Daihatsu Rocky 1987-1998 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Daihatsu Model: Rocky Model Generation: F70/F80/F90 Series Production Years Covered By Manual: 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998 Codes Chassis Codes: F70, F73, F75, F77, F78, F80, F85, F90, F95, F97 (Varies by engine and drivetrain) 👋 Introduction Market Position Vehicle Segment: Compact SUV / Off-road Utility Vehicle Target Audience: Do-it-yourself enthusiasts and professional mechanics. Competitive Analysis Key Competitors: Suzuki Samurai, Jeep Wrangler, Toyota Land Cruiser (early models), Nissan Patrol (smaller variants) Key Features Manual Advantage: Comprehensive, detailed, and official factory service information for cost-effective maintenance and repair. Vehicle Advantage: Renowned for its robust off-road capability, compact size, and reliability. 📋 Manual Details Coverage Areas Geographic Coverage: Global (Focus on markets where the Rocky was sold, e.g., Europe, Asia, Australia) Trim Level Coverage: All styles covered (Assumed to include base, deluxe, and any specific regional variants) Page Count Estimated Page Count: Hundreds of pages (Exact count not specified, but implies a comprehensive document) Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format File Format: PDF Delivery Method: Digital Download 📖 Manual Coverage Systems Covered Engine Service And Repair: Detailed procedures for disassembly, inspection, repair, and reassembly of engines. Transmission Service And Repair: Covers manual and potentially automatic transmissions, including clutch, gearbox, and transfer case. Brake System: Maintenance, repair, and troubleshooting of disc and drum brakes, hydraulic systems, and parking brake. Electrical System: Comprehensive coverage including wiring diagrams, component testing, troubleshooting, and repair of electrical faults. Suspension And Steering: Service procedures for front and rear suspension components, steering gear, power steering system, and alignment. Cooling System: Radiator, thermostat, water pump, cooling fan, and coolant management. Fuel System: Carburetor or fuel injection systems, fuel pump, fuel filter, and fuel lines. Emission Control System: Diagnosis and repair of emissions-related components and systems. Heating And Air Conditioning: Service and repair of HVAC components, refrigerant system, and climate control. Chassis And Body: Bodywork repair, frame inspection, door mechanisms, and interior trim. Restraint System: Seat belts, airbags (if applicable to specific models within the range), and associated components. Differential And Axle: Front and rear differentials, drive axles, CV joints, and hub assemblies. Procedures Included General Maintenance: Routine checks, fluid changes, filter replacements, and lubrication. Troubleshooting: Systematic diagnostic procedures for identifying and resolving common and complex problems. Repair Procedures: Step-by-step instructions for component replacement and repair, from minor adjustments to major overhauls. Periodic Lubrication: Specific lubrication points, types of lubricants, and service intervals. Technical Depth Diagnostic Capabilities: Includes troubleshooting charts, symptom analysis, and electrical diagnostic procedures. Rebuild Procedures: Detailed instructions for complete engine, transmission, and differential rebuilds. Illustrations And Diagrams: Hundreds of photos, illustrations, drawings, and detailed wiring diagrams. Precision Of Instructions: Step-by-step, numbered instructions with substeps, notes, cautions, and warnings. 📊 Manual Specifications File Format File Type: PDF Reader Requirement: Adobe PDF Reader Print Quality Printability: Printable without restriction (Entire manual or selected pages). Binding Type Binding Type: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) Other Compatibility: PC-based Windows operating systems and Mac. ⚙️ Engine Specifications Primary Engine Engine Options: Commonly featured 2.0L (3Y) and 2.4L (4Y) petrol engines. Also diesel variants like 2.4L (2L/2L-T) and 2.8L (3L/4Y-T) depending on market and year. Performance Horsepower Range: Approx. 80-100 hp for petrol variants, potentially higher for turbocharged diesel. Torque Range: Approx. 150-180 Nm for petrol variants. Fuel System Fuel Delivery: Carburetor or Electronic Fuel Injection (EFI) depending on engine and market. Engine Management Ignition System: Distributor-based ignition system or Electronic Ignition (EI). Emission Controls: Catalytic converter, EGR (Exhaust Gas Recirculation) for certain markets/engines. 🔧 Transmission Standard Transmission Type Standard: 5-speed manual transmission Optional Transmission Type Optional: 4-speed automatic transmission (available on some models) Features Drivetrain: Part-time 4WD system with manual locking hubs. Transfer Case: Two-speed transfer case with high and low range. Fluid Specifications Manual Transmission Fluid: API GL-4 or GL-5 gear oil, SAE 75W-90 or 80W-90 recommended. Automatic Transmission Fluid: Dexron II or equivalent 📐 Dimensions Exterior Length: Approx. 3,960 mm (for short wheelbase) Width: Approx. 1,690 mm Height: Approx. 1,840 mm (for soft top) Weights Curb Weight: Approx. 1,400 - 1,600 kg Gross Vehicle Weight Rating: Varies by configuration, typically around 2,000 kg Wheels And Tires Standard Tire Size: 215/75R15 or similar Wheel Bolt Pattern: 5x139.7 mm (5x5.5 inches) Wheel Size: 15x6JJ or 15x7JJ 🛡️ Safety Features Ratings Crash Test Performance: Limited contemporary crash test data available for this era of compact SUV. Known for rugged construction. Active Features Braking System: Front disc brakes, rear drum brakes. Some higher trims may have rear discs. Passive Features Seat Belts: 3-point front seat belts, 2-point rear seat belts (or 3-point depending on rear seating configuration). Roll Over Protection: Integrated roll bar or reinforced structure in soft-top models; rigid construction in hardtop models. 💡 Technology Features Infotainment Audio System:...
