Daihatsu Rocky F77 1984-1992 Workshop Repair Service Manual
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🏷️ Basic Information Identification Make: Daihatsu Model: Rocky Chassis Code: F77 Production Years: 1984-1992 Codes Engine Code Primary: Likely 2.0L or 2.8L diesel variants (e.g., DL42, 3L, 14B) common to F70/F77 chassis Engine Code Secondary: Petrol variants might include 1.6L (AB20) or 2.2L (4Z) 👋 Introduction Market Position Segment: Compact SUV / Off-road vehicle Target Audience: DIY enthusiasts, independent mechanics, owners seeking to maintain and repair their Daihatsu Rocky. Competitive Analysis Competitors Era: Suzuki Samurai/Jimny, Toyota 4Runner, Mitsubishi Pajero/Montero, Nissan Patrol/Pathfinder. Key Features Vehicle Type: Rugged, body-on-frame, four-wheel-drive SUV known for off-road capability and durability. Manual Purpose: To provide comprehensive technical guidance for maintaining, diagnosing, and repairing the Daihatsu Rocky F77, enabling users to perform service like a professional. 📋 Manual Details Coverage Areas Model Years Covered: 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992 Chassis Variants: F77 (likely encompasses various body styles like soft-top, hardtop, and potentially pick-up variants if applicable to F77) Page Count Estimated Page Count: Extensive (typical workshop manuals for this era can range from 500 to over 1000 pages) Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, overhaul, tuning, diagnostics, lubrication system, cooling system, fuel system, intake and exhaust systems. Engine Management: Ignition system, fuel injection (if applicable), emissions control systems. Transmission: Manual transmission repair, removal/installation, overhaul, clutch system, transfer case. Drivetrain: Front and rear axle assembly, differentials, driveshafts, constant velocity (CV) joints, four-wheel-drive system operation and repair. Suspension: Front and rear suspension components, shock absorbers, springs, bushings, steering linkage. Brakes: Hydraulic brake system, front and rear brake assembly (disc/drum), parking brake, brake fluid specifications. Steering: Steering gear box, steering column, power steering system (if equipped), steering linkage. Electrical: Wiring diagrams, lighting system, charging system (alternator, battery), starting system, instrument cluster, body electricals, fuses and relays. Body: Body panel removal/installation, doors, hood, tailgate, interior trim, glass replacement, rust prevention. Chassis: Frame construction, body mounts, underbody protection. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt adjustments, air filter service. Troubleshooting: Diagnostic procedures for common symptoms, fault finding charts, electrical circuit tracing. Repair Overhaul: Detailed step-by-step instructions for disassembly, inspection, repair, and reassembly of all major vehicle components. Technical Specifications: Torque specifications, clearances, fluid capacities, engine data, electrical component resistance values. Special Tools: Identification and usage of specialized tools required for specific procedures, often with part numbers. Technical Depth Depth: Comprehensive (covers routine maintenance to full engine and transmission rebuilds, including diagnostics and electrical system troubleshooting). 📊 Manual Specifications File Format Format: PDF Searchability: Likely text-searchable PDF, allowing for quick access to specific topics. Print Quality Printability: Printable Binding Type Binding: N/A (Digital PDF delivery) Paper Type Paper Type: N/A (Digital PDF delivery) Delivery Method Delivery: Electronic delivery via Email ⚙️ Engine Specifications Primary Engine Engine Type Diesel: Likely 2.8L (3L) or 2.4L (2L) naturally aspirated diesel engines, or potentially the 3.0L (14B) diesel. Turbocharged variants may also exist. Engine Type Petrol: Possible petrol engines include 1.6L (AB20) or 2.2L (4Z) overhead camshaft engines. Performance Horsepower Range Diesel: Typically 70-90 hp for 2.4L/2.8L diesel engines. Horsepower Range Petrol: Likely 75-95 hp for 1.6L/2.2L petrol engines. Torque Characteristics: Diesel engines offer strong low-end torque, crucial for off-road and towing. Fuel System Diesel Fuel System: Typically rotary injection pumps (e.g., Bosch VE) with mechanical injectors. Petrol Fuel System: Carbureted or early electronic fuel injection systems. 