The Daihatsu Hijet S85 represents the quintessential Japanese kei truck, combining minimal dimensions with maximum utility and legendary reliability. With its compact 550-660cc engine, rear-wheel drive layout, and simple mechanical design, the Hijet became the preferred commercial vehicle for small businesses, farmers and tradespeople who needed affordable, economical transport. The S85 generation spanning 1998 to 2010 benefits from electronic fuel injection, improved emissions and refined drivability while retaining the straightforward maintenance that makes these vehicles owner-serviceable. This comprehensive workshop manual provides all the technical information required to properly maintain and repair your Hijet including complete engine overhaul procedures, fuel injection diagnostics, 5-speed transmission service, brake system overhaul, steering rack rebuild, suspension maintenance, cooling system service, and detailed electrical system troubleshooting with complete wiring diagrams. With factory torque specifications, exploded views and maintenance schedules, this manual ensures your Hijet S85 stays running strong for years to come.
1998-2010 Daihatsu Hijet S85 Service Repair Workshop Manual PDF
VEHICLE/EQUIPMENT INTRODUCTION:
The Daihatsu Hijet S85 embodies the Japanese kei truck philosophy of maximum utility in minimum dimensions. Produced by one of Japans oldest mini-vehicle manufacturers, the Hijet served as the workhorse of small-scale commercial transport in Japan and became increasingly popular worldwide for its economical operation, tight turning radius, and remarkable practicality. The S85 generation featured a rear-engine, rear-wheel-drive layout with an efficient three or four-cylinder engine displacing within kei car limits of 660 cc. These rugged little trucks found use in agriculture, light delivery, facility maintenance, and as base vehicles for specialized conversions. The Hijet is known for simple mechanical systems that make routine maintenance and repair accessible to owners with basic tool sets and mechanical knowledge.
SERVICE & REPAIR SCOPE:
- Engine complete overhaul for 3-cylinder and 4-cylinder variants
- Cylinder head gasket replacement and valve train service
- Timing belt or timing chain replacement procedures
- Fuel injection system diagnostics and injector cleaning
- Throttle body cleaning and idle speed adjustment
- Fuel pump and fuel filter replacement
- Engine oil cooler inspection and service
- Radiator and cooling system service
- Water pump replacement and cooling system pressure test
- Clutch assembly replacement and hydraulic clutch system bleed
- 5-speed manual transmission overhaul
- Transmission oil change and gear selection
- Differential overhaul and axle shaft bearing service
- Driveshaft and U-joint inspection
- Brake system including master cylinder rebuild
- Disc front and drum rear brake shoe/pad replacement
- Brake booster and vacuum system inspection
- Proportioning valve test and brake hydraulic bleeding
- Steering rack overhaul and tie rod end replacement
- Front strut and rear leaf spring service
- Alternator testing and replacement
- Starter motor overhaul
- Complete electrical system diagnostics with wiring diagrams
- HVAC and heater core service
- Body panel repair and door adjustment
- Wiper motor and mechanism repair
- Complete maintenance schedule and fluid specifications
TECHNICAL SPECIFICATIONS:
- Engine: 3-cylinder or inline 4-cylinder, SOHC
- Displacement: 550 cc to 660 cc (kei specification)
- Fuel System: Electronic fuel injection
- Cooling: Liquid-cooled
- Transmission: 5-speed manual
- Drivetrain: Rear-wheel drive
- Layout: Engine mid/rear-mounted, RWD
- Brakes: Front disc, Rear drum
- Front Suspension: MacPherson strut
- Rear Suspension: Leaf springs with live axle
- Steering: Rack and pinion
DIAGNOSTIC INFORMATION:
- Engine warning light and diagnostic trouble code reading
- Rough idle and hesitation from throttle position and MAF sensor issues
- Overheating diagnosis from thermostat to radiator cap pressure testing
- Clutch slip and release bearing noise
- Gear jumping and synchromesh wear diagnosis
- Brake fade and drum brake adjustment procedures
- Steering play from rack wear and tie rod inspection
- Excessive exhaust smoke (blue, white, black) diagnosis
- Battery drain and alternator output verification
- Oil leak identification at valve covers, oil pan, and rear main seal
- Suspension sag and leaf spring fatigue assessment
ILLUSTRATIONS & DIAGRAMS INCLUDED:
- Engine assembly exploded views with torque specifications
- Cylinder head and timing component diagrams
- Complete wiring diagrams for all model years
- Fuel injection system component locations
- Brake hydraulic system schematics
- Suspension and steering assembly illustrations
- Transmission and drivetrain exploded views
- Body panel and door lock mechanism diagrams
- HVAC system routing illustrations
COMPATIBILITY:
- Covers Daihatsu Hijet S85 kei truck and van
- Model years 1998 through 2010
- Includes 3-cylinder and 4-cylinder engine variants
- Applicable to both truck and van body styles
FILE PROPERTIES:
- Format: Searchable PDF
- Language: English
- Delivery: Instant digital download
- Access: Download anytime after purchase
1998-2010 Daihatsu Hijet S85 Service Repair Workshop Manual PDF
VEHICLE/EQUIPMENT INTRODUCTION:
The Daihatsu Hijet S85 embodies the Japanese kei truck philosophy of maximum utility in minimum dimensions. Produced by one of Japans oldest mini-vehicle manufacturers, the Hijet served as the workhorse of small-scale commercial transport in Japan and became increasingly popular worldwide for its economical operation, tight turning radius, and remarkable practicality. The S85 generation featured a rear-engine, rear-wheel-drive layout with an efficient three or four-cylinder engine displacing within kei car limits of 660 cc. These rugged little trucks found use in agriculture, light delivery, facility maintenance, and as base vehicles for specialized conversions. The Hijet is known for simple mechanical systems that make routine maintenance and repair accessible to owners with basic tool sets and mechanical knowledge.