F70, F73, F75, F77, F78, F80, F85, F90, F95, F97 (Varies by engine and drivetrain)
👋 Introduction
Market Position
Vehicle Segment:
Compact SUV / Off-road Utility Vehicle
Target Audience:
Do-it-yourself enthusiasts and professional mechanics.
Competitive Analysis
Key Competitors:
Suzuki Samurai, Jeep Wrangler, Toyota Land Cruiser (early models), Nissan Patrol (smaller variants)
Key Features
Manual Advantage:
Comprehensive, detailed, and official factory service information for cost-effective maintenance and repair.
Vehicle Advantage:
Renowned for its robust off-road capability, compact size, and reliability.
📋 Manual Details
Coverage Areas
Geographic Coverage:
Global (Focus on markets where the Rocky was sold, e.g., Europe, Asia, Australia)
Trim Level Coverage:
All styles covered (Assumed to include base, deluxe, and any specific regional variants)
Page Count
Estimated Page Count:
Hundreds of pages (Exact count not specified, but implies a comprehensive document)
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
Delivery Method:
Digital Download
📖 Manual Coverage
Systems Covered
Engine Service And Repair:
Detailed procedures for disassembly, inspection, repair, and reassembly of engines.
Transmission Service And Repair:
Covers manual and potentially automatic transmissions, including clutch, gearbox, and transfer case.
Brake System:
Maintenance, repair, and troubleshooting of disc and drum brakes, hydraulic systems, and parking brake.
Electrical System:
Comprehensive coverage including wiring diagrams, component testing, troubleshooting, and repair of electrical faults.
Suspension And Steering:
Service procedures for front and rear suspension components, steering gear, power steering system, and alignment.
Cooling System:
Radiator, thermostat, water pump, cooling fan, and coolant management.
Fuel System:
Carburetor or fuel injection systems, fuel pump, fuel filter, and fuel lines.
Emission Control System:
Diagnosis and repair of emissions-related components and systems.
Heating And Air Conditioning:
Service and repair of HVAC components, refrigerant system, and climate control.
Chassis And Body:
Bodywork repair, frame inspection, door mechanisms, and interior trim.
Restraint System:
Seat belts, airbags (if applicable to specific models within the range), and associated components.
Differential And Axle:
Front and rear differentials, drive axles, CV joints, and hub assemblies.
Procedures Included
General Maintenance:
Routine checks, fluid changes, filter replacements, and lubrication.
Troubleshooting:
Systematic diagnostic procedures for identifying and resolving common and complex problems.
Repair Procedures:
Step-by-step instructions for component replacement and repair, from minor adjustments to major overhauls.
Periodic Lubrication:
Specific lubrication points, types of lubricants, and service intervals.
Technical Depth
Diagnostic Capabilities:
Includes troubleshooting charts, symptom analysis, and electrical diagnostic procedures.
Rebuild Procedures:
Detailed instructions for complete engine, transmission, and differential rebuilds.
Illustrations And Diagrams:
Hundreds of photos, illustrations, drawings, and detailed wiring diagrams.
Precision Of Instructions:
Step-by-step, numbered instructions with substeps, notes, cautions, and warnings.
📊 Manual Specifications
File Format
File Type:
PDF
Reader Requirement:
Adobe PDF Reader
Print Quality
Printability:
Printable without restriction (Entire manual or selected pages).
