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Name: Ilias Papastamatiou Manufacturer: Daihatsu

Address: Model: j210
Year: 2009
Registration:
Tel - Private: Mileage:
Tel - Business: Job number:
Tel - Mobile Date 8/2/2010

Notes Specified value Measured value

Vehicle identification
No. of cylinders Type 4/DOHC
Capacity (Fiscal) cc 1495
Compression ratio :1 10,0
Suitable for unleaded petrol Yes
Minimum octane rating RON 95
Ignition system Make Daihatsu
Ignition system Description Map-DI
Trigger location Cam / Crankshaft
Fuel system Make Daihatsu
Fuel system Type EFI
Fuel system Description MFI-s
Air metering Type MAP
Combined ignition and fuel ECM Yes
Diagnostic socket Yes
Ignition system
Ignition coil supply voltage + with ballast V 12,0
Firing order 1-3-4-2
Tuning and emissions
Ignition timing - basic BTDC °Engine/rpm Not adjustable
Ignition advance checks °Engine/rpm ECM Controlled
Idle speed rpm 700±50 Not adjustable
Oil temperature for CO test °C 80
CO level at idle speed - tailpipe Vol. % CO 0,3 Max Not adjustable
HC level at idle speed ppm 100
CO2 level at idle speed Vol. % CO2 14,5-16
O2 level at idle speed Vol. % O2 0,1-0,5
Increased idle speed for CO test rpm 2300-2700
CO content at increased idle speed Vol. % 0,2
Lambda at increased idle λ 0,97-1,03
Spark plugs
Spark plugs Original equipment NGK
Spark plug Type IKR7C
Electrode gap mm 0,8-0,9
Spark plugs Make NGK
Spark plug Type IKR7C
Electrode gap mm 0,8-0,9

Manufacturer: Daihatsu Model: Terios (06-) 1,5 © Autodata Limited 2008

Engine code: 3SZ-VE Output: 77 (105) 6000 8/2/2010
Tuned for: R-Cat Year: 2006-09 V7.412-ENGI147441
 Fuel system
System pressure bar 3,0-3,4
Engine coolant temperature (ECT) sensor Ohm/°C 318/80
Crankshaft position (CKP) sensor/engine speed (RPM)
Ohm 1985-2450
sensor
Injector Ohm 12,0
Service checks and adjustments
Valve clearance -INLET mm 0,15-0,24 cold
Valve clearance -EXHAUST mm 0,28-0,37 cold
Compression pressure bar 10,8
Oil pressure bar/rpm 2,1/3000
Radiator cap bar 0,8-1,2
Thermostat opens °C 78-82
Lubricants and capacities
Engine oil options
Ambient temperature range —> 16°C
Engine oil grade SAE 0W/20, 5W/20
Engine oil classification API/ACEA SH/A1
Ambient temperature range All temperatures
Engine oil grade SAE 5W/30
Engine oil classification API/ACEA SH/A1, A3
Ambient temperature range -18°C —>
Engine oil grade SAE 10W/30, 10W/40, 10W/50
Engine oil classification API/ACEA SH/A3
Ambient temperature range -14°C —>
Engine oil grade SAE 20W/40, 20W/50
Engine oil classification API/ACEA SH/A3
Engine with filter(s) litres 3,2
Other lubricants and capacities
Manual gearbox oil grade SAE 75W/80
Manual gearbox oil classification GL-3/4
Manual gearbox litres 1,2 4x4=2,2
Automatic transmission fluid Type Dexron III
Automatic transmission (drain & refill) litres 4,6
Differential oil grade - front SAE 80W/90
Differential front/AT litres 0,5
Differential oil grade - rear SAE 80W/90 GL-5
Differential rear litres 1,8
Cooling system litres 4,6 AT=4,4
Brake fluid Type DOT 3/4
Power steering fluid Type Dexron III
Power steering fluid litres 0,7
Tightening torques
Cylinder head instructions
Cylinder head
Renew bolts Yes
Stage 1 Tighten 15 Nm
Stage 2 Tighten 34 Nm
Stage 3 Tighten 180°
Other engine tightening torques
Main bearings Renew bolts/nuts No
Main bearings Stage 1 30 Nm
Main bearings Stage 2 59±6 Nm
Big end bearings Renew bolts/nuts Yes
Big end bearings Stage 1 22±3 Nm
Big end bearings Stage 2 90°
Oil pump to cylinder block 9 Nm
Sump bolts 9 Nm

Manufacturer: Daihatsu Model: Terios (06-) 1,5 © Autodata Limited 2008

Engine code: 3SZ-VE Output: 77 (105) 6000 8/2/2010
Tuned for: R-Cat Year: 2006-09 V7.412-ENGI147441
 Sump drain bolt 30 Nm
Flywheel/driveplate 78 Nm
Clutch pressure plate 19 Nm
Crankshaft pulley/damper centre bolt 130 Nm
Camshaft sprocket/gear 47 Nm
Camshaft carrier/cap 13 Nm
Camshaft/rocker cover 9 Nm
Inlet manifold to cylinder head 19 Nm
Exhaust manifold to cylinder head 35 Nm
Exhaust downpipe to manifold 46 Nm
Water pump 9 Nm
Spark plugs 20 Nm
Fuel rail 21 Nm
Crankshaft position (CKP) sensor/engine speed (RPM)
8 Nm
sensor
Camshaft position (CMP) sensor 8 Nm
Engine coolant temperature (ECT) sensor 19 Nm
Lambda sensor (Oxygen) 34 Nm
Knock sensor (KS) 20 Nm
Engine oil pressure switch 15 Nm
Chassis tightening torques
23 Front hub 206 Nm
Rear hub - wheel bearing housing bolts 42 Nm
Steering wheel 34 Nm
Steering rack/box mounting 90 Nm
Steering track rod end 47 Nm
29 Brake caliper to carrier Front
Brake caliper carrier to hub Front 113 Nm
Back plate to hub Rear 42 Nm
ABS sensor Front 8 Nm
ABS sensor Rear 8 Nm
Road wheels 103 Nm
Starting and charging
Battery V/RC(Ah) 12
Alternator output at engine speed A/V/rpm /14,2-14,8/2500
Brake disc and drum dimensions
Minimum disc thickness - solid Front 15 mm
Minimum disc thickness - ventilated Front 21 mm
Disc runout Front 0,10 mm
Maximum drum diameter Rear 229,6 mm
Minimum pad thickness Front 1 mm
Minimum shoe thickness Rear 1 mm
Parking brake travel No. of notches 4-7
Air conditioning
Air conditioning refrigerant Type R134a
28 Air conditioning refrigerant quantity grams
Air conditioning oil Type Dens oil 8
Air conditioning oil viscosity ISO 46

Autodata Note 23

Use new nuts/bolts.

Autodata Note 29

Brake caliper to carrier

Apply brake grease to guide pin.

Upper guide pin = 83 Nm
Manufacturer: Daihatsu Model: Terios (06-) 1,5 © Autodata Limited 2008
Engine code: 3SZ-VE Output: 77 (105) 6000 8/2/2010
Tuned for: R-Cat Year: 2006-09 V7.412-ENGI147441
 Lower guide pin = 49 Nm

Autodata Note 28

Refrigerant quantity

RHD = 300±30 grams

LHD = 350±30 grams

Cylinder layout Tightening sequence

Manufacturer: Daihatsu Model: Terios (06-) 1,5 © Autodata Limited 2008

Engine code: 3SZ-VE Output: 77 (105) 6000 8/2/2010
Tuned for: R-Cat Year: 2006-09 V7.412-ENGI147441