Gi PDF
Gi PDF
Gi PDF
J100
TO INDEX
GENERAL INFORMATION
NO. 9711-JE
GI–2 Revised on ’98 Oct.
The UNITS used in this manual are showed as the SI UNIT (International System of Unit), and alter-
natively showed in the metric system.
“Example”
24.5 - 34.3 N·m (2.5 - 3.5 kgf-m)
JGI00002-00000
GI–4 Revised on ’98 Oct.
(Example)
T : Tightening torque
Unit : N·m (kgf-m)
★ : Non-reusable parts
T : 11.80 - 17.7
(1.2 - 1.8)
JGI00003-00001
2. Servicing Procedure
(1) In principle, the servicing procedure is described in the following sequence given below: Removal →
Inspection → Installation, and Disassembly → Inspection → Assembly.
(2) The explanation covers detailed servicing methods, specifications and notes.
(3) The main point of each item explains the servicing section and servicing procedure, using illustrations.
(Example)
What to do How to do it
What to do and where
JGI00004-00002
Revised on ’98 Oct. GI–5
(4) The inspection in this manual describes only checking operation. Therefore, if you find any malfunc-
tion, replace any defective parts with new ones.
3. SST
For those operations which require the use of any SST, the SST numbers concerned are given in bold
letters.
4. Service Specifications
Service specifications are indicated in bold letters or enclosed by heavy lines. Be certain to confirm the
specifications concerned.
5. Tightening Torque
For those operations which require the control of tightening torque, the relevant tightening torque is
given in bold letters. Be certain to confirm the tightening torque concerned.
6. Definitions of Terms
Specified Value …… A value which represents the allowable range during the inspection
and adjustment.
Limit ………………… A maximum or a minimum limit which the value should not exceed or fall below.
JGI00005-00000
GI–6 Revised on ’98 Oct.
ABBREVIATION CODES
The abbreviation codes that appear in this workshop manual stand for the following, respectively.
Abbreviation code Original word Meaning
A/C Air Conditioner Refers to air conditioner.
A/T, AT Automatic Transmission Refers to automatic transmission
A/Y or Ay Assembly Refers to an assembled component comprising more than two single parts or sub-assembly
parts.
API American Petroleum The standards set forth by the American Petroleum Institute (abbreviated as API
Institute Classification) have been employed to evaluate and classify properties of various oils.
Engine oils for gasoline engines are classified as SF, SG, SH and so on, whereas engine oils
for diesel engines are classified as CC, CD and so on.
ECU Electronic Control Unit Refers to electronic control unit.
Electronic Refers to electronic fuel injection.
EFI Fuel Injection
F/L Fusible Link Refers to fusible link.
L.H.D. Left-Hand Drive Left-hand drive vehicle.
LH Left Hand Refers to left side.
M/T, MT Manual Transmission Refers to manual transmission.
MP Multipurpose Means that the following item has multi-purposes.
O/S Oversize In instances where fitting becomes too loose due to wear resulting from use for a long period
of time or due to frequent removal/installation operations, if the fitting part (e.g. piston) is
replaced with a part having larger dimensions, the other mating part may be put into use
again. “Oversized” parts denote those parts having larger dimensions compared with the
standard parts.
PR Ply Rating Represents strength of tires.
The larger the ply rating number, the stronger the tire strength.
R.H.D. Right-Hand Drive Right hand drive vehicle
RH Right Hand Refers to right side.
S/A Sub-Assembly Refers to a component comprising more than two single parts which are welded, staked, or
studded to each other to form a single component.
SAE Society of Automotive For example, automotive oils are designated as SAE so and so number.
Engineers These designation numbers have been set forth by the Society of Automotive Engineers in the
United States of America (SAE). The larger the SAE number, the higher the oil viscosity.
Conversely, the smaller the SAE number, the lower the oil viscosity.
SST Special Service Tool Refers to a tool designed for a specific purpose.
STD Standard When referring to automotive parts, “standard” represents those parts which have been
installed originally by the manufacturer and which have standard dimensions.
T Torque Refers to tightening torque.
U/S Under Size In the same manner as with the “oversized” parts, if fitting part (e.g. bush and bearing) is
replaced with a part having smaller bore dimensions, the other mating part may be put into
use again. “Under sized” parts denote those parts having smaller dimensions compared with
standard parts.
VSV Vacuum Switching
Refers to vacuum switching valve.
Valve
W/ With Denotes that the following part is attached.
ETR Electronic Tuning Radio which incorporates variable capacitance, etc. which varies the value according to an
Radio applied voltage or current.
