Generations
L880 — First Generation
2002–2012
659cc Turbo, 1.3L Naturally Aspirated
Top issues to watch for
The most serious Daihatsu Copen problems ranked by severity. We track 5 known issues — here are the ones you need to know about first.
Dangerous
Structural corrosion at mounting points
The Copen's lightweight construction uses thin steel sections that are highly susceptible to corrosion, particularly around suspension mounting points and structural load-bearing areas. MOT data shows this model fails at 90 times the national average for body corrosion at mounting points, with the problem appearing as early as 20,000 miles. The convertible body structure relies on precise mounting point integrity for rigidity, making even minor corrosion a serious safety concern. This is compounded by poor factory corrosion protection on early examples.
What happens if ignoredStructural corrosion at mounting points compromises the vehicle's safety in a collision and can lead to sudden suspension failure. Repair typically requires cutting out corroded sections and welding in new metal, costing £800-£2,000 depending on extent. Severe corrosion may render the vehicle uneconomical to repair. The car should not be driven if structural integrity is compromised.
Independent garage
£500–£1,500
Specialist
£800–£2,000
Main dealer
£1,200–£3,000
Parts only
£100–£400
Dangerous
Vehicle structure rigidity loss from corrosion
The Copen's convertible body structure is inherently less rigid than a fixed-roof equivalent and relies on strategic strengthening points to maintain structural integrity. Corrosion in these critical areas reduces the assembly's rigidity to dangerous levels, with MOT data showing failures at 87.7 times the national average. Both the 659cc and 1298cc variants are affected equally, suggesting the issue is related to the common body shell rather than engine-specific factors.
What happens if ignoredLoss of structural rigidity compromises occupant protection in a collision and may cause the roof mechanism to bind or fail. Repair requires extensive bodywork and strengthening, typically costing £1,500-£4,000. In severe cases the vehicle becomes uneconomical to repair. The car should not be driven if significant structural weakness is present.
Independent garage
£1,000–£2,500
Specialist
£1,500–£4,000
Main dealer
£2,000–£5,000
Parts only
£200–£800
Dangerous
Brake hose ferrule corrosion
Brake hose ferrules (the metal crimped ends that connect flexible hoses to rigid brake lines) corrode at extremely high rates on the Copen, with MOT failures at 41.2 times the national average. The problem appears across all mileage bands including very low mileage cars, suggesting poor quality control or inadequate corrosion protection from the factory. Corroded ferrules can leak brake fluid or fail completely, causing immediate loss of braking power.
What happens if ignoredCorroded brake hose ferrules can fail without warning, causing complete loss of braking power and immediate accident risk. Even minor leakage reduces braking efficiency and allows air to enter the system. Repair requires replacement of affected brake hoses and full system bleeding, costing £150-£400 depending on how many hoses need replacement.
Independent garage
£100–£250
Specialist
£150–£350
Main dealer
£200–£500
Parts only
£40–£120
Major
Wheel bearing excessive play (659cc)
Wheel bearings on the 659cc Copen variants develop excessive play at 25.8 times the national average failure rate, typically appearing from 20,000 miles onwards. The lightweight construction and small wheel bearings are likely undersized for the vehicle's weight distribution and cornering loads. The problem affects both front and rear bearings but is more common at the front due to steering and braking loads.
What happens if ignoredWorn wheel bearings cause poor handling, increased tyre wear, and eventual seizure if left unrepaired. Complete bearing failure can cause the wheel to lock or detach, creating immediate accident risk. Replacement typically costs £200-£400 per bearing including labour.
Independent garage
£150–£300
Specialist
£200–£400
Main dealer
£300–£500
Parts only
£60–£150
1 more known issues tracked
Including wear items, electrical niggles, and generation-specific problems.
MOT failure hotspots
Based on DVSA MOT test data. These are the items where the Daihatsu Copen fails at a significantly higher rate than the average car.
ABS fault
Suspension · 40-60k miles
MOT failure rate: 134x the fleet average
Sample: 573 tests
Structural corrosion
Bodywork · 20-40k miles
MOT failure rate: 90x the fleet average
Sample: 506 tests
Seat mounting fault
Seatbelts & Airbags · 20-40k miles
MOT failure rate: 52x the fleet average
Sample: 506 tests
Vehicle structure corroded to the extent that t...
Bodywork · 20-40k miles
MOT failure rate: 52x the fleet average
Sample: 655 tests
Brake hoses perished or damaged
Brakes · 0-20k miles
MOT failure rate: 41x the fleet average
Sample: 201 tests
Emissions failure
Exhaust & Emissions · 20-40k miles
MOT failure rate: 33x the fleet average
Sample: 489 tests
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Related
Daihatsu Copen reliability FAQs
What are the most common problems with the Daihatsu Copen?
The Daihatsu Copen has 5 known issues across 2 severity levels. The most serious are: Structural corrosion at mounting points, Vehicle structure rigidity loss from corrosion, Brake hose ferrule corrosion.
Is the Daihatsu Copen reliable?
The Daihatsu Copen has 3 dangerous and 2 major known issues. Most can be avoided with a thorough pre-purchase check and full service history.
How much does it cost to fix Daihatsu Copen problems?
Repair costs range widely. The most significant issue (Structural corrosion at mounting points) costs £500–£1,500 at an independent garage. Minor issues can be under £200. Always get a full inspection before buying.