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1990 Daihatsu Rocky (1st gen) Service and Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Rocky Year: 1990 Codes Chassis Code Designation: F70 Series (Short Wheelbase), F75 Series (Long Wheelbase) Engine Code Primary: HD-C (Diesel) Engine Code Secondary: AB20 (Petrol - less common for this manual's focus, but potentially covered) 👋 Introduction Market Position Segment: Compact SUV / Off-road Utility Vehicle. Target Audience: Enthusiasts, DIY mechanics, and professional technicians working on the Daihatsu Rocky. Competitive Analysis Competitors 1990: Suzuki Samurai, Jeep Wrangler, Toyota Land Cruiser (smaller models), Mitsubishi Pajero/Montero (smaller models). Key Features Vehicle Strengths: Compact size, robust 4WD system, reliable diesel engine (HD-C), go-anywhere capability, lightweight construction. Manual Value Proposition Uniqueness: Vehicle-specific, factory-issued data, essential for accurate and effective maintenance and repair, avoiding generic information. 📋 Manual Details Coverage Areas Models Covered: All 1990 Daihatsu Rocky (1st gen) models and variants. Trim Levels Covered: All trim levels equipped with the specified engine and drivetrain configurations. Page Count Estimated Page Count: Likely 500-800 pages (typical for a comprehensive factory service manual of this era). Manual Type Type: Factory Service and Repair Manual. Language Language: English (assumed for North American market sales, or translated). Format Format: Digital (likely PDF or similar electronic format, based on typical modern sales). 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, overhaul, and component specifications for the HD-C diesel engine, including fuel system, lubrication, cooling, and emission controls. Transmission Drivetrain: Coverage for manual transmissions (e.g., 5-speed), transfer case (4WD system), and drive axles, including service procedures, fluid capacities, and torque specifications. Suspension Steering: Front and rear suspension components (leaf springs, shock absorbers), steering system (power steering if equipped), wheel alignment specifications. Brakes: Front disc and rear drum brake systems, parking brake, hydraulic system diagnostics and repair, component replacement procedures. Electrical System: Wiring diagrams, charging system (alternator, battery), starting system (starter motor), ignition system (if applicable to diesel), lighting, gauges, and accessories. Body Chassis: Body panel removal and installation, door mechanisms, interior trim, chassis frame inspection and repair, glass replacement. Heating Ventilation Air Conditioning: HVAC system operation, component testing, refrigerant handling (if applicable). Procedures Included Maintenance: Scheduled maintenance intervals, fluid changes (oil, coolant, brake fluid), filter replacements, tune-up procedures. Troubleshooting: Diagnostic charts and flowcharts for common drivability issues, electrical faults, and mechanical problems. Repair: Step-by-step instructions for component removal, repair, overhaul, and reinstallation across all major vehicle systems. Specifications: Torque values, clearances, fluid types and capacities, electrical resistance readings, timing settings, and diagnostic parameters. Technical Depth Depth: Comprehensive: Covers everything from basic fluid checks to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) or similar e-book format, enabling search functionality and easy navigation. Print Quality Scanned Quality: High-resolution scans ensuring clarity of text and diagrams; may include searchable text if OCR'd. Binding Type Digital Binding: N/A (Digital format; printable pages if desired). Paper Type Digital Paper Type: N/A (Digital format). ⚙️ Engine Specifications Primary Engine Engine Type: Naturally Aspirated Diesel. Engine Code: HD-C. Displacement Cc: 2659. Bore X Stroke Mm: 92.0 x 98.0. Compression Ratio: 21.0:1. Power Hp Rpm: 84 HP @ 3600 RPM (approximate). Torque Lb-Ft Rpm: 150 lb-ft @ 2000 RPM (approximate). Fuel System Fuel Delivery: Direct Injection, Bosch inline injection pump. Fuel Type: Diesel Fuel. Cooling System Cooling Type: Water-cooled. Lubrication System Oil Capacity Liters: 6.5 Liters (including filter). Recommended Oil Viscosity: API CD/CE, SAE 15W-40 (check manual for specific grade based on climate). 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission. Optional Transmission Type: 3-speed Automatic Transmission (less common, but may be covered). Features Drivetrain: Part-time 4WD system with selectable 2WD/4WD High/4WD Low. Fluid Specifications Manual Transmission Fluid Type: GL-4 (e.g., SAE 75W-90 or SAE 80W-90 gear oil). Transfer Case Fluid Type: GL-4 (e.g., SAE 75W-90 or SAE 80W-90 gear oil). 📐 Dimensions Exterior Wheelbase Mm: 2345 mm (Short Wheelbase), 2660 mm (Long Wheelbase). Length Mm: 3890 mm (SWB), 4240 mm (LWB) (approximate). Width Mm: 1545 mm. Height Mm: 1800 mm (approximate, varies with roof type). Weights Curb Weight Kg: 1300-1450 kg (approximate, varies with configuration). Gross Vehicle Weight Rating Kg: 1800-1950 kg (approximate). Wheels Tires Wheel Size: 15 inch. Bolt Pattern: 5x139.7 (5x5.5 inch). Tire Size Standard: 215/75R15 (common fitment). 🛡️ Safety Features Ratings Crash Test Data: Limited official crash test data available for this specific model year from major agencies like NHTSA or IIHS. Emphasis on robust construction for its class. Active Features Braking System: Front Disc Brakes, Rear Drum Brakes. No ABS typically equipped. Passive Features Seat Belts: Standard front seat belts, rear seat belts (if equipped). Frame Construction: Body-on-frame construction, providing structural integrity for off-road use. 💡 Technology Features Infotainment Audio System: Basic AM/FM radio, possibly with a cassette player. Aftermarket upgrades common. Dashboard Features: Analog gauges for speedometer, tachometer (if equipped), fuel, temperature, oil pressure. Basic warning lights. Driver Assistance...
