1996 Daihatsu Rocky (2nd gen) Service and Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Rocky Year: 1996 Codes Generation Code: F300/F310 (Second Generation) Chassis Codes: F300, F310 👋 Introduction Market Position Vehicle Segment: Compact SUV / Off-road vehicle Target Audience: Enthusiasts, DIY mechanics, and professional technicians seeking in-depth repair and maintenance information for the Daihatsu Rocky. Competitive Analysis Competitors 1996: Suzuki Vitara/Sidekick, Jeep Cherokee XJ, Toyota RAV4 (early models), Isuzu Amigo. Key Features Vehicle Appeal: Compact size, 4x4 capability, robust construction, off-road prowess, affordability. Manual Value Proposition: Provides essential, specific information for maintaining and repairing a less common vehicle, empowering owners to perform their own servicing and repairs. 📋 Manual Details Coverage Areas Primary Coverage: All models and all repairs A-Z Specific Models Covered: All 1996 Daihatsu Rocky variants, including different engine and drivetrain configurations. Page Count Estimated Page Count: Approximately 1000-1500 pages (typical for comprehensive service manuals of this era). Manual Type Type: Service and Repair Manual Language Language: English Format Format: Likely a physical printed manual or a high-quality PDF reproduction. (Clarification on exact format is recommended from seller). File Format: Likely PDF for digital versions, or professionally bound for print. Searchable text is a key advantage of PDF. Print Quality: High-resolution scans/digital reproductions ensuring clarity of text and diagrams. Binding Type: If printed: Perfect bound or spiral bound for ease of use and durability in a workshop environment. Paper Type: If printed: Durable, often glossy paper to withstand workshop conditions and prevent smudging. 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, rebuilding, diagnostics, timing belt/chain replacement, cylinder head, pistons, crankshaft, lubrication system. Engine Fuel System: Fuel injection system, fuel pump, injectors, fuel filter replacement, fuel pressure testing. Engine Cooling System: Radiator, water pump, thermostat, hoses, coolant types, flushing procedures. Engine Ignition System: Spark plugs, ignition coils, distributor (if applicable), timing, diagnostic procedures. Engine Emission Controls: EGR system, catalytic converter, O2 sensors, emissions testing and troubleshooting. Transmission Manual: Clutch system, gearbox overhaul, shift linkages, fluid changes, diagnostic procedures. Transmission Automatic: Torque converter, transmission control module, gear selection, fluid changes, diagnostic procedures. Drivetrain 4Wd: Transfer case, front and rear differentials, drive shafts, CV joints, hub locking mechanisms. Suspension System: Front and rear suspension components, shock absorbers, springs, bushings, alignment specifications. Steering System: Steering rack, power steering pump, tie rods, steering column, alignment. Brake System: Front and rear brakes (disc/drum), hydraulic system, brake fluid, ABS (if equipped), parking brake. Electrical System: Battery, charging system, starter, alternator, wiring diagrams, fuses, relays. Lighting System: Headlights, taillights, turn signals, interior lighting, bulb types and replacement. HVAC System: Air conditioning, heater core, blower motor, refrigerant, system diagnostics and repair. Body And Frame: Body panels, doors, glass, trim, chassis repair, rust prevention. Interior Trim: Seats, dashboard, upholstery, door panels, carpeting. Diagnostic Troubleshooting: Systematic troubleshooting charts, symptom-based diagnostics, error code interpretation. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotation, spark plug replacement. Major Repairs: Engine rebuilds, transmission overhauls, suspension component replacement, brake caliper rebuilds. Component Replacement: Detailed steps for replacing virtually all mechanical and electrical components. Diagnostics: Step-by-step diagnostic guides for identifying the root cause of problems. Adjustments: Carburetor adjustments (if applicable), idle speed adjustments, parking brake adjustments. Wiring Repair: Comprehensive wiring diagrams, troubleshooting shorts, open circuits, and component failures. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds. Diagnostic Tools Required: Mentions specialized tools if needed, such as timing lights, compression testers, vacuum gauges, and potentially early scan tools. Torque Specifications: Detailed torque specifications for all critical fasteners. Clearances And Tolerances: Precise engine clearances and component tolerances for proper assembly. ⚙️ Engine Specifications Primary Engine Engine Code Common: HD-E (1.6L SOHC), possibly HD-F (1.3L SOHC) or HE-C (2.4L SOHC diesel for some markets). Displacement 1.6L: 1590 cc (97.0 cu in) Bore X Stroke 1.6L: 76.0 mm x 87.0 mm (3.0 in x 3.4 in) Performance 1.6L Horsepower: Approximately 75-93 hp @ 5000-5200 rpm (depending on market and specific engine variant). Torque: Approximately 123-130 Nm (91-96 lb-ft) @ 3200-3600 rpm. Fuel System Fuel Delivery 1.6L: Multi-point fuel injection (MPI). Fuel Type: Unleaded Gasoline (Octane rating specified by Daihatsu for the region). Engine Construction Block Material: Cast Iron Cylinder Head Material: Aluminum Alloy 🔧 Transmission Standard Transmission Type Common: 5-speed manual transmission Optional Transmission Type Optional: 4-speed automatic transmission Features Drivetrain: Part-time 4WD system with a 2-speed transfer case and optional free-wheeling hubs (manual locking). Clutch Type: Dry single plate (for manual transmission) Fluid Specifications Manual Transmission Fluid: API GL-4, SAE 75W-90 or 80W-90 gear oil (refer to manual for exact specification). Automatic Transmission Fluid: Dexron II or equivalent (refer to manual for exact specification). Transfer Case Fluid: API GL-4, SAE 75W-90 or 80W-90 gear oil (refer to manual for exact specification). Differential Fluid Front: API GL-5, SAE 80W-90 gear oil (refer to manual for exact specification). Differential Fluid Rear: API...