JGI00006-00000
The abbreviation codes that appear in the figure stand for the following, respectively.
B Bolt S Screw
N Nut W Washer
JGI00007-00000
Revised on ’98 Oct. GI–7
GENERAL SERVICE INSTRUCTION
1. Use fender covers, seat covers and floor sheets so that the vehicle may not get dirty or be scratched.
2. Jacking up
(1) When only the front section or rear section of the vehicle is jacked up, be sure to place chocks at
the wheels so as to insure safe operations.
(2) When the vehicle has been jacked up, be sure to support the vehicle at the specified section using
safety stands. (See page GI–9)
(2) When it becomes necessary to disconnect the battery power supply for the purpose of carrying out
checks or repairs, always disconnect the battery ground cable terminal from the negative terminal
of the battery first.
(3) To avoid damaging battery plates, after the terminal nut has been loosened, pull out the battery
ground cable terminal straight upward, rather than turning or prying the terminal.
NOTE:
• Be sure to employ a battery terminal puller (commercially available) to remove the battery ground
cable terminal from the negative terminal of the battery, if encountered any difficulty.
(4) Clean the battery terminal posts or battery ground terminals, using a cloth. Never use a file or other
adhesive agents.
(5) When connecting the battery ground cable terminal to the battery, first the battery ground cable ter-
minal should be fitted onto the battery post with the attaching nut in a loose state.
Then, tighten the nut. Never tap the terminal onto the battery post, using a hammer or spanner wrench
or the like.
(6) As for the cover at the positive (+) terminal side, be sure to install it at the correct position.
5. For increased work efficiency and improved accuracy, be sure to utilize SSTs (Special Service Tools) ef-
fectively.
JGI00008-00000
GI–8 Revised on ’98 Oct.
3. Be sure to observe the following points when performing the spark jump tests.
(1) The spark jump test must be limited to cases where such test is absolutely necessary. Also, be sure
to finish the test in the shortest possible time.
(2) Be sure to shut off the fuel supply when performing the spark jump test in advance.
4. Do not run the engine when the fuel tank becomes nearly empty.
Failure to observe this caution will cause misfiring. Also, it will apply excessive load to the catalytic con-
verter, even leading to catalyst damage.
5. Do not dispose of the waste catalyst along with parts contaminated with gasoline or oil.
JGI00009-00000
Revised on ’98 Oct. GI–9
JACKING POINTS AND SUPPORTING POINTS OF SAFETY STANDS
CAUTION:
• Be sure to support the vehicle at the flat surface of the rocker panel.
• Do not support the vehicle at the edge part rocker panel.
• Jacking Points
Front side ………… Differential mount bracket
Rear side ………… Rear axle housing
Front side Rear side
Supporting points
JGI00010-00003
GI–10 Revised on ’98 Oct.
TOWING INFORMATION
When towing the model J100 follow the manner mentioned below.
CAUTION:
• Never perform towing, using sling type equipment.
Failure to observe this caution may lead to severe damage on the vehicle body.
JGI00011-00000
Use a towing dolly when towing the vehicle with the front
wheels or rear wheels on ground.
WARNING:
• Never allow anyone to be in the vehicle being towed.
CAUTION:
• Be sure to secure the front or rear tires on the towing
dolly.
• Never perform the towing, using sling type equipment.
Failure to observe this caution may severely damage
the vehicle body. JGI00013-00005
Emergency towing
This manner can be employed if the vehicle is equipped with
a manual transmission and the road surface is hard and
smooth. In this case, be certain to follow the WARNING and
CAUTION mentioned below.
WARNING:
• The driver in the vehicle to be towed should always
keep in mind that braking will require more force than
usual when the engine is stopped, because the brake
booster is not functioning when the engine is stopped. JGI00014-00006
Revised on ’98 Oct. GI–11
• Never tow the vehicle at speed more than 30 km/h.
• Turn the ignition switch of the vehicle to be towed in the “ACC” position during the towing. Never pull
out the key or turn the ignition switch to the “LOCK” position during the towing. Failure to observe this
warning will loose controllability, causing an accident.
• Never tow the vehicle in this manner unless the wheels, axles, drive train, steering, and brakes are in
a good condition.
CAUTION:
• Never tow an automatic transmission vehicle in this manner. Be sure to always use a towing dolly.
• Always pull the hook in a straight-ahead direction to prevent it from being damaged. Never pull it
from side or in a vertical direction. Also, never pull it sharply.
• Never connect the towing rope, cable or such to the parts other than the hooks provided on the vehi-
cle shell. Connection of the towing rope, cable or such to other pants than hooks may damage these
components
• Ensure that the hooks are installed on the vehicle shell securely before towing.