🔧 Transmission Standard Type Standard: 5-speed manual transmission Optional Type Optional: 4-speed automatic transmission (less common, but potentially available on some F77 models) Features Drivetrain Configuration: Part-time four-wheel drive with manual front hub engagement or automatic locking hubs. High-range (2H) and low-range (4H, 4L) gearing. 📐 Dimensions Exterior Wheelbase Short Wheelbase: Approx. 2,300 mm (90.6 inches) for SWB variants Wheelbase Long Wheelbase: Approx. 2,600 mm (102.4 inches) for LWB variants (common for F77 models) Ground Clearance: Generally good, often exceeding 200 mm (7.9 inches) depending on tire size and suspension. Weights Curb Weight: Varies significantly by body style and engine, typically ranging from 1,400 kg to 1,800 kg (3,086 lbs to 3,968 lbs). 🛡️ Safety Features Ratings Crash Test Results: Limited official crash test data available for this era and market. Focus would have been on structural integrity for off-road use rather than modern impact safety standards. Active Features Active Safety: Four-wheel drive system enhances traction; ABS was not standard in early models and may have been an option on later ones. Passive Features Passive Safety: Seat belts, reinforced chassis and body structure. 💡 Technology Features Infotainment Infotainment System: Basic AM/FM radio, optional cassette player. Limited to fundamental audio playback without modern features like Bluetooth or touchscreens. Driver Assistance Driver Assistance Features: Minimal to none. Features like ABS were optional or absent. Focus is on mechanical function rather than electronic...
Likely 2.0L or 2.8L diesel variants (e.g., DL42, 3L, 14B) common to F70/F77 chassis
Engine Code Secondary:
Petrol variants might include 1.6L (AB20) or 2.2L (4Z)
👋 Introduction
Market Position
Segment:
Compact SUV / Off-road vehicle
Target Audience:
DIY enthusiasts, independent mechanics, owners seeking to maintain and repair their Daihatsu Rocky.
Competitive Analysis
Competitors Era:
Suzuki Samurai/Jimny, Toyota 4Runner, Mitsubishi Pajero/Montero, Nissan Patrol/Pathfinder.
Key Features
Vehicle Type:
Rugged, body-on-frame, four-wheel-drive SUV known for off-road capability and durability.
Manual Purpose:
To provide comprehensive technical guidance for maintaining, diagnosing, and repairing the Daihatsu Rocky F77, enabling users to perform service like a professional.
Identification and usage of specialized tools required for specific procedures, often with part numbers.
Technical Depth
Depth:
Comprehensive (covers routine maintenance to full engine and transmission rebuilds, including diagnostics and electrical system troubleshooting).
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Likely text-searchable PDF, allowing for quick access to specific topics.
Print Quality
Printability:
Printable
Binding Type
Binding:
N/A (Digital PDF delivery)
Paper Type
Paper Type:
N/A (Digital PDF delivery)
Delivery Method
Delivery:
Electronic delivery via Email
⚙️ Engine Specifications
Primary Engine
Engine Type Diesel:
Likely 2.8L (3L) or 2.4L (2L) naturally aspirated diesel engines, or potentially the 3.0L (14B) diesel. Turbocharged variants may also exist.
Engine Type Petrol:
Possible petrol engines include 1.6L (AB20) or 2.2L (4Z) overhead camshaft engines.
Performance
Horsepower Range Diesel:
Typically 70-90 hp for 2.4L/2.8L diesel engines.
Horsepower Range Petrol:
Likely 75-95 hp for 1.6L/2.2L petrol engines.
Torque Characteristics:
Diesel engines offer strong low-end torque, crucial for off-road and towing.
Fuel System
Diesel Fuel System:
Typically rotary injection pumps (e.g., Bosch VE) with mechanical injectors.
Petrol Fuel System:
Carbureted or early electronic fuel injection systems.