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Tags: 1996 Car Daihatsu Rocky (2nd gen)

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Description

🏷️ Basic Information

Identification

Make:

Daihatsu

Model:

Rocky

Year:

Codes

Generation Code:

F300/F310 (Second Generation)

Chassis Codes:

F300, F310

👋 Introduction

Market Position

Vehicle Segment:

Compact SUV / Off-road vehicle

Target Audience:

Enthusiasts, DIY mechanics, and professional technicians seeking in-depth repair and maintenance information for the Daihatsu Rocky.

Competitive Analysis

Competitors 1996:

Suzuki Vitara/Sidekick, Jeep Cherokee XJ, Toyota RAV4 (early models), Isuzu Amigo.

Key Features

Vehicle Appeal:

Compact size, 4x4 capability, robust construction, off-road prowess, affordability.

Manual Value Proposition:

Provides essential, specific information for maintaining and repairing a less common vehicle, empowering owners to perform their own servicing and repairs.

📋 Manual Details

Coverage Areas

Primary Coverage:

All models and all repairs A-Z

Specific Models Covered:

All 1996 Daihatsu Rocky variants, including different engine and drivetrain configurations.

Page Count

Estimated Page Count:

Approximately 1000-1500 pages (typical for comprehensive service manuals of this era).

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

Likely a physical printed manual or a high-quality PDF reproduction. (Clarification on exact format is recommended from seller).

File Format:

Likely PDF for digital versions, or professionally bound for print. Searchable text is a key advantage of PDF.

Print Quality:

High-resolution scans/digital reproductions ensuring clarity of text and diagrams.

Binding Type:

If printed: Perfect bound or spiral bound for ease of use and durability in a workshop environment.

Paper Type:

If printed: Durable, often glossy paper to withstand workshop conditions and prevent smudging.

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, rebuilding, diagnostics, timing belt/chain replacement, cylinder head, pistons, crankshaft, lubrication system.

Engine Fuel System:

Fuel injection system, fuel pump, injectors, fuel filter replacement, fuel pressure testing.

Engine Cooling System:

Radiator, water pump, thermostat, hoses, coolant types, flushing procedures.

Engine Ignition System:

Spark plugs, ignition coils, distributor (if applicable), timing, diagnostic procedures.

Engine Emission Controls:

EGR system, catalytic converter, O2 sensors, emissions testing and troubleshooting.

Transmission Manual:

Clutch system, gearbox overhaul, shift linkages, fluid changes, diagnostic procedures.

Transmission Automatic:

Torque converter, transmission control module, gear selection, fluid changes, diagnostic procedures.

