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Daihatsu Fourtrak F80 1984-1992 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Fourtrak Model Code: F80 Generation Generation Designation: First Generation (F80/F70 Series) Codes Platform Code: F80 👋 Introduction Market Position Segment: Compact SUV / Off-road Vehicle Target Audience: Owners, DIY enthusiasts, professional mechanics working on Daihatsu Fourtrak vehicles. Competitive Analysis Key Competitors Era: Suzuki Samurai/Jimny, Toyota Land Cruiser (smaller variants), Nissan Patrol (earlier generations), Mitsubishi Pajero/Montero (earlier generations). Key Features Vehicle Strengths: Robust construction, genuine off-road capability, relatively compact size for maneuverability, reliable mechanicals. Manual Value Proposition: Provides essential, detailed technical information for maintaining, troubleshooting, and repairing the Daihatsu Fourtrak F80, enabling cost-effective ownership and maximizing vehicle longevity. 📋 Manual Details Coverage Areas Vehicle Years Covered: 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992 Page Count Number Of Pages: 394 Manual Type Type: Workshop Service Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine overhaul, tuning, diagnostics, lubrication, cooling, fuel, ignition, emission control systems. Drivetrain Systems: Clutch, transmission (manual and automatic), transfer case, driveshafts, differentials (front, rear, center), axle assemblies, hubs. Suspension Systems: Front and rear suspension components (leaf springs, shock absorbers, bushings), steering system (power steering, linkage), wheel alignment. Braking Systems: Front and rear brake systems (disc/drum), hydraulic system, parking brake, ABS (if equipped on later models within range). Electrical Systems: Wiring diagrams, starter system, charging system (alternator, battery), lighting, instrumentation, ignition switch, fuses, relays, basic electronic controls. Body And Chassis: Body panel removal and installation, interior trim, glass, doors, chassis lubrication, corrosion protection. Heating And Air Conditioning: HVAC system components, refrigerant handling (basic), blower motor, controls. Procedures Included Maintenance: Periodic maintenance, fluid changes (oil, coolant, transmission, differential), filter replacements, lubrication points, spark plug service. Troubleshooting: Systematic diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides. Repair And Overhaul: Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation. Adjustments: Carburetor adjustment, ignition timing, valve clearance, clutch adjustment, brake adjustments, steering alignment. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to major component overhaul and rebuilding. Diagnostic Capability: Includes diagnostic procedures, specifications, and reference data for identifying and rectifying faults. Illustrations: Features detailed pictorial diagrams, exploded views, and photographs to guide repair procedures. Special Tools: References specific Daihatsu special service tools and their applications where necessary for correct repair. 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: Yes, all pages are printable for workshop use. Binding Type Binding: Digital (PDF), no physical binding. Paper Type Digital Format Details: Adobe Reader compatible, viewable on Windows, Mac, and Linux OS. ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-cylinder, naturally aspirated gasoline and diesel engines (specific displacements vary by market and sub-model). Common Gasoline Engine Code: e.g., DL Series (DL51, DL52) Common Diesel Engine Code: e.g., DL Series (DL41, DL42) Performance Typical Horsepower Range: Approximately 70-95 hp (depending on engine variant) Typical Torque Range: Approximately 110-160 Nm (depending on engine variant) Fuel System Fuel Delivery: Carburetor (gasoline engines) or indirect injection diesel (diesel engines). Fuel Type: Unleaded gasoline (for gasoline variants), Diesel fuel (for diesel variants). 🔧 Transmission Standard Standard Transmission Type: 5-speed manual transmission Optional Optional Transmission Type: 3-speed or 4-speed automatic transmission (availability varied by market and trim) Features Transfer Case: Two-speed manual transfer case with selectable 2WD/4WD and 4WD Low range. 📐 Dimensions Exterior Body Styles: 2-door short wheelbase, 4-door long wheelbase, Soft-top and Hard-top variants. Typical Wheelbase Short: Approximately 2240 mm (88.2 inches) Typical Wheelbase Long: Approximately 2770 mm (109.1 inches) Weights Curb Weight Range: Approximately 1200 - 1500 kg (2645 - 3300 lbs), depending on configuration. 🛡️ Safety Features Ratings Crash Test Data Availability: Limited specific crash test data available for this era of vehicle, especially for models primarily sold in non-US markets. Active Features Active Safety Features: Generally basic; 4WD system for enhanced traction, potentially optional power steering on higher trims. Passive Features Passive Safety Features: Seatbelts, reinforced chassis for its class, basic crumple zones. 💡 Technology Features Infotainment Infotainment System: Basic; typically AM/FM radio with cassette player. Optional upgrades may have been available. Driver Assistance Driver Assistance Features: Minimal to none by modern standards. Focus is on mechanical capability. Connectivity Connectivity Options: None. 🔧 Maintenance Service Intervals Engine Oil Change: Typically every 5,000 - 7,500 km (3,000 - 5,000 miles) or 6-12 months, depending on usage. Transmission Fluid Change: Manual: typically every 40,000 - 60,000 km (25,000 - 37,000 miles). Automatic: more frequent, often around 30,000 - 40,000 km (18,000 - 25,000 miles). Differential Fluid Change: Typically every 40,000 - 60,000 km (25,000 - 37,000 miles). Fluid Specifications Engine Oil Type: API SF/SG or equivalent, viscosity typically 10W-30 or 10W-40 (consult manual for specific engine). Coolant Type: Ethylene glycol-based coolant (traditional green type), 50/50 mix with distilled water. Brake Fluid Type: DOT 3 or DOT 4 (check manual for specific recommendation). Known...
