2002-2012 Daihatsu Copen Workshop Repair Service Manual BEST

SECTION I General information Maintenance PI i m Engine Engine Mechanical rn Em Intake System Exhaust System lira mm Lubrication System rn Cooling System Ea Fuel System rn Engine Control System rn Emission Control System Im Ignition System Starting System / Charging System Ea BlEl Engine Mounting ma Front suspension Rear Suspension w Wheel & Tire m mm Drive Shaft / Propeller Shaft / Axle rn Brake Parking Brake m Brake Control rn m Clutch m Manual Transmission / Manual Transaxle m Steering Power Steering Em Em SRS Airbag System m Body am Exterior / Interior Windshield Windowglass / Mirror aa- IB SECTION 2 Door Lock & Theft Deterrent Sunmof / T-Ber Roof /Convertible mI -- - Lighting Wiper & Washer rn Meter ma Audio & Visual System ma m Heater and Air Conditioner mI Wiring Diagrams - A, B, C & D

A1 GENERAL INFORMATION IMPORTANT SAFETY NOTICE ------------ A1 - 1 GENERAL DESCRIPTION--------------- A1 - 1 WARNINGS, CAUTIONS AND NOTES ------------------------------------- A1 - 1 GENERAL WARNINGS .................... A1 - 2 HOW TO USE THIS MANUAL------------- A1 - 3 ARTICLES TO BE PREPARED--------- A1 - 3 REMOVAL AND INSTALLATION PROCEDURES A1 - 3 DESCRIPTION OF SERVICE STANDARD VALUE Af - 4 CONTENTS NOT DESCRIBED IN THIS MANUAL A1 - 5 DEFINITIONS OF TERMS ---------------- A1 - 5 ABBREVlATlON CODES -------------------- A1 - 6 HOW TO GRASP SPECIFIED TIGHTENING TORQUE FOR GENERAL STANDARD BOLT AND NUT A1 - 7 DETERMINING PROCEDURE FOR TIGHTENING TORQUE FOR GENERAL STANDARD BOLTS AND NUTS A1 - 7 UNIT A1 - 9 NEW UNIT BECAUSE OF THE INTRODUCTION OF THE SI UNIT----- A1 - 9 GENERAL SERVICE INSTRUCTION --- A1 - 10 SUPPORTING POINTS FOR JACKS AND SAFETY STANDS A1 - 12 JACKING POINTS A1 - 12 (.- SUPPORTING POINTS OF SAFETY STANDS A1 - 13 SUPPORTING POINTS OF LIFTS-------A1 - 14 SWING ARM TYPE ....................... A1 - 14 PLATE TYPE A1 - 14 TOWING INSTRUCTIONS---------------- A1 - 15 TOWING WlTH ROPE( ONLY FOR EMERGENCY ) A1 - 15 USING FLAT BED TRUCK--------------A1 - 15 WHEEL LIFT TYPE A1 - 15 DIAGNOSTICS INSTRUCTIONS--------- A1 - 16 DIAGNOSIS A1 - 16 DATA LlNK CONNECTOR ----------------- A1 - 18 DATA LlNK CONNECTOR TERMINAL ARRANGEMENT ---------- A1 - 18 CONNECTION METHOD OF DATA LINK CONNECTOR ....................... A1 - 18 CONNECTION METHOD OF EACH SYSTEM ..................................... A1 - 18 INSTRUCTIONS FOR SYSTEM lNSPECTlON .................................. A1 - 19 HANDLING INSTRUCTION OF CONNECTOR .............................. A1 - 1 9 CONNECTOR REMOVAUINSTALLATION PROCEDURE A1 - 19 CHECK PROCEDURE OF WIRE HARNESS AND CONNECTOR--------A1 - 21 CIRCUIT INSPECTION OF COMPUTER UNIT A1 - 22 HANDLING INSTRUCTION OF SYSTEM ..................................... A1 - 23 INSTRUCTIONS FOR RADIO INSTALLATION ------------------------. A1 - 24 HANDLING INSTRUCTIONSON CATALYTIC CONVERTER-EQUIPPED VEHICLES A1 - 24 PRECAUTION FOR VEHICLES EQUIPPED WlTH SRS AIRBAG AND SEAT BELT PRETENSIONER A1 - 25 INSTRUCTIONSFOR SERVICE OPERATION A1 - 25 VEHICLE IDENTIFICATION --------------- A1 - 27 BODY COLOR CODE A1 - 27 CHASSIS SERIAL NUMBER A1 - 27 ENGINE TYPE AND ENGINE NUMBER A1 - 27 MANUFACTURER'S PLATE POS~TION A1 - 28

