Download DAIHATSU TERIOS J100 Service Repair Manual 1997-2000 –

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I’m Maisha the mechanic, and I’m thrilled to take you through the detailed process of replacing the drive belt on a Daihatsu Terios J100. This task is crucial for ensuring your vehicle runs smoothly, as the drive belt is responsible for powering various components, such as the alternator, power steering pump, and air conditioning compressor. So, let’s dive into the specifics, including the tools you’ll need and a step-by-step guide.

### Tools and Equipment Needed:

1. **Socket Set**: A standard metric socket set (often 10mm to 14mm) will be necessary for removing bolts and securing components.
2. **Ratchet Wrench**: This will make loosening and tightening bolts much simpler and faster.
3. **Torque Wrench**: To ensure that bolts are tightened to the manufacturer’s specifications, which is crucial for safety and performance.
4. **Belt Tension Gauge**: While not strictly necessary, this tool helps to ensure that the new belt is properly tensioned.
5. **Pliers**: Needle-nose pliers are useful for removing any clips or fasteners that might be in the way.
6. **Flathead and Phillips Screwdrivers**: These are essential for removing any screws that may secure components.
7. **Belt Routing Diagram**: Usually located in the engine compartment, this diagram will guide you on how the belt should be routed around the pulleys.
8. **Flashlight**: To illuminate dark engine compartments, making it easier to see what you’re working on.
9. **Work Gloves**: These will protect your hands from sharp edges and dirt.
10. **Safety Goggles**: always a good idea to protect your eyes from debris.

### Step-by-Step Guide to Drive Belt Replacement:

#### Step 1: Preparation

1. **Safety First**: Before you start, make sure the vehicle is parked on a level surface, and engage the parking brake. If necessary, disconnect the battery to avoid any electrical issues while working on the engine.
2. **Gather Your Tools**: Lay out all the tools in an accessible manner so you can easily reach them during the process. This will save time and keep you organized.

#### Step 2: Access the Drive Belt

1. **Remove Any Obstructions**: Depending on the model, you might need to remove the engine cover or other components that obstruct access to the drive belt. Use your flathead screwdriver to remove screws and your ratchet wrench for any bolts.
2. **Locate the Belt Tensioner**: The drive belt will be under tension, so you need to locate the tensioner pulley. This is usually a spring-loaded pulley that helps maintain the appropriate tension on the belt.

#### Step 3: Release the Tension

1. **Using the Ratchet Wrench**: Fit the appropriate socket onto the bolt of the tensioner pulley. Turn the ratchet wrench counterclockwise to relieve tension on the belt. You may need to apply significant force, so ensure you have a good grip.
2. **Remove the Belt**: Once the tension is released, you can carefully slide the belt off the pulleys. Take note of how the belt is routed; refer to the belt routing diagram if necessary, as this will be crucial when installing the new belt.

#### Step 4: Inspect Components

1. **Inspect Pulleys and Tensioners**: Before installing the new belt, check the condition of the pulleys and tensioner. Look for any signs of wear, such as cracks or rough spots. If any components appear damaged, it’s best to replace them now.
2. **Clean the Area**: Wipe down the pulleys with a clean cloth to remove any debris or old belt material that may have accumulated.

#### Step 5: Install the New Belt

1. **Position the New Belt**: Begin threading the new drive belt around the pulleys according to the routing diagram. Make sure the belt sits properly in the grooves of each pulley.
2. **Reapply Tension**: Use the ratchet wrench again to move the tensioner pulley. Once you’ve got the belt in place, release the tensioner back into position, which will apply tension to the new belt.

#### Step 6: Check Tension download DAIHATSU TERIOS J100 workshop manual and Alignment

1. **Belt Tension Check**: If you have a tension gauge, now is the time to use it. Proper tension is crucial for the belt’s longevity and performance.
2. **Visual Inspection**: Double-check the belt alignment on all pulleys to ensure it’s seated correctly and that there are no twists or misalignment.

#### Step 7: Reassemble Components

1. **Reattach Any Removed Components**: If you took off any components or covers to access the drive belt, now is the time to reinstall them. Use your socket set and screwdrivers to secure everything back in place.
2. **Reconnect the Battery**: If you disconnected the battery earlier, make sure to reconnect it now.

#### Step 8: Testing

1. **Start the Engine**: With everything back in place, start the engine and observe the new belt in operation. Listen for any unusual noises, which might indicate improper installation.
2. **Final Checks**: Check the belt tension and alignment once more after a short period of running the engine to ensure everything is still secure and functioning well.

### Conclusion

And there you have it! Replacing the drive belt on a Daihatsu Terios J100 is a task that, with the right tools and careful attention to detail, can be accomplished relatively easily. Remember, the drive belt is critical for the proper functioning of various systems in your vehicle, so ensuring it is in good condition is paramount. If you encounter any issues or are unsure about any step, don’t hesitate to consult a professional mechanic. Happy wrenching!
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