Binding Type
Binding Type:
Not Applicable (Digital Download)
Paper Type
Paper Type:
Not Applicable (Digital Download)
Other
Compatibility:
PC-based Windows operating systems and Mac.
⚙️ Engine Specifications
Primary Engine
Engine Options:
Commonly featured 2.0L (3Y) and 2.4L (4Y) petrol engines. Also diesel variants like 2.4L (2L/2L-T) and 2.8L (3L/4Y-T) depending on market and year.
Performance
Horsepower Range:
Approx. 80-100 hp for petrol variants, potentially higher for turbocharged diesel.
Torque Range:
Approx. 150-180 Nm for petrol variants.
Fuel System
Fuel Delivery:
Carburetor or Electronic Fuel Injection (EFI) depending on engine and market.
Engine Management
Ignition System:
Distributor-based ignition system or Electronic Ignition (EI).
Emission Controls:
Catalytic converter, EGR (Exhaust Gas Recirculation) for certain markets/engines.
🔧 Transmission
Standard
Transmission Type Standard:
5-speed manual transmission
Optional
Transmission Type Optional:
4-speed automatic transmission (available on some models)
Features
Drivetrain:
Part-time 4WD system with manual locking hubs.
Transfer Case:
Two-speed transfer case with high and low range.
Fluid Specifications
Manual Transmission Fluid:
API GL-4 or GL-5 gear oil, SAE 75W-90 or 80W-90 recommended.
Automatic Transmission Fluid:
Dexron II or equivalent
📐 Dimensions
Exterior
Length:
Approx. 3,960 mm (for short wheelbase)
Width:
Approx. 1,690 mm
Height:
Approx. 1,840 mm (for soft top)
Weights
Curb Weight:
Approx. 1,400 - 1,600 kg
Gross Vehicle Weight Rating:
Varies by configuration, typically around 2,000 kg
Wheels And Tires
Standard Tire Size:
215/75R15 or similar
Wheel Bolt Pattern:
5x139.7 mm (5x5.5 inches)
Wheel Size:
15x6JJ or 15x7JJ
🛡️ Safety Features
Ratings
Crash Test Performance:
Limited contemporary crash test data available for this era of compact SUV. Known for rugged construction.
Active Features
Braking System:
Front disc brakes, rear drum brakes. Some higher trims may have rear discs.
Passive Features
Seat Belts:
3-point front seat belts, 2-point rear seat belts (or 3-point depending on rear seating configuration).
Roll Over Protection:
Integrated roll bar or reinforced structure in soft-top models; rigid construction in hardtop models.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio and cassette player. Optional CD player in later models.
Gauges And Displays:
Standard analog gauges for speedometer, tachometer (optional), fuel, temperature, and oil pressure. Warning lights for various systems.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was an optional feature on some models, particularly in later years.
Connectivity
Connectivity Features:
Minimal to non-existent by modern standards. Focus on mechanical functionality.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 km or 6 months, whichever comes first.
Air Filter Replacement:
Every 20,000 km or as needed based on operating conditions.
Spark Plug Replacement:
Every 30,000 - 40,000 km, depending on spark plug type.
Fluid Specifications
Engine Oil Type:
API SG/SH or higher, SAE 10W-30 or 10W-40 recommended for most conditions.
Engine Oil Capacity:
Approx. 4.0 - 4.5 liters with filter change (varies by engine).
Coolant Type:
Ethylene glycol-based antifreeze/coolant, typically a 50/50 mix with distilled water.
Known Issues
Common Faults And Repairs:
Corrosion on chassis and body panels, wear of clutch components, potential issues with exhaust systems, and aging of rubber bushings and seals.
Engine Wear:
Piston ring wear leading to oil consumption, timing belt wear (if applicable to specific engine variants, though some had chains).
Electrical Aging:
Degradation of wiring insulation, contact issues in switches and connectors due to age and environment.
📚 Vehicle History
Brand Heritage
Daihatsu Offroad Legacy:
Daihatsu has a long history of producing compact and capable off-road vehicles, starting with models like the Taft.
Model Evolution
Rocky Lineage:
The Rocky was Daihatsu's answer to the growing demand for compact, affordable off-roaders. It evolved from earlier models and was sold under various names globally, including the Daihatsu Feroza in some markets.
Production
Manufacturing Location:
Primarily Japan.
Production Period:
Original generation (preceding this manual's scope) began in the early 1970s, with the F70/F80/F90 series being the primary focus of this manual.
🏆 Awards & Recognition
Recognitions
Offroad Capability Recognition:
Generally well-regarded for its off-road prowess and durability relative to its class and price point during its production run.
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