DIAGNOSIS CONNECTOR
The diagnosis connector is provided under the instrument
panel at the driver’s seat side as shown.
Terminal table
Terminal number and name
q IG For DS-21 o T (ITC)
e ABST !0 SIO For DS-21
r ECUT !1 EFIT
i REV !3 Body ground
!6 VF JGI00016-00007
JGI00017-00008
GI–12 Revised on ’98 Oct.
JGI00018-00009
CAUTION:
• Never connect the terminals other than that specified in
the main text in each section. Failure to observe this
caution may lead to serlus damage or malfunction.
JGI00019-00010
4. Reference
(1) Output of diagnosis code of EFI system.
Connect the 11(EFIT) and 13 (Body ground)
(2) Output of diagnosis code of ABS system.
Connect the 4(ECUT) and 13 (Body ground)
(3) Switching to the test of ABS system. 1 2 3 4 5 6 7 8
Connect the 3(ABST) and 13 (Body ground) 9 10 11 12 13 14 15 16
(4) Vf output (oxygen sensor function)
Connect the 16(VF) and 13(body ground)
(5) Output of diagnosis code of air bag system.
Connect the 4(ECUT) and 13 (Body ground) JGI00020-00011
CAUTION:
• Never connect the DS–21 in another way than that
manner specified.
Revised on ’98 Oct. GI–13
MODEL VARIATION
Specification General AUS EC
Engine Handle position RHD LHD RHD RHD LHD
Grade Lo Hi Lo Hi Lo Hi Lo Hi Lo Hi
Model code J100RG J100LG J100RG J100RG J100LG
HC-EJ 5MT GMDE GMXE GMDE GMXE GMDEQ GMXEQ GMDEW GMXEW GMDEW GMXEW
4AT GPDE GPXE GPDE GPXE GPDEQ GPXEQ GPDEW GPXEW GPDEW GPXEW
JGI00021-00000
Drive system
0 : Four-Wheel Drive Vehicle (Full-time 4WD)
Engine type
Body type 0 : Type HC-EJ engine
G : Station
wagon Steering position
Number of doors L : Left-Hand Drive Vehicle
G : Five Door R : Right-Hand Drive Vehicle
JGI00023-00012
JGI00024-00013
q
w
e
r t
u
y !4 q Manufacturer’s name, Country
w Vehicle model
i e Chassis No.
r Engine type
o t Engine displacement
y Body colors
u Trim code
(2) European Specification (except for Norway and Finland) i Engine number
o Manufacturer’s name in Japanese
q !0 Gross vehicle weight
!1 Gross combination weight
!5 !2 Maximum permissible front axle weight
e !3 Maximum permissible rear axle weight
!4 Production month-year (Only for AUS spec.)
!0
!5 Authorized number of W.V.T.A.
!1 (Only for European specification.)
!2
!3
w
r y
JGI00025-00014
Revised on ’98 Oct. GI–15
ENGINE NUMBER AND ENGINE TYPE
STAMPED POSITIONS
• The engine number is stamped on the cylinder block. Serial number
• The engine type is indicated by embossed letters on the stamped
cylinder block. position
JGI00026-00015
GI–16 Revised on ’98 Oct.
TRIM CODE
F C S5 Trim color code (Serial code)
Serial code
Seat main material
F: Fabric
S: Gray
JGI00028-00000
Revised on ’98 Oct. GI–17
COLOR CODE IN THE WORLD
SPIES
DAIHATSU AKZO DUPONT ICI STNDOX
HECKER
Silver Metallic S07 DAHS07 L8842 B127B 97097 S07
Black Metallic 6A5 DAH6A5 G8742 A403B 96326 6A5
Purplish blue mica Metallic B38 DAHB38 F3425 JNE4B 55603 B38
Mono- Jade green Metallic G31 DAHG31 F5146 NMH2B 65649 G31
tone Sea sapphire blue mica Metallic B44 DAHB44 F5147 NMH3B 56715 B44
Maple red mica Metallic R27 DAHR27 F7151 MCE2B 34314 R27
Violet Metallic P05 DAHP05 F3426 JNE5B 40868 P05
White W19 DAHW19 M0004 RAA7 23024 W19
NF7 DAHS07 L8842 B127B 97097
Silver Metallic (S07/S07) /DAHS07 /L8842 /B127B /97097 S07/S07
AUTOMATIC TRANSMISSION
1. Outline
The basic construction of the automatic transmission remains the same as the hitherto-employed transmis-
sion mounted on the Terios. However, for improved transmitting efficiency and enhanced durability, reliabili-
ty and quietness, the hitherto-employed automatic transmission for the Terios has been further improved.