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Daihatsu Fourtrak F80 1984-1992 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Fourtrak
Model Code:
F80
Generation
Generation Designation:
First Generation (F80/F70 Series)
Codes
Platform Code:
F80
👋 Introduction
Market Position
Segment:
Compact SUV / Off-road Vehicle
Target Audience:
Owners, DIY enthusiasts, professional mechanics working on Daihatsu Fourtrak vehicles.
Competitive Analysis
Key Competitors Era:
Suzuki Samurai/Jimny, Toyota Land Cruiser (smaller variants), Nissan Patrol (earlier generations), Mitsubishi Pajero/Montero (earlier generations).
Key Features
Vehicle Strengths:
Robust construction, genuine off-road capability, relatively compact size for maneuverability, reliable mechanicals.
Manual Value Proposition:
Provides essential, detailed technical information for maintaining, troubleshooting, and repairing the Daihatsu Fourtrak F80, enabling cost-effective ownership and maximizing vehicle longevity.
📋 Manual Details
Coverage Areas
Vehicle Years Covered:
1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992
Page Count
Number Of Pages:
394
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine overhaul, tuning, diagnostics, lubrication, cooling, fuel, ignition, emission control systems.
Drivetrain Systems:
Clutch, transmission (manual and automatic), transfer case, driveshafts, differentials (front, rear, center), axle assemblies, hubs.
Suspension Systems:
Front and rear suspension components (leaf springs, shock absorbers, bushings), steering system (power steering, linkage), wheel alignment.
Braking Systems:
Front and rear brake systems (disc/drum), hydraulic system, parking brake, ABS (if equipped on later models within range).
Electrical Systems:
Wiring diagrams, starter system, charging system (alternator, battery), lighting, instrumentation, ignition switch, fuses, relays, basic electronic controls.
Body And Chassis:
Body panel removal and installation, interior trim, glass, doors, chassis lubrication, corrosion protection.
Heating And Air Conditioning:
HVAC system components, refrigerant handling (basic), blower motor, controls.
Procedures Included
Maintenance:
Periodic maintenance, fluid changes (oil, coolant, transmission, differential), filter replacements, lubrication points, spark plug service.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides.
Repair And Overhaul:
Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation.
Adjustments:
Carburetor adjustment, ignition timing, valve clearance, clutch adjustment, brake adjustments, steering alignment.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to major component overhaul and rebuilding.
Diagnostic Capability:
Includes diagnostic procedures, specifications, and reference data for identifying and rectifying faults.
Illustrations:
Features detailed pictorial diagrams, exploded views, and photographs to guide repair procedures.
Special Tools:
References specific Daihatsu special service tools and their applications where necessary for correct repair.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Printability:
Yes, all pages are printable for workshop use.
Binding Type
Binding:
Digital (PDF), no physical binding.
Paper Type
Digital Format Details:
Adobe Reader compatible, viewable on Windows, Mac, and Linux OS.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, naturally aspirated gasoline and diesel engines (specific displacements vary by market and sub-model).
Common Gasoline Engine Code:
e.g., DL Series (DL51, DL52)
Common Diesel Engine Code:
e.g., DL Series (DL41, DL42)
Performance
Typical Horsepower Range:
Approximately 70-95 hp (depending on engine variant)
Typical Torque Range:
Approximately 110-160 Nm (depending on engine variant)
Fuel System
Fuel Delivery:
Carburetor (gasoline engines) or indirect injection diesel (diesel engines).
Fuel Type:
Unleaded gasoline (for gasoline variants), Diesel fuel (for diesel variants).
🔧 Transmission
Standard
Standard Transmission Type:
5-speed manual transmission
Optional
Optional Transmission Type:
3-speed or 4-speed automatic transmission (availability varied by market and trim)
Features
Transfer Case:
Two-speed manual transfer case with selectable 2WD/4WD and 4WD Low range.
📐 Dimensions
Exterior
Body Styles:
2-door short wheelbase, 4-door long wheelbase, Soft-top and Hard-top variants.
Typical Wheelbase Short:
Approximately 2240 mm (88.2 inches)
Typical Wheelbase Long:
Approximately 2770 mm (109.1 inches)
Weights
Curb Weight Range:
Approximately 1200 - 1500 kg (2645 - 3300 lbs), depending on configuration.
🛡️ Safety Features
Ratings
Crash Test Data Availability:
Limited specific crash test data available for this era of vehicle, especially for models primarily sold in non-US markets.
Active Features
Active Safety Features:
Generally basic; 4WD system for enhanced traction, potentially optional power steering on higher trims.
Passive Features
Passive Safety Features:
Seatbelts, reinforced chassis for its class, basic crumple zones.
💡 Technology Features
Infotainment
Infotainment System:
Basic; typically AM/FM radio with cassette player. Optional upgrades may have been available.
Driver Assistance
Driver Assistance Features:
Minimal to none by modern standards. Focus is on mechanical capability.
Connectivity
Connectivity Options:
None.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Typically every 5,000 - 7,500 km (3,000 - 5,000 miles) or 6-12 months, depending on usage.
Transmission Fluid Change:
Manual: typically every 40,000 - 60,000 km (25,000 - 37,000 miles). Automatic: more frequent, often around 30,000 - 40,000 km (18,000 - 25,000 miles).
Differential Fluid Change:
Typically every 40,000 - 60,000 km (25,000 - 37,000 miles).
Fluid Specifications
Engine Oil Type:
API SF/SG or equivalent, viscosity typically 10W-30 or 10W-40 (consult manual for specific engine).
Coolant Type:
Ethylene glycol-based coolant (traditional green type), 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 (check manual for specific recommendation).
Known Issues
Common Wear Items:
Suspension bushings, leaf springs (sagging), brake