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1990 Daihatsu Rocky (1st gen) Service and Repair Manual
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Rocky
Year:
1990
Codes
Chassis Code Designation:
F70 Series (Short Wheelbase), F75 Series (Long Wheelbase)
Engine Code Primary:
HD-C (Diesel)
Engine Code Secondary:
AB20 (Petrol - less common for this manual's focus, but potentially covered)
👋 Introduction
Market Position
Segment:
Compact SUV / Off-road Utility Vehicle.
Target Audience:
Enthusiasts, DIY mechanics, and professional technicians working on the Daihatsu Rocky.
Competitive Analysis
Competitors 1990:
Suzuki Samurai, Jeep Wrangler, Toyota Land Cruiser (smaller models), Mitsubishi Pajero/Montero (smaller models).
Key Features
Vehicle Strengths:
Compact size, robust 4WD system, reliable diesel engine (HD-C), go-anywhere capability, lightweight construction.
Manual Value Proposition
Uniqueness:
Vehicle-specific, factory-issued data, essential for accurate and effective maintenance and repair, avoiding generic information.
📋 Manual Details
Coverage Areas
Models Covered:
All 1990 Daihatsu Rocky (1st gen) models and variants.
Trim Levels Covered:
All trim levels equipped with the specified engine and drivetrain configurations.
Page Count
Estimated Page Count:
Likely 500-800 pages (typical for a comprehensive factory service manual of this era).
Manual Type
Type:
Factory Service and Repair Manual.
Language
Language:
English (assumed for North American market sales, or translated).
Format
Format:
Digital (likely PDF or similar electronic format, based on typical modern sales).
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnostics, repair, overhaul, and component specifications for the HD-C diesel engine, including fuel system, lubrication, cooling, and emission controls.
Transmission Drivetrain:
Coverage for manual transmissions (e.g., 5-speed), transfer case (4WD system), and drive axles, including service procedures, fluid capacities, and torque specifications.
Suspension Steering:
Front and rear suspension components (leaf springs, shock absorbers), steering system (power steering if equipped), wheel alignment specifications.
Brakes:
Front disc and rear drum brake systems, parking brake, hydraulic system diagnostics and repair, component replacement procedures.
Electrical System:
Wiring diagrams, charging system (alternator, battery), starting system (starter motor), ignition system (if applicable to diesel), lighting, gauges, and accessories.
Body Chassis:
Body panel removal and installation, door mechanisms, interior trim, chassis frame inspection and repair, glass replacement.
Heating Ventilation Air Conditioning:
HVAC system operation, component testing, refrigerant handling (if applicable).
Procedures Included
Maintenance:
Scheduled maintenance intervals, fluid changes (oil, coolant, brake fluid), filter replacements, tune-up procedures.
Troubleshooting:
Diagnostic charts and flowcharts for common drivability issues, electrical faults, and mechanical problems.
Repair:
Step-by-step instructions for component removal, repair, overhaul, and reinstallation across all major vehicle systems.
Specifications:
Torque values, clearances, fluid types and capacities, electrical resistance readings, timing settings, and diagnostic parameters.
Technical Depth
Depth:
Comprehensive: Covers everything from basic fluid checks to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format) or similar e-book format, enabling search functionality and easy navigation.
Print Quality
Scanned Quality:
High-resolution scans ensuring clarity of text and diagrams; may include searchable text if OCR'd.
Binding Type
Digital Binding:
N/A (Digital format; printable pages if desired).
Paper Type
Digital Paper Type:
N/A (Digital format).
