2002 DAIHATSU COPEN

Typical onset: 70,000-110,000 mi

Symptoms: ticking or tapping from valve cover that worsens when warm, loss of power and rough idle, check engine light with misfire codes, metallic rattling on cold start

Fix: The JB-DET engine's hydraulic lifters wear prematurely, especially if oil changes were skipped. Once lifters collapse, rocker arms score the cam lobes. Full job requires cylinder head removal, resurface, new lifters, camshaft inspection or replacement, and head gasket set. Budget 12-16 labor hours for head R&R plus machine work.

Estimated cost: $2,800-4,500

Typical onset: 80,000-130,000 mi

Symptoms: transmission fluid puddles under the front of the car, burnt ATF smell, delayed or harsh shifts when hot, transmission temperature warning if equipped

Fix: The rubber hoses to the small external oil cooler harden and crack. If ignored, the transmission overheats and clutch packs glaze. Replace cooler lines and flush fluid immediately. If already overheating, expect internal damage requiring rebuild. Lines and flush are 2-3 hours; rebuild adds 10-14 hours.

Estimated cost: $300-600 for lines and fluid; $2,200-3,200 for rebuild

Typical onset: 90,000-140,000 mi

Symptoms: visible rubber separation or wobble on the crank pulley, belt squealing or throwing, rough vibration at idle, accessory belt shredding repeatedly

Fix: The rubber damper ring delaminates from the pulley hub, causing severe vibration that can damage the crankshaft snout or timing. Replacement requires removal of the accessory belt and mounting bolt. Parts are JDM-only or aftermarket. 2-3 hours labor, but delays waiting for parts are common.

Estimated cost: $400-700

Symptoms: roof gets stuck halfway during open or close cycle, clicking or grinding from trunk area, roof won't latch in closed position, error light on dash

Fix: Micro-switches, hydraulic rams, and cable guides all age badly. Dried grease in linkages causes binding. Diagnosis is time-consuming because the system is complex with multiple failure points. Often requires disassembly of trunk trim, re-lubrication of pivots, and replacement of sensors or hydraulic lines. Budget 4-8 hours for diagnosis and repair depending on which component failed.

Estimated cost: $600-1,800

Typical onset: 80,000-120,000 mi

Symptoms: blue smoke on acceleration, oil consumption increasing noticeably, turbo whistle becomes louder or changes pitch, loss of boost pressure

Fix: The small turbo runs high shaft speeds and suffers if oil changes were neglected. Seals leak oil into the exhaust or intake. Rebuild kits exist but labor access is tight. Remove intake piping, downpipe, and heat shields. 5-7 hours for R&R and reinstall with new gaskets. Core rebuild or replacement turbo required.

Estimated cost: $900-1,600

Typical onset: 60,000-100,000 mi

Symptoms: clunking when shifting from park to drive, excessive engine movement visible from engine bay, vibration through shifter and floor, harsh engagement into gear

Fix: Rubber mounts perish and allow the transmission to sag and move excessively. Replacement requires supporting the transmission and unbolting old mounts. Tight access in the kei-car engine bay. 2-3 hours labor for both mounts.

Estimated cost: $350-600