🔧 Transmission
Standard
Type Standard:
5-speed manual transmission
Optional
Type Optional:
4-speed automatic transmission (less common, but potentially available on some F77 models)
Features
Drivetrain Configuration:
Part-time four-wheel drive with manual front hub engagement or automatic locking hubs. High-range (2H) and low-range (4H, 4L) gearing.
📐 Dimensions
Exterior
Wheelbase Short Wheelbase:
Approx. 2,300 mm (90.6 inches) for SWB variants
Wheelbase Long Wheelbase:
Approx. 2,600 mm (102.4 inches) for LWB variants (common for F77 models)
Ground Clearance:
Generally good, often exceeding 200 mm (7.9 inches) depending on tire size and suspension.
Weights
Curb Weight:
Varies significantly by body style and engine, typically ranging from 1,400 kg to 1,800 kg (3,086 lbs to 3,968 lbs).
🛡️ Safety Features
Ratings
Crash Test Results:
Limited official crash test data available for this era and market. Focus would have been on structural integrity for off-road use rather than modern impact safety standards.
Active Features
Active Safety:
Four-wheel drive system enhances traction; ABS was not standard in early models and may have been an option on later ones.
Passive Features
Passive Safety:
Seat belts, reinforced chassis and body structure.
💡 Technology Features
Infotainment
Infotainment System:
Basic AM/FM radio, optional cassette player. Limited to fundamental audio playback without modern features like Bluetooth or touchscreens.
Driver Assistance
Driver Assistance Features:
Minimal to none. Features like ABS were optional or absent. Focus is on mechanical function rather than electronic assistance.
Connectivity
Connectivity Options:
None beyond basic 12V power outlet for accessories.
🔧 Maintenance
Service Intervals
Oil Change Interval Diesel:
Typically every 5,000-7,500 km (3,000-5,000 miles) or 6 months, depending on driving conditions.
Oil Change Interval Petrol:
Typically every 7,500-10,000 km (5,000-6,000 miles) or 6 months.
Transmission Fluid Change:
Manual: Inspect every 20,000 km (12,000 miles), change as needed. Automatic: Every 40,000-50,000 km (25,000-30,000 miles).
Fluid Specifications
Engine Oil Diesel:
API CD or higher, SAE 10W-30 or 15W-40 depending on climate.
Engine Oil Petrol:
API SG or higher, SAE 10W-30 or 10W-40 depending on climate.
Coolant:
Ethylene glycol based coolant, 50/50 mix with distilled water.
Brake Fluid:
DOT 3 or DOT 4.
Gear Oil Transmission:
API GL-4 or GL-5, SAE 75W-90 or 80W-90.
Gear Oil Differential:
API GL-5, SAE 80W-90 or 85W-140.
Known Issues
Common Wear Items:
Clutch wear, universal joint (U-joint) wear, wheel bearings, suspension bushings, exhaust system corrosion, body rust (especially on older models).
Engine Specific Concerns:
Diesel engines can be prone to injector issues or glow plug failure; older petrol engines might suffer from carburetor issues or valve stem seal wear.
📚 Vehicle History
Brand Heritage
Daihatsu Legacy:
Daihatsu, a subsidiary of Toyota, has a long history of producing small, rugged, and reliable vehicles, particularly known for its kei cars and off-roaders.
Model Evolution
Rocky Development:
The Rocky was Daihatsu's answer to the growing demand for compact, capable off-road vehicles. It shared many mechanical components with other Daihatsu models and was often produced under license by other manufacturers globally.
Production
Manufacturing Locations:
Primarily Japan, but also manufactured under license in various countries.
Production Period Rocky:
The Rocky (F-series) was produced from 1984 to 1992, with successors like the F300 series (Sportrak/Terios) emerging later.
🏆 Awards & Recognition
Recognitions
Awards:
While specific awards for the F77 model are scarce, the Daihatsu Rocky lineage is recognized for its ruggedness, affordability, and off-road capability within its class and era.
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