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Daihatsu

Daihatsu Copen 2002-2012 All Service Repair Manual

Daihatsu Copen 2002-2012 All Service Repair Manual

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Vehicle data plateRef 450111
Brand
Daihatsu
Vehicle
Cars
Models covered
Copen
Years
2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

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🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Copen
Generation:
L880K
Chassis Code:
L880K
Body Style:
Convertible Coupe
Codes
Model Years Covered:
2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012
👋 Introduction
Market Position
Vehicle Segment:
Kei car convertible sports car, niche market segment.
Competitive Analysis
Key Competitors:
While direct competitors were few, it competed on style and open-top motoring with larger roadsters in some markets.
Key Features
Design Philosophy:
Compact, stylish, sporty convertible with an electrically operated retractable hardtop.
Unique Selling Points:
Unique styling, compact dimensions, affordable open-top experience, turbocharged engine option.
📋 Manual Details
Coverage Areas
Manual Coverage Scope:
Comprehensive service and repair for all aspects of the Daihatsu Copen (2002-2012).
Page Count
Estimated Page Count:
1500-2000+ (typical for comprehensive service manuals)
Manual Type
Manual Type:
Service and Repair Manual / Workshop Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Service And Repair:
Detailed procedures for engine disassembly, assembly, diagnostics, and overhaul of the JB-DET engine.
Transmission Service And Repair:
Covers both the 5-speed manual and 4-speed automatic transmissions, including clutch, gearbox, and differential.
Brake System:
Service and repair of front ventilated discs, rear discs, ABS, and hydraulic components.
Electrical System And Wiring Diagrams:
Comprehensive wiring schematics, component location, diagnostic procedures for all electrical systems, including the convertible roof mechanism.
Suspension And Steering:
Front MacPherson struts, rear torsion beam, power steering system, wheel alignment specifications.
Cooling System:
Radiator, thermostat, water pump, hoses, and coolant specifications.
Fuel Injection And Fuel System:
EFI system, fuel pump, injectors, fuel filter, fuel pressure specifications.
Emission Control System:
ECU control, catalytic converter, EGR system, emission test procedures.
Engine Control System:
ECU functions, sensor inputs (MAP, TPS, IAT, O2), actuator outputs, diagnostic trouble codes (DTCs).
Chassis And Body:
Body panel removal and installation, structural components, convertible roof mechanism operation and repair.
Restraint System:
Airbag system, seatbelts, pre-tensioners, SRS diagnosis.
Axle And Drivetrain:
Front-wheel drive components, CV joints, drive shafts.
Periodic Maintenance And Lubrication:
Scheduled maintenance tasks, fluid types, capacities, and replacement intervals.
Procedures Included
General Maintenance:
Routine checks, fluid changes, filter replacements, spark plug service.
Troubleshooting:
Systematic diagnostic guides for common and uncommon problems with symptom analysis and repair steps.
Disassembly And Reassembly:
Step-by-step instructions for dismantling and reassembling all major vehicle components.
Repair And Rebuild:
Detailed repair procedures for worn or damaged components, including engine and transmission rebuilds.
Refurbishment And Renovation:
Guidance on restoring specific components or systems to optimal condition.
Technical Depth
Depth Of Information:
Extremely detailed, covering everything from basic fluid checks to complete engine and transmission overhauls, including specialized tools and torque specifications.
📊 Manual Specifications
File Format
Compatibility:
Compatible with all versions of Windows and Mac operating systems.
Software Requirements:
Adobe PDF Reader and WinZip (or equivalent for unpacking archives).
Print Quality
Printability:
Printable pages for use in a workshop environment.
Binding Type
Binding Type:
Digital Download (PDF)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
JB-DET
Engine Type:
