Daihatsu Rocky 1987-1998 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Daihatsu Model: Rocky Generation: F70/F80/F90 Series Codes Chassis Codes: F70, F73, F75, F77, F78, F80, F85, F90, F95, F97 👋 Introduction Market Position Segment: Compact SUV / Off-road utility vehicle Competitive Analysis Competitors Era: Suzuki Samurai, Jeep Wrangler, Toyota Land Cruiser (smaller variants), Isuzu Trooper (early models). Key Features Off Road Capability: Renowned for its rugged construction, body-on-frame chassis, and capable 4WD system, making it a popular choice for off-roading. Compact Size: Compact dimensions provided good maneuverability in urban environments and on trails. Durability: Built with robust mechanicals, contributing to its reputation for longevity and reliability when properly maintained. Manual Value Proposition Diy Savings: $50-$60 per hour savings on labor costs by enabling owners to perform maintenance and repairs themselves. Information Access: Provides access to factory-level information, empowering owners with the knowledge of professional technicians. 📋 Manual Details Coverage Areas Applicable Years: 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998 Body Styles Covered: All styles (including Hardtop, Soft Top, Wagon, and Pick-up variants) Page Count Estimated Page Count: Hundreds of pages (precise count not specified, but implies comprehensive coverage) Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Service Repair: Complete engine service and repair procedures, including diagnostics, disassembly, inspection, assembly, and tuning. Transmission Service Repair: Detailed procedures for manual and automatic transmission service, repair, and overhaul. Brake System: Comprehensive coverage of hydraulic and mechanical brake systems, including disc and drum brake service, hydraulic component repair, and ABS diagnostics (if equipped). Wiring Diagrams: Detailed and accurate wiring diagrams for all electrical systems. Electrical System: In-depth coverage of the vehicle's electrical system, including starting and charging, lighting, ignition, accessories, and electronic control units. Suspension: Complete service and repair for front and rear suspension components, including shock absorbers, springs, control arms, and bushings. Periodic Lubrication: Detailed schedule and specifications for all lubrication points and fluid changes. Steering: Service and repair for manual and power steering systems, including steering gear, linkages, and power steering pump. Cooling System: Procedures for radiator, water pump, thermostat, hoses, and coolant system maintenance and repair. Fuel Injection Fuel System: Detailed diagnostics and repair for fuel delivery system, fuel injectors, fuel pump, and fuel pressure regulator. Emission System: Information on emissions control devices, diagnosis, and repair procedures. Heater Air Conditional: Service and repair for HVAC system, including cabin filter, blower motor, A/C compressor, and refrigerant system. Engine Control System: Diagnostics and troubleshooting for the engine control unit (ECU) and related sensors and actuators. Chassis Body: Repair procedures for chassis components, body panels, doors, windows, and structural elements. Restraint System: Information on seat belts, airbags (if equipped), and related safety systems. Interior: Service and repair for interior trim, seats, dashboard, and console components. Differential Drive: Detailed overhaul and maintenance procedures for front and rear differentials, transfer cases, and drive shafts. Axle: Service and repair for front and rear axles, including CV joints and bearings. Procedures Included General Maintenance: Routine maintenance tasks, fluid checks, filter replacements, and tune-ups. Troubleshooting: Advanced troubleshooting guide with diagnostic flowcharts and symptom-based problem solving. Repair Procedures: Step-by-step repair instructions for virtually every component and system. Rebuild Procedures: Complete rebuild instructions for major components like engines and transmissions. Diagnostic Procedures: Detailed diagnostic steps for identifying and resolving mechanical and electrical issues. Technical Depth Depth: Factory trained technician level; covers everything from basic maintenance to complete engine and transmission rebuilds, including electrical diagnostics. 📊 Manual Specifications File Format Format: PDF Readability: High resolution, suitable for viewing on various devices and printing. Print Quality Printability: Printable without restriction; allows printing of entire manual or individual pages. Binding Type Binding: Digital download (printable, can be burned to CD-ROM) Paper Type Paper Type Equivalent: N/A (Digital) Software Requirements Software: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Engine Codes And Types: Commonly equipped with 4-cylinder gasoline engines such as the F5A (1.0L), F6A (0.66L - Kei car variant), F7M (2.0L), F10A (1.0L), F20A (2.0L), and F22B (2.2L). Diesel options also included (e.g., DM-90 2.0L). Performance Horsepower Range: Varies by engine, typically from 55 hp (1.0L gasoline) to around 95-115 hp (2.0L/2.2L gasoline) and 60-70 hp (2.0L diesel). Torque Range: Varies by engine, typically from 50 lb-ft (1.0L gasoline) to around 120-140 lb-ft (2.0L/2.2L gasoline) and 90-100 lb-ft (2.0L diesel). Fuel System Fuel Delivery: Carbureted fuel systems in earlier models; Electronic Fuel Injection (EFI) in later models, especially for larger displacement engines. Fuel Type Fuel Type: Unleaded Gasoline (for gasoline engines), Diesel (for diesel engines) Cooling System Coolant Capacity: Typically around 4-5 liters, depending on engine and radiator size. (Specifics detailed in manual). 🔧 Transmission Standard Transmission Type Standard: Typically a 5-speed manual transmission with a 2-speed transfer case for 4WD. Optional Transmission Type Optional: Optional 3-speed or 4-speed automatic transmission available...