Drivetrain 4Wd:

Transfer case, front and rear differentials, drive shafts, CV joints, hub locking mechanisms.

Suspension System:

Front and rear suspension components, shock absorbers, springs, bushings, alignment specifications.

Steering System:

Steering rack, power steering pump, tie rods, steering column, alignment.

Brake System:

Front and rear brakes (disc/drum), hydraulic system, brake fluid, ABS (if equipped), parking brake.

Electrical System:

Battery, charging system, starter, alternator, wiring diagrams, fuses, relays.

Lighting System:

Headlights, taillights, turn signals, interior lighting, bulb types and replacement.

HVAC System:

Air conditioning, heater core, blower motor, refrigerant, system diagnostics and repair.

Body And Frame:

Body panels, doors, glass, trim, chassis repair, rust prevention.

Interior Trim:

Seats, dashboard, upholstery, door panels, carpeting.

Diagnostic Troubleshooting:

Systematic troubleshooting charts, symptom-based diagnostics, error code interpretation.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotation, spark plug replacement.

Major Repairs:

Engine rebuilds, transmission overhauls, suspension component replacement, brake caliper rebuilds.

Component Replacement:

Detailed steps for replacing virtually all mechanical and electrical components.

Diagnostics:

Step-by-step diagnostic guides for identifying the root cause of problems.

Adjustments:

Carburetor adjustments (if applicable), idle speed adjustments, parking brake adjustments.

Wiring Repair:

Comprehensive wiring diagrams, troubleshooting shorts, open circuits, and component failures.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds.

Diagnostic Tools Required:

Mentions specialized tools if needed, such as timing lights, compression testers, vacuum gauges, and potentially early scan tools.

Torque Specifications:

Detailed torque specifications for all critical fasteners.

Clearances And Tolerances:

Precise engine clearances and component tolerances for proper assembly.

⚙️ Engine Specifications

Primary Engine

Engine Code Common:

HD-E (1.6L SOHC), possibly HD-F (1.3L SOHC) or HE-C (2.4L SOHC diesel for some markets).

Displacement 1.6L:

1590 cc (97.0 cu in)

Bore X Stroke 1.6L:

76.0 mm x 87.0 mm (3.0 in x 3.4 in)

Performance 1.6L

Horsepower:

Approximately 75-93 hp @ 5000-5200 rpm (depending on market and specific engine variant).

Torque:

Approximately 123-130 Nm (91-96 lb-ft) @ 3200-3600 rpm.

Fuel System

Fuel Delivery 1.6L:

Multi-point fuel injection (MPI).

Fuel Type:

Unleaded Gasoline (Octane rating specified by Daihatsu for the region).

Engine Construction

Block Material:

Cast Iron

Cylinder Head Material:

Aluminum Alloy

🔧 Transmission

Standard

Transmission Type Common:

5-speed manual transmission

Optional

Transmission Type Optional:

4-speed automatic transmission

Features

Drivetrain:

Part-time 4WD system with a 2-speed transfer case and optional free-wheeling hubs (manual locking).

Clutch Type:

Dry single plate (for manual transmission)

Fluid Specifications

Manual Transmission Fluid:

API GL-4, SAE 75W-90 or 80W-90 gear oil (refer to manual for exact specification).

Automatic Transmission Fluid:

Dexron II or equivalent (refer to manual for exact specification).

Transfer Case Fluid:

API GL-4, SAE 75W-90 or 80W-90 gear oil (refer to manual for exact specification).

Differential Fluid Front:

API GL-5, SAE 80W-90 gear oil (refer to manual for exact specification).

Differential Fluid Rear:

API GL-5, SAE 80W-90 gear oil (refer to manual for exact specification).

📐 Dimensions

Exterior

Length:

Approx. 3,720 mm (146.5 in) - Varies slightly by body style (e.g., soft top vs. hardtop).

Width:

Approx. 1,545 mm (60.8 in) - Varies slightly by body style.

Height:

Approx. 1,700 mm (66.9 in) - Varies slightly by body style and roof rack.

Wheelbase:

Approx. 2,050 mm (80.7 in)

Weights

Curb Weight:

Approx. 1,050 - 1,200 kg (2,315 - 2,645 lb) - Varies by configuration.