In line with the rolling-off of the new Terios of this time, modifications have been made on the following com-
ponents with an asterisk mark (*) indicated in the sectional view of the automatic transmission for the Terios.
Furthermore, the parking brake mechanism, etc. indicated in the following page has been modified.
JGI00031-00000
q w e r t y u i o !0
!1 !2 !3 !4 !5 !6 !7 !8 !9
Output shaft
Parking rod
Cam spring
Parking cam
*: Modification has been made on the components with an asterisk mark indicated.
JGI00033-00017
GI–20 Revised on ’98 Oct.
2. Specifications
Transmission Type A4JA
Transmission ID code F64
Driving method 4WD
Engine type HC-EJ
Torque Type Three-element, one-stage, two-phase type
converter Stall torque ratio 2.0
Type Four forward speed, one reverse gear
Wet type multiple clutch: 3 set
Band type brake: 1 set
Control element
Wet type multiple brake: 1 set
One-way clutch: 1 set
1st 2.730
Trans- 2st 1.526
mission Gear ratio 3rd 1.000
type
4th 0.696
R 2.290
Speed meter gear ratio 24/5
Fluid to be used ATF DEXRON 3
Fluid capacity litter 4.2
Cooling method Water-cooled (radiator built-in type)
Control Gear shift control method Four forward speeds, full automatic shift
system Manual control pattern P-R-N-D-2-L (with over drive switch)
JGI00034-00000
JGI00035-00018
2. Forward clutch
For improved transmitting efficiency, the number of teeth
of the forward clutch disc No. 2 and forward clutch hub
has been increased from 20 to 35.
JGI00036-00019
Revised on ’98 Oct. GI–21
4. Enhanced quietness
1. Reduction of gear noise Planetary Intermediate shaft
short pinion
For reduced gear noise, the profile and number of teeth of
each gear of the planetary long pinion, rear planetary sun
gear, front planetary sun gear, planetary short pinion and Planetary
output shaft
planetary output shaft.
Rear planetary
Number of teeth
Planetary gear sun gear
Former New
Front planetary Planetary long
Planetary long pinion 36 31 sun gear pinion
Rear planetary sun gear 24 20 JGI00038-00021
JGI00039-00022
Output shaft
Parking rod
Cam spring
Parking cam
*: Modification has been made on the components with an asterisk mark indicated.
JGI00041-00024
JGI00042-00025
Revised on ’98 Oct. GI–23
2. Abolishment of oil cooler hose
In order to reduce the number of components of the oil cooler piping, the automatic transmission tube
has become integral with the engine side tube. Consequently, the oil cooler hose has been abolished.
Front tube
A/T tubes
JGI00043-00026
PROPELLER SHAFT
1. Enhanced quietness
In order to reduce the bead noise that is emitted at the time of shaft rotation, the shape of the propeller
shaft bearing center support housing has been changed.
[Former] [New]
JGI00044-00027
GI–24 Revised on ’98 Oct.
REAR AXLE
1. Improvement of driving stability
For enhanced roll rigidity, the rebound spring built-in type shock absorber has been adopted for the rear
shock absorber so as to improve the driving stability, while maintaining the driving comfort.
JGI00045-00028
2. Enhanced quietness
For reduced differential noise, the sheet thickness of the rear
axle housing has been increased and the reinforcement has
been abolished.
JGI00046-00029
Revised on ’98 Oct. GI–25
BODY-RELATED ITEMS
With regard to the body-related items, the following design changes have been made as the measures for
appealing the product quality so that the ODB conformity collision safety body may be attained, the physi-
cal comfort may be improved and any deficiency encountered in the market may be eliminated.
JGI00047-00000
[Former] [New]
JGI00048-00030
JGI00049-00031
JGI00050-00032
GI–26 Revised on ’98 Oct.
10mm
20mm
JGI00051-00033
195
446 (X670)
*246 (X556)
(Hi Grade)
60 53
0 3
134
159
446 (X670)
*246 (X556)
(Lo Grade)
JGI00052-00034
Revised on ’98 Oct. GI–27
3. Enhanced performance of vehicle interior ventilation
In order to assure adequate ventilating performance, a
ventilation valve has been provided at two points behind
the rear combination lamp of the left side “D” pillar and
behind the right bumper.
JGI00053-00035
JGI00054-00036
JGI00055-00037
JGI00056-00038
GI–28 Revised on ’98 Oct.