All styles (including Hardtop, Soft Top, Wagon, and Pick-up variants)
Page Count
Estimated Page Count:
Hundreds of pages (precise count not specified, but implies comprehensive coverage)
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Service Repair:
Complete engine service and repair procedures, including diagnostics, disassembly, inspection, assembly, and tuning.
Transmission Service Repair:
Detailed procedures for manual and automatic transmission service, repair, and overhaul.
Brake System:
Comprehensive coverage of hydraulic and mechanical brake systems, including disc and drum brake service, hydraulic component repair, and ABS diagnostics (if equipped).
Wiring Diagrams:
Detailed and accurate wiring diagrams for all electrical systems.
Electrical System:
In-depth coverage of the vehicle's electrical system, including starting and charging, lighting, ignition, accessories, and electronic control units.
Suspension:
Complete service and repair for front and rear suspension components, including shock absorbers, springs, control arms, and bushings.
Periodic Lubrication:
Detailed schedule and specifications for all lubrication points and fluid changes.
Steering:
Service and repair for manual and power steering systems, including steering gear, linkages, and power steering pump.
Cooling System:
Procedures for radiator, water pump, thermostat, hoses, and coolant system maintenance and repair.
Fuel Injection Fuel System:
Detailed diagnostics and repair for fuel delivery system, fuel injectors, fuel pump, and fuel pressure regulator.
Emission System:
Information on emissions control devices, diagnosis, and repair procedures.
Heater Air Conditional:
Service and repair for HVAC system, including cabin filter, blower motor, A/C compressor, and refrigerant system.
Engine Control System:
Diagnostics and troubleshooting for the engine control unit (ECU) and related sensors and actuators.
Chassis Body:
Repair procedures for chassis components, body panels, doors, windows, and structural elements.
Restraint System:
Information on seat belts, airbags (if equipped), and related safety systems.
Interior:
Service and repair for interior trim, seats, dashboard, and console components.
Differential Drive:
Detailed overhaul and maintenance procedures for front and rear differentials, transfer cases, and drive shafts.
Axle:
Service and repair for front and rear axles, including CV joints and bearings.
Procedures Included
General Maintenance:
Routine maintenance tasks, fluid checks, filter replacements, and tune-ups.
Troubleshooting:
Advanced troubleshooting guide with diagnostic flowcharts and symptom-based problem solving.
Repair Procedures:
Step-by-step repair instructions for virtually every component and system.
Rebuild Procedures:
Complete rebuild instructions for major components like engines and transmissions.
Diagnostic Procedures:
Detailed diagnostic steps for identifying and resolving mechanical and electrical issues.
Technical Depth
Depth:
Factory trained technician level; covers everything from basic maintenance to complete engine and transmission rebuilds, including electrical diagnostics.
📊 Manual Specifications
File Format
Format:
PDF
Readability:
High resolution, suitable for viewing on various devices and printing.
Print Quality
Printability:
Printable without restriction; allows printing of entire manual or individual pages.
Binding Type
Binding:
Digital download (printable, can be burned to CD-ROM)
Paper Type
Paper Type Equivalent:
N/A (Digital)
Software Requirements
Software:
Adobe PDF Reader
⚙️ Engine Specifications
Primary Engine
Engine Codes And Types:
Commonly equipped with 4-cylinder gasoline engines such as the F5A (1.0L), F6A (0.66L - Kei car variant), F7M (2.0L), F10A (1.0L), F20A (2.0L), and F22B (2.2L). Diesel options also included (e.g., DM-90 2.0L).
Performance
Horsepower Range:
Varies by engine, typically from 55 hp (1.0L gasoline) to around 95-115 hp (2.0L/2.2L gasoline) and 60-70 hp (2.0L diesel).
Torque Range:
Varies by engine, typically from 50 lb-ft (1.0L gasoline) to around 120-140 lb-ft (2.0L/2.2L gasoline) and 90-100 lb-ft (2.0L diesel).
