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Daihatsu

Daihatsu Boon 2004-2010 Workshop Service Manual for Repair

Daihatsu Boon 2004-2010 Workshop Service Manual for Repair

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$16.99
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Vehicle data plateRef 425613
Brand
Daihatsu
Vehicle
Cars
Models covered
Boon
Years
2004, 2005, 2006, 2007, 2008, 2009, 2010
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

What happens after you pay

  • Download link opens on the order page immediately
  • The same link is emailed to you — re-download any time
  • Open on phone, tablet or PC; print only the pages you need
  • Not sure it covers your model year? Ask us before you buy
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Boon
Model Generation:
First Generation
Chassis Code:
M300
Production Years Covered:
2004-2010
👋 Introduction
Market Position
Vehicle Segment:
Subcompact hatchback, popular in urban environments and for its fuel efficiency.
Competitive Analysis
Competitors:
Competes with vehicles like the Toyota Yaris (Vitz), Honda Fit (Jazz), and Suzuki Swift.
Key Features
Design Philosophy:
Focus on compact dimensions, practical interior packaging, and economical operation.
Value Proposition
Manual Value:
Provides essential information for DIY enthusiasts and professional mechanics to maintain and repair the Daihatsu Boon effectively.
📋 Manual Details
Coverage Areas
Coverage Type:
Comprehensive Workshop Service and Repair
Page Count
Total Pages:
2622
Manual Type
Type:
Workshop Service Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
All engine variants, including disassembly, assembly, troubleshooting, and diagnostics.
Transmission:
Manual and Automatic transmission service, repair, and adjustment procedures.
Drivetrain:
Front-wheel drive (FWD) and All-wheel drive (AWD) systems, including differentials and driveshafts.
Suspension:
Front and rear suspension components, alignment, and related adjustments.
Steering:
Power steering system, steering column, and wheel assembly.
Brakes:
Hydraulic brake system, ABS, disc and drum brake service, and parking brake.
Electrical System:
Full electrical system diagnostics, wiring diagrams, component testing, and repair.
Cooling System:
Radiator, water pump, thermostat, hoses, and fan assembly service.
Fuel System:
Fuel tank, fuel pump, injectors, and emissions control systems.
Exhaust System:
Exhaust manifold, catalytic converter, muffler, and pipe repair/replacement.
Body And Chassis:
Body panel removal/installation, door mechanisms, glass replacement, and chassis component service.
HVAC:
Heating, Ventilation, and Air Conditioning system servicing and repair.
Interior:
Seating, dashboard, trim panels, and interior component service.
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, and general upkeep.
Troubleshooting:
Comprehensive diagnostic charts and procedures for identifying and resolving common and uncommon faults.
Repair:
Detailed step-by-step repair instructions for all vehicle systems and components.
Removal And Installation:
Explicit instructions for the removal and installation of all major and minor components.
Disassembly And Assembly:
In-depth procedures for the disassembly and reassembly of mechanical and electrical units.
Adjustment:
Precise instructions for adjustments to various systems, including brakes, clutch, and engine components.
Technical Depth
Depth:
From basic maintenance checks to complete engine and transmission overhauls. Includes factory specifications and tolerances.
Illustrations
Diagrams And Photos:
Richly illustrated with detailed pictorial diagrams, exploded views, schematics, and photographs.
Special Tools
Tool References:
References to required special service tools and their usage, often depicted in illustrations.
Safety Precautions
Notes And Warnings:
Includes specific notes, cautions, warnings, and DANGER indicators for safety during repair procedures.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Printability:
Fully printable, allowing for high-quality hard copy output of all pages.
Binding Type
Binding:
Digital Download (PDF), user printable.
Paper Type
Paper Quality:
Not applicable (digital format), but designed for clear printing on standard paper.
Compatibility
Operating Systems:
Compatible with Windows, Mac, and Linux operating systems.
Requirements