JGI00058-00040
Revised on ’98 Oct. GI–29
2. Improvements of installation method of roof mouldings
The following measures given below have been taken as
the measures for complaints for floated roof mouldings.
(1) Improvements of shape of mouldings
The shape of mouldings has been altered into such a
shape in which the floating or bend of mouldings may
not become conspicuous by setting the moulding in-
stallation seating surface at a point lower than the
body surface.
(2) Installation method of mouldings
In order to prevent the mouldings from being floated, JGI00059-00041
ELECTRICAL COMPONENTS
For enhanced safety and improved physical comfort, the following design changes enumerated below
have been made on the electrical components.
1. Enhanced safety
1. Improvements of airbag system
In addition to the installation of an airbag on the driver’s seat as well as on the front passenger seat,
seat belts equipped with a pretensioner & force limiter have been mounted on all vehicles.
As a result of this change, the airbag ECU and cowl wire have been altered.
At the same time, changes have been effected on the steering wheel (from the two-spoke with airbag to
the three-spoke with airbag).Furthermore, the roll connector has been modified.
JGI00060-00000
OC3 F/L ABS 50A OC6 ABS
Head lamp 30A O69 H/L
Tail 40A OF1 TAIL
ALT Back up 10A C90 B/U
GI–30
10 A
10 A
10 A
Engine
ECU IG
Air bag
AIRBAG SYSTEM CIRCUIT DIAGRAM
Battery
QB2 N31 T45
H61
T37
Air bag ECU
Warning lamp
(Combination meter)
T26 W DC-DC Back-up Safing
circuit condenser sensor
A Roll
connector
Z08
B
DB+ T11
Driver's
DB— T12 air bag
T01 IG1 Control Drive
circuit circuit PB+ T09
Diagnosis connector T02 IG2 Passenger's
PB— T10 air bag
IG ECU IMB T28 TC CPU
REV
T W DP+ T48
ITC E G sensor Driver's
VF
T SIO DP— T47 pretensioner
Diagnosis Drive
code circuit PP+ T29
memory Passenger's
Air bag ECU connector (at cowl wire harness side) T44 SIO PP— T13 pretensioner
T14 E1
T10 T09 T44 T26 T12 T11 T28
A B
T14 T13 T29 T47 T48 T02 T01
JGI00061-00042
Revised on ’98 Oct.
Revised on ’98 Oct. GI–31
STEERING
A new three-spoke type steering wheel with air bag has been
employed.
JGI00062-00043
ROLL CONNECTOR
The full stroke of the roll connector from the lock to the lock
TOP mark
has been increased from five turns to six turns. Consequently,
in the former setting during the roll connector installation, the
roll connector was set after it is backed off 3.0 turns from the
lock point, while in the new setting, it is necessary that this ini-
tial setting is made after the roll connector is backed off 3
turns.
JGI00063-00044
JGI00064-00045
F/L ABS 50A ABS
Head lamp 30A H/L
Tail 40A TAIL
GI–32
F/L AM 60A
Buzzer
20 A
Stop 10 A
Wiper/Turn
Door lock 15 A
locking switch alone was mounted.
Gauge 10 A
Battery
Courtesy SW
HZD TRN
RH LH
Turn signal lamp OFF
Room lamp
2. Employment of two-contact points on door lock switch
Flasher relay
F48 Multi-use lever
ITC ECU Q47 QB3 QC7 QB7 QB5 QC4 QB9 QC5 QB4 QB6
+B IG1 CHZD T/H CHR CHL CFL FL+ DCSD CRL
Buzzer
ITC ECU connector (wire harness side) Door lock Diagnosis connector
D motor
CHL FL+ T/H T LKS IG1 E1 LKM ABS ECU IMB
CSD M IG REV
S
Collision T T W
N
C
N
CHR CFL CRL UKS SPD CS1 +B CS– ULM ITC EFI
S
HZD sensor SIO E VF
Vehicle
M T T
M
speed sensor
Door lock M
Switch
M
that the locking/unlocking state of the door may be detected accurately. In the former system, the un-
JGI00065-00046
For improved safety, a lock switch has been added to the impact sensing door lock release system so
Revised on ’98 Oct.
Revised on ’98 Oct. GI–33
3. Enhanced conspicuousness of switches
In order to enhance conspicuousness of the switches during night driving, night illumination has been
added to the following switches listed below:
ON
Indicator OFF
light
ON
OFF
JGI00066-00047
Seat belt Sw
A13
LED
JGI00067-00048
GI–34 Revised on ’98 Oct.
L.H.D.
JGI00068-00049