUTION Never reuse the us...

Page 89: ...nsure that the connector is connected properly by pull the connector from the fuel pipe lightly 3 Connect the breather hose with new hose band to the fuel inlet and tighten the hose band securely Refe...

Page 90: ...by removing the two attaching bolts 5 Remove the fuel tank filler pipe shield from the fuel inlet box INSTALLATION OF FUEL INLET Install the components in the reversed order of the removal procedure...

Page 91: ...t bracket 4 Remove the accelerator link rod return spring and bushs from the accelerator pedal support bracket 5 Remove the cushion from the accelerator pedal support bracket ASSEMBLY 1 Install the cu...

Page 92: ...on the accel erator cable grommet with the recessed sections of accelerator pedal 4 Adjust the accelerator pedal free play to specified value by adjusting the free play of accelerator inner cable at t...

Page 93: ...m 4 0 5 5 kgf m 3 Install the exhaust pipe support No 1 bracket to transfer case with the attaching bolts and tighten the attaching bolts to specified tightening torque Tightening Torque 24 0 56 4 N m...

Page 94: ...G INSULATOR COMPONENTS REAR 7 3 mm 5 3 mm 1 5 1 0 RH 7 5 mm 2 2 5 LH 5 5 mm 2 2 5 34 3 61 8 3 5 6 3 34 3 61 8 3 5 6 3 21 6 39 2 2 2 4 0 21 6 39 2 2 2 4 0 21 6 39 2 2 2 4 0 JBO00253 00218 Tightening to...

Page 95: ...s to the specified tightening torque as mentioned in the figure 4 Remove the engine lifter and or transmission jack etc from the engine and transmission 5 Ensure that the clearance of the engine mount...

Page 96: ...ith flange An example of part number Hexagonal bolt Strength division Nominal length mm Nominal diameter mm Nominal diameter Nominal length 9 1 1 1 1 4 0 6 2 0 4 T 5 T 6 T 7 T Strength division Nomina...

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