Gross Vehicle Weight Rating:

Typically around 1,500 kg (3,300 lb).

Cargo

Cargo Volume Rear Seats Up:

Limited due to compact size, practical for essentials.

Cargo Volume Rear Seats Down:

Significantly increased by folding rear seats, offering utility for gear and supplies.

🛡️ Safety Features

Ratings

Crash Test Results:

Information from 1996 for this model is scarce. Focus on structural integrity and basic safety features.

Active Features

Optional Anti-lock Braking System (ABS) on some models.

Part-time 4WD system enhances traction and stability in slippery conditions.

Passive Features

Seatbelts:

Front and rear seatbelts, potentially with pre-tensioners on front belts.

Body Construction:

Body-on-frame construction, providing robustness and durability.

Child Seat Anchors:

Likely limited to lap belts or basic ISOFIX compatibility (verify with specific vehicle/manual).

💡 Technology Features

Infotainment

Audio System:

Factory fitted radio/cassette player, often with 2-4 speakers. Aftermarket head unit upgrades are common.

Climate Control:

Manual HVAC controls (heater and ventilation). Air conditioning was optional.

Driver Assistance

ABS Availability:

Optional ABS available on higher trim levels or specific model years.

Cruise Control:

Rarely fitted as standard; typically an aftermarket addition if available.

Connectivity

OBD Ii Support:

This era of vehicles predates widespread OBD-II compliance. Diagnostics are likely based on proprietary systems or general troubleshooting.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000 km (3,000 miles) or 6 months, whichever comes first (refer to manual for exact OEM recommendation).

Air Filter Replacement:

Inspect every 10,000 km (6,000 miles), replace as needed or every 20,000 km (12,000 miles).

Spark Plug Replacement:

Typically every 30,000-40,000 km (18,000-24,000 miles), depending on plug type (copper vs. platinum).

Timing Belt Replacement:

Crucial for HD-E engine. Usually around 90,000 - 100,000 km (56,000 - 62,000 miles) or 5 years. **This is an interference engine, so timely replacement is critical to prevent catastrophic damage.**

Fluid Specifications

Engine Oil Capacity 1.6L:

Approximately 3.7 liters (3.9 US quarts) with filter change. Refer to manual for exact capacity.

Engine Oil Type:

API SG or higher, SAE 10W-30 or 10W-40 (consider viscosity based on climate).

Coolant Type:

Ethylene glycol based coolant, typically a 50/50 mix with distilled water. Consult manual for specific Daihatsu coolant recommendations.

Brake Fluid Type:

DOT 3 or DOT 4 (refer to manual for specific recommendation).

Known Issues

Common Wear Items:

Clutch wear, suspension bushings, exhaust system corrosion, timing belt degradation (critical).

Electrical Gremlins:

Older wiring harnesses can develop issues; inspect connections, especially for the ignition and fuel systems.

Rust Prone Areas:

Wheel arches, rocker panels, chassis frame, and around the rear tailgate hinges due to age and exposure.

Engine Performance Loss:

Can be attributed to clogged fuel injectors, worn spark plugs, or ignition system issues. Proper diagnosis is key.

📚 Vehicle History

Brand Heritage

Daihatsu Focus:

Daihatsu, a subsidiary of Toyota, has a long history of producing small, practical, and reliable vehicles, often with a focus on compact cars and off-roaders.

Model Evolution

First Generation Rocky:

Launched in 1984 (F100 series), based on the chassis of the Daihatsu Taft.

Second Generation Rocky:

Introduced in 1990 (F300 series), featuring a more modern design and improved chassis, including independent front suspension on some models.

Second Generation Updates 1996:

The 1996 model falls within the facelifted F300 series, which saw minor styling updates and potential engine refinements.

Production

Manufacturing Location:

Japan

Production Period 2Nd Gen:

1990-2002

🏆 Awards & Recognition

Recognitions

Industry Awards:

While specific awards for the 1996 Rocky are not widely documented, Daihatsu vehicles of this era were often recognized for their value, fuel efficiency, and reliability in their respective segments.

Ratings

Consumer Reports Historical:

Daihatsu models generally received decent ratings for reliability and affordability from consumer publications of the time, though their compact size and basic features meant they were not performance-oriented vehicles.