A1 -1 - , . 1 IMPORTANT SAFETY NOTICE 1-1 GENERAL DESCRIPTION 1.The vehicle is a machine comprising a great number of parts. Basically speaking, the vehicle is potentially hazard. However, one can handle it safely if he has the required knowledge. 2.Correct service methods and repair procedures are very vital for assuring not only the safety and reliability of a vehicle, but also the safety of service personnel concerned. 3.The methods and procedures contained in this manual describe in a general way the techniques which the manufacturer has recommended. Thus, they will contribute to ensuring the reliability of the products. The contents of the servicing operations come in a wide variety of ways. Moreover, techniques, tools and parts necessary for each operation are different widely from each other. 4.This manual does not cover all details of techniques, procedures, parts, tools and handling instructions which are necessary for these operations, for such coverage is impossible. Hence, any one who obtains this manual is expected first to make his responsible selection as to techniques, tools and parts which are necessary for servicing the vehicle concerned properly. Furthermore, he must assume responsibility for his actions in connection with his own safety. S.Therefore, one should not perform any service if he is not capable of making responsible selection and/or if he can not understand the contents herein described, for this manual has been prepared for i ~ experienced service personnel. 1-2 WARNINGS, CAUTIONS AND NOTES 1.All these symbols have their specific purposes, respectively. WARNING r This symbol means that there is the possibility of personal injury of the operator himself or the nearby workers if the operator fails to follow the operating procedure prescribed in this manual. CAUTION r This symbol means that there is the possibility of damage to the component being repaired if the operator fails to follow the operating procedure prescribed in this manual. NOTE r To accomplish the operation in an efficient manner, additional instructions concerning the operation are given in this section. i I : 1 ,.-_,

- A1 -2 ! 1-3 GENERAL WARNINGS 1-3-1 WARNING OVER THE WHOLE SERVICE OPERATIONS 1 .Always wear safety glasses for eye protection. 2.Use safety stands whenever a procedure requires you to be under the vehicle. 3.Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure. 4.Set the oarkina brake when workina on the vehicle. - - 5.0perate the engine only in a well-ventilated area to avoid the danger of carbon monoxide. 6.Keep yourself and your clothing away from moving parts, when the engine is running, especially from the fan and belts. 7.To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. 8.Do not smoke while working on a vehicle. 9.To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle. 10.Keep hands and other objects clear of the radiator fan blades! The electric cooling fan is mounted on the radiator and can start to operate anytime by a rise in coolant temperature or turning ON of the air conditioner switch in the case of vehicles equipped with an air conditioner. The electric cooling fan is also mounted on the condenser for air conditioner and starts to operate anytime when the air conditioner switch is turned ON. For this reason care should be taken to ensure that the electric cooling fan motor is completely disconnected when working under the hood.