⚙️ Engine Specifications
Primary Engine
Engine Type:
Naturally Aspirated Diesel.
Engine Code:
HD-C.
Displacement Cc:
2659.
Bore X Stroke Mm:
92.0 x 98.0.
Compression Ratio:
21.0:1.
Power Hp Rpm:
84 HP @ 3600 RPM (approximate).
Torque Lb-Ft Rpm:
150 lb-ft @ 2000 RPM (approximate).
Fuel System
Fuel Delivery:
Direct Injection, Bosch inline injection pump.
Fuel Type:
Diesel Fuel.
Cooling System
Cooling Type:
Water-cooled.
Lubrication System
Oil Capacity Liters:
6.5 Liters (including filter).
Recommended Oil Viscosity:
API CD/CE, SAE 15W-40 (check manual for specific grade based on climate).
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transmission.
Optional
Transmission Type:
3-speed Automatic Transmission (less common, but may be covered).
Features
Drivetrain:
Part-time 4WD system with selectable 2WD/4WD High/4WD Low.
Fluid Specifications
Manual Transmission Fluid Type:
GL-4 (e.g., SAE 75W-90 or SAE 80W-90 gear oil).
Transfer Case Fluid Type:
GL-4 (e.g., SAE 75W-90 or SAE 80W-90 gear oil).
📐 Dimensions
Exterior
Wheelbase Mm:
2345 mm (Short Wheelbase), 2660 mm (Long Wheelbase).
Length Mm:
3890 mm (SWB), 4240 mm (LWB) (approximate).
Width Mm:
1545 mm.
Height Mm:
1800 mm (approximate, varies with roof type).
Weights
Curb Weight Kg:
1300-1450 kg (approximate, varies with configuration).
Gross Vehicle Weight Rating Kg:
1800-1950 kg (approximate).
Wheels Tires
Wheel Size:
15 inch.
Bolt Pattern:
5x139.7 (5x5.5 inch).
Tire Size Standard:
215/75R15 (common fitment).
🛡️ Safety Features
Ratings
Crash Test Data:
Limited official crash test data available for this specific model year from major agencies like NHTSA or IIHS. Emphasis on robust construction for its class.
Active Features
Braking System:
Front Disc Brakes, Rear Drum Brakes. No ABS typically equipped.
Passive Features
Seat Belts:
Standard front seat belts, rear seat belts (if equipped).
Frame Construction:
Body-on-frame construction, providing structural integrity for off-road use.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio, possibly with a cassette player. Aftermarket upgrades common.
Dashboard Features:
Analog gauges for speedometer, tachometer (if equipped), fuel, temperature, oil pressure. Basic warning lights.
Driver Assistance
ABS:
Not typically equipped on this model year.
Traction Control:
Not equipped.
Connectivity
Bluetooth Usb:
Not equipped. Requires aftermarket installation.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000 km or 6 months, whichever comes first (diesel).
Fuel Filter Replacement:
Every 20,000 km or 12 months.
Engine Coolant Replacement:
Every 40,000 km or 24 months.
Transmission Fluid Change:
Every 40,000 km or 24 months.
Fluid Specifications
Engine Coolant Type:
Daihatsu Genuine Coolant or equivalent (ethylene glycol-based, typically a 50/50 mix with distilled water).
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Diesel Engine:
Glow plug issues, injector pump wear, potential for injector nozzle clogging with poor fuel quality, exhaust manifold cracks on high-mileage examples.
Suspension:
Worn leaf springs (sagging), shock absorber fatigue, potential for steering box play.
Rust:
Common issue on vehicles of this era, particularly in the body panels, wheel arches, and frame chassis.
Electrical:
Corroded connections, failing grounds, and intermittent issues with switches or gauges due to age.
📚 Vehicle History
Brand Heritage
Daihatsu Overview:
Daihatsu, a subsidiary of Toyota, is Japan's oldest automobile manufacturer, known for its compact and specialized vehicles.
Model Evolution
Rocky Generation 1:
Launched in 1984, the first-generation Daihatsu Rocky (also known as Feroza in some markets) was designed as a compact, rugged off-road vehicle.
1990 Updates:
The 1990 model year represents a refinement of the initial F70/F75 series, often featuring minor cosmetic updates and potential improvements to the HD-C diesel engine's efficiency or emissions.
Production
Production Location:
Japan.
Production Period Gen1:
1984-1997.
🏆 Awards & Recognition
Recognitions
Off Road Capability Awards:
While specific awards are scarce, the Rocky was widely recognized for its excellent off-road prowess and durability in its class, earning a strong following among enthusiasts.
Ratings
Consumer Reviews Historical:
Generally praised for its reliability and off-road ability, though often criticized for its basic interior and less refined on-road manners compared to later SUVs.
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