SERVICE & REPAIR SCOPE:
- Engine complete overhaul for 3-cylinder and 4-cylinder variants
- Cylinder head gasket replacement and valve train service
- Timing belt or timing chain replacement procedures
- Fuel injection system diagnostics and injector cleaning
- Throttle body cleaning and idle speed adjustment
- Fuel pump and fuel filter replacement
- Engine oil cooler inspection and service
- Radiator and cooling system service
- Water pump replacement and cooling system pressure test
- Clutch assembly replacement and hydraulic clutch system bleed
- 5-speed manual transmission overhaul
- Transmission oil change and gear selection
- Differential overhaul and axle shaft bearing service
- Driveshaft and U-joint inspection
- Brake system including master cylinder rebuild
- Disc front and drum rear brake shoe/pad replacement
- Brake booster and vacuum system inspection
- Proportioning valve test and brake hydraulic bleeding
- Steering rack overhaul and tie rod end replacement
- Front strut and rear leaf spring service
- Alternator testing and replacement
- Starter motor overhaul
- Complete electrical system diagnostics with wiring diagrams
- HVAC and heater core service
- Body panel repair and door adjustment
- Wiper motor and mechanism repair
- Complete maintenance schedule and fluid specifications
TECHNICAL SPECIFICATIONS:
- Engine: 3-cylinder or inline 4-cylinder, SOHC
- Displacement: 550 cc to 660 cc (kei specification)
- Fuel System: Electronic fuel injection
- Cooling: Liquid-cooled
- Transmission: 5-speed manual
- Drivetrain: Rear-wheel drive
- Layout: Engine mid/rear-mounted, RWD
- Brakes: Front disc, Rear drum
- Front Suspension: MacPherson strut
- Rear Suspension: Leaf springs with live axle
- Steering: Rack and pinion
DIAGNOSTIC INFORMATION:
- Engine warning light and diagnostic trouble code reading
- Rough idle and hesitation from throttle position and MAF sensor issues
- Overheating diagnosis from thermostat to radiator cap pressure testing
- Clutch slip and release bearing noise
- Gear jumping and synchromesh wear diagnosis
- Brake fade and drum brake adjustment procedures
- Steering play from rack wear and tie rod inspection
- Excessive exhaust smoke (blue, white, black) diagnosis
- Battery drain and alternator output verification
- Oil leak identification at valve covers, oil pan, and rear main seal
- Suspension sag and leaf spring fatigue assessment
ILLUSTRATIONS & DIAGRAMS INCLUDED:
- Engine assembly exploded views with torque specifications
- Cylinder head and timing component diagrams
- Complete wiring diagrams for all model years
- Fuel injection system component locations
- Brake hydraulic system schematics
- Suspension and steering assembly illustrations
- Transmission and drivetrain exploded views
- Body panel and door lock mechanism diagrams
- HVAC system routing illustrations
COMPATIBILITY:
- Covers Daihatsu Hijet S85 kei truck and van
- Model years 1998 through 2010
- Includes 3-cylinder and 4-cylinder engine variants
- Applicable to both truck and van body styles
FILE PROPERTIES:
- Format: Searchable PDF
- Language: English
- Delivery: Instant digital download
- Access: Download anytime after purchase