Software Requirement:
Requires Adobe Reader or a compatible PDF viewer.
⚙️ Engine Specifications
Primary Engine
Engine Options:
Primarily features 1.0L (1KR-FE) and 1.3L (K3-VE) inline-3 and inline-4 gasoline engines, respectively.
Performance
Horsepower Range:
Typically ranging from 65-70 hp for the 1.0L and 90-100 hp for the 1.3L, depending on specific market tuning.
Torque Range:
Approximate torque figures of 85-95 Nm for the 1.0L and 120-135 Nm for the 1.3L.
Fuel System
Injection Type:
Electronic Fuel Injection (EFI).
Engine Management
ECU Details:
Detailed information on Engine Control Unit (ECU) operation, diagnostics, and reprogramming procedures.
Emissions
Emissions Control:
Information on catalytic converters, oxygen sensors, and other emissions control systems.
🔧 Transmission
Standard
Transmission Options:
Commonly equipped with either a 5-speed manual transmission or a Continuously Variable Transmission (CVT).
Optional
Gear Ratios:
Detailed gear ratios for both manual and CVT transmissions are provided for performance analysis and repair.
Features
Transmission Fluid:
Specifications for automatic transmission fluid (ATF) type and capacity, as well as manual gearbox oil.
📐 Dimensions
Exterior
Overall Length:
Approximately 3,615 mm (may vary slightly by specific model year and trim).
Overall Width:
Approximately 1,665 mm.
Overall Height:
Approximately 1,500 mm.
Wheelbase
Wheelbase:
Approximately 2,400 mm.
Weights
Curb Weight:
Typically around 850-950 kg, depending on engine and transmission.
🛡️ Safety Features
Ratings
Crash Test Results:
While specific ratings vary by region, the manual provides safety-related information and component specifications for crashworthiness.
Active Features
ABS:
Information on the Anti-lock Braking System (ABS) operation, components, and troubleshooting.
Passive Features
Airbags:
Details on airbag systems, SRS (Supplemental Restraint System) components, and related safety precautions.
Seatbelts:
Information pertaining to seatbelt mechanisms and their importance in vehicle safety.
💡 Technology Features
Infotainment
Audio System:
Information on factory audio systems, speaker replacement, and basic troubleshooting.
Driver Assistance
Cruise Control:
Details on the operation and service of the cruise control system, if equipped.
Connectivity
Lighting System:
Comprehensive coverage of headlights, taillights, interior lighting, and electrical circuits.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to the manual for specific engine oil and filter change intervals, typically recommended every 5,000-10,000 km or 6-12 months, depending on driving conditions.
Spark Plug Replacement:
Intervals for spark plug replacement will vary by plug type (standard, platinum, iridium) and are detailed within the manual.
Fluid Specifications
Engine Oil Type:
Typically 0W-20 or 5W-30 API SN or higher, with specific viscosity grades detailed in the manual.
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors, typically a pink or red long-life formulation.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid as specified in the manual.
Known Issues
Common Wear Items:
Potential wear items include brake pads, clutch components (on manual transmissions), suspension bushings, and oxygen sensors. The manual details inspection and replacement procedures.
Cvt Considerations:
CVT transmissions may require specific maintenance procedures and fluid types; the manual provides detailed guidance.
📚 Vehicle History
Brand Heritage
Daihatsu Legacy:
Daihatsu, a subsidiary of Toyota, has a long history of producing small, economical, and reliable vehicles.
Model Evolution
Boon Origin:
The Daihatsu Boon (also known as Toyota Passo in some markets) was developed as a compact city car with a focus on interior space and practicality.
Production
Manufacturing Location:
Primarily manufactured in Japan.
🏆 Awards & Recognition
Recognitions
Fuel Efficiency Awards:
While not directly listed, the Boon/Passo series has historically been recognized for its strong fuel economy ratings in its class.
Ratings
Reliability Perception:
Generally perceived as a reliable vehicle due to Toyota's engineering influence and Daihatsu's focus on dependable small cars.

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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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