Inline 3-cylinder, turbocharged, intercooled, DOHC, 12-valve
Displacement:
659 cc
Bore X Stroke:
64.0 mm x 68.0 mm
Compression Ratio:
8.3:1
Performance
Horsepower Output:
64 PS (47 kW; 63 hp) at 6400 rpm (JDM regulations), some export models may have higher output.
Torque Output:
10.5 kg⋅m (103 N⋅m; 76 lb⋅ft) at 3600 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Recommended Fuel:
Unleaded gasoline (Octane rating 91 or higher)
Engine Control System
ECU Type:
ECU controlled ignition and fuel injection.
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission
Optional
Transmission Type Optional:
4-speed Automatic Transmission
Features
Clutch Type:
Hydraulically operated, dry single plate (Manual)
Gear Ratios Manual:
1st: 3.250, 2nd: 1.870, 3rd: 1.345, 4th: 1.032, 5th: 0.871, Reverse: 3.250
Final Drive Ratio:
4.058
📐 Dimensions
Exterior
Length:
3395 mm (133.7 in)
Width:
1475 mm (58.1 in)
Height:
1245 mm (49.0 in)
Wheelbase:
2430 mm (95.7 in)
Ground Clearance:
135 mm (5.3 in)
Weights
Curb Weight:
Approximately 830-870 kg (1829-1918 lbs) depending on transmission and equipment.
Gross Vehicle Weight Rating:
Approximately 1100 kg
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Kei car regulations mean typical NCAP ratings are not directly applicable; JNCAP focused on specific criteria).
Active Features
ABS:
Standard on most models, Anti-lock Braking System.
Limited Slip Differential:
Optional on some performance variants.
Passive Features
Airbags:
Driver and passenger airbags standard on most models.
Seatbelts:
3-point seatbelts with pre-tensioners.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/CD player, often with 4 speakers. Aftermarket options are common.
Driver Assistance
Stability Control:
Traction Control System (TCS) available on some models.
Connectivity
Original Features:
Limited by era; focus on essential vehicle operation and comfort features rather than advanced connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 km (4,660 mi) or 6 months, whichever comes first (refer to manual for specific type).
Air Filter Replacement:
Every 30,000 km (18,600 mi) or 2 years.
Spark Plug Replacement:
Every 100,000 km (62,100 mi) for iridium-tipped plugs (check specific type).
Fluid Specifications
Engine Oil Type:
API SG or SH, ACEA A1/B1 or higher, viscosity 5W-30 or 10W-30 (consult manual for precise specification).
Engine Oil Capacity:
Approx. 3.0 - 3.2 Liters (with filter change)
Coolant Type:
Ethylene glycol-based coolant, mixed 50/50 with distilled water.
Transmission Fluid Type Manual:
API GL-4, SAE 75W-85 or 75W-90 gear oil.
Transmission Fluid Type Automatic:
Dexron III or equivalent ATF fluid.
Known Issues
Common Wear Items:
Turbocharger seals (oil leaks/smoke), suspension bushings, ignition coils, clutch wear.
Convertible Roof Mechanism:
Potential issues with hydraulic seals, motors, and limit switches; requires regular lubrication and inspection.
Engine Management:
Occasional issues with boost pressure leaks, wastegate actuator, and O2 sensors.
📚 Vehicle History
Brand Heritage
Daihatsu Focus:
Daihatsu is known for producing reliable, compact, and economical vehicles, often with a focus on Kei car regulations in Japan.
Model Evolution
First Generation:
The L880K generation was a significant step for Daihatsu in offering a premium-feeling, stylish sports convertible.
Key Updates:
Minor styling updates and equipment changes throughout its production run, with a focus on retaining the core sporty character.
Production
Manufacturing Location:
Japan
Production Years Overall:
2002-2012
🏆 Awards & Recognition
Recognitions
Automotive Journalism:
Consistently praised by automotive media for its style, affordability, and fun-to-drive character within the Kei car segment.

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Check the model year and engine before you buy

Manufacturers change procedures, wiring and part numbers between model years and engine options. If your VIN plate shows a year or engine code that is not listed on the data plate above, contact us with the model, year and VIN and we will confirm coverage before you order.

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