Fuel System
Fuel Delivery:
Carbureted fuel systems in earlier models; Electronic Fuel Injection (EFI) in later models, especially for larger displacement engines.
Typically around 4-5 liters, depending on engine and radiator size. (Specifics detailed in manual).
🔧 Transmission
Standard
Transmission Type Standard:
Typically a 5-speed manual transmission with a 2-speed transfer case for 4WD.
Optional
Transmission Type Optional:
Optional 3-speed or 4-speed automatic transmission available on some models.
Features
Drive System:
Part-time 4WD system with selectable 2WD/4WD engagement, and a low-range gear for off-road driving.
Fluid Specifications
Manual Transmission Fluid:
API GL-4 gear oil, SAE 75W-90 or 80W-90 viscosity. (Specifics in manual).
Automatic Transmission Fluid:
Dexron II or equivalent (for automatic transmissions). (Specifics in manual).
📐 Dimensions
Exterior
Overall Length:
Varies by body style, but generally around 3,700mm - 3,900mm for short wheelbase versions.
Overall Width:
Approximately 1,500mm - 1,600mm.
Overall Height:
Approximately 1,750mm - 1,800mm (including roof).
Weights
Curb Weight:
Typically ranges from 950 kg to 1,200 kg depending on configuration.
Gross Vehicle Weight Rating Gvwr:
Around 1,500 kg - 1,800 kg (varies by model and market).
🛡️ Safety Features
Ratings
Crash Test Data:
Limited comprehensive crash test data publicly available for this era and model, often relying on anecdotal evidence and build quality.
Active Features
Active Safety Features:
Primarily four-wheel drive system for enhanced traction and stability. ABS not commonly found on earlier models.
Passive Features
Passive Safety Features:
Seat belts, reinforced chassis construction for its class. Airbags were generally not standard or available on most models of this generation.
💡 Technology Features
Infotainment
Infotainment Systems:
Basic AM/FM radio and cassette player were common. Later models might have offered CD players. Features were generally rudimentary by modern standards.
Driver Assistance
Driver Assistance Features:
Virtually no advanced driver-assistance systems (ADAS) were available. Focus was on mechanical capability and driver control.
Connectivity
Connectivity Features:
No integrated smartphone connectivity or Bluetooth features were present in this generation.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 km (3,100 miles) or 6 months, whichever comes first, for gasoline engines. Diesel intervals might be slightly longer. (Refer to manual for exact specification).
Air Filter Replacement:
Recommended every 20,000 km (12,500 miles) or as needed based on driving conditions. (Refer to manual).
Spark Plug Replacement:
Varies by spark plug type, but generally around 30,000 - 50,000 km. (Refer to manual for specific types and intervals).
Fluid Specifications
Engine Oil Specification:
API SG or SH classification, SAE 10W-30 or 10W-40 viscosity recommended for most gasoline engines. Diesel engines may require different specifications. (Refer to manual).
Engine Oil Capacity:
Approximately 3.5 - 4.5 liters with oil filter change, depending on engine. (Refer to manual).
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid. (Refer to manual).
Coolant Specification:
Ethylene glycol based antifreeze/coolant (typically a 50/50 mix with distilled water). Ensure it is suitable for aluminum components. (Refer to manual).
Known Issues
Common Wear Items:
Suspension bushings, clutch components (on manual transmissions), exhaust system components, fuel injectors (on EFI models), and potential rust in certain climates due to age.
Electrical Gremlins:
As with vehicles of this age, minor electrical issues related to aging wiring harnesses, grounds, or switches can occur.
📚 Vehicle History
Brand Heritage
Daihatsu Specialization:
Daihatsu has a long history of producing small, fuel-efficient, and robust vehicles, often specializing in Kei cars and compact utility vehicles.
Model Evolution
Rocky Lineage:
The Rocky was Daihatsu's answer to the growing demand for compact, rugged SUVs. It served as a versatile vehicle for both on-road commuting and off-road adventuring. It was also sold under different badges in various markets (e.g., Daihatsu Feroza in some regions).
Production
Production Period:
The F70/F80/F90 generation Rocky was produced from roughly 1984 through 1998, with the covered period being the latter half of this lifespan.
Manufacturing Location:
Primarily manufactured in Japan by Daihatsu Motor Co., Ltd.
🏆 Awards & Recognition
Recognitions
Off Road Awards:
While not typically receiving formal 'awards' in the consumer sense, the Daihatsu Rocky gained significant recognition and a loyal following within the off-road enthusiast community for its capability and value.
Ratings
Reliability Reputation:
Generally considered reliable with good longevity, provided it has been maintained according to factory recommendations. The robust, simpler mechanical design contributes to this.
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