2 HOW TO USE THIS MANUAL 2-1 ARTICLES TO BE PREPARED When SST, tool, measuring instrument, a sort of fat and oil to be prepared before operation are necessary, those are described by compiling in the table as preparation tools at the beginning of each item. However, the general tools, jacks, fixtures as considered being equipped aiways at the service shop are usually omitted. 2-2 REMOVAL AND INSTALLATION PROCEDURES 1.Block diagrams are posted so as to show the installed state of each part. 2.The application of a sort of fat and oil and sealer are instructed in the figure with arrow. And the indication of a tightening torque and non-reusable parts are also described. The explanation of each code is posted below the block diagram concerned. 3.The removal and installation (disassembling and assembling ) procedure list is shown just beneath of components figure. The removal (disassembling) procedure, the installation (assembling) procedure and parts name are described in the sequence from left side of list. And the alphabet written before a part name links with alphabet in the figure. 4 . h principle, reverse the removal (or disassembly) procedure to install (or assemble) the parts. NOTE Only in cases where the installation (or assembly) can not be carried out by reversing the removal (or disassembly) procedure, the installation (or assembly) procedure is provided. 5 . h cases where a special procedure is required for the operation, a marking "VA" is provided in front of the removal (or disassembly) procedure. Furthermore, explanation is given in the "Main points of Removal (Disassembly)" or the "Main points of Installation (Assembly)." The marking shows that there are the "Main points of Removal (Disassembly)." whereas "A" shows that there are the "Main points of lnstallation (Assembly).''

I 2-2-1 ENTRY EXAMPLE ) COMPONENTS + : Rubber grease %: Non-reusable part Unit:Nm(kgf.cm] (2) DISASSEMBLY AND ASSEMBLY PROCEDURES 1 a Cap, cylinder slide pin 8 h Plate, disc brake pad guide 2 b Pin, cylinder slide. No.1 9 i Boot, cylinder A 3 c Pad, disc brake, No2 r 10 j Piston, disc brake \. 4 d Shim, anti squeal, No.1 11 k Seal, piston A 5 e Pad, disc brake w/ indicator. No.? 12 1 Boot, pin 6 f Shim, anti squeal, No.1 13 rnPin, cylinder slide, No.1 7 g Plate, disc brake pad guide 14 n Bush, cylinder slide 2-3 DESCRIPTION OF SERVICE STANDARD VALUE The necessary service standard value for inspection and service operation are described with bold letter in the text as standard and allowable limit. The details of terms are described in the section for definition of terms.

2-4 CONTENTS NOT DESCRIBED IN THIS MANUAL The description of the next elemental operation may omit in this service manual, but please perform in an actual operation. 1.Jacking operation and lifting operation 2.Cleaning and cleansing of removed parts to perform at need 3.Visual inspection 2-5 DEFINITIONS OF TERMS I LtWt, 4 I DEVIATION Th~s vaLe refers to lne d~flerence be!ween tne maxlmm clearance ano the m i n i m ~ ~ . clearance VALUE This mark shows the standard value a! the time of the check or adjustment. This mark shows the maximum or minimum value at the time of the check or adjustment.

t 3 ABBREVIATION CODES The abbreviation codes that appear in this manual stand for the following, respectively. I ABBREVIATION CODE I ORIGINAL WORD I ABBREVIATION CODE I ORIGINAL WORD I FR GND HC IG IN ISC LED Front Ground Hydro Carbon Ignition Intake Idle Speed Control Light Emitting Diode W/ WVTA @ 0 0 @ 0 With Whole Vehicle Type Approval Bolt Screw Nut Washer Clip

4 HOW TO GRASP SPECIFIED TIGHTENING TORQUE FOR GENERAL STANDARD BOLT AND NUT 4-1 DETERMINING PROCEDURE FOR TIGHTENING TORQUE FOR GENERAL STANDARD BOLTS AND NUTS 4-1-1 DETERMINING PROCEDURE FOR TIGHTENING TORQUE FOR BOLTS Determine the strength division of bolts, based on the table below. Then, obtain the value, based on the tightening torque table. 4-1-2 DETERMINING PROCEDURE FOR TIGHTENING TORQUE FOR NUTS Determine with the aforesaid method, based on the mating bolt. 4-1 -3 IDENTIFICATION Identification of strenglh division by checkhg bolts themselves Identification by part number Hexagonal bolt Exampleofpartnumber9 1111-4 0620 ,saGqJ JJ Nominaldiameter (mm) Nominal length (mm) f Nominal diameter t----i Nominal length Classification (Strength division) 4 T 5 T Shape of head (how to know strength division) Bolt without collar @ 0 @ 0 Bolt with collar @ 0 -

2002-2012 Daihatsu Copen Workshop Repair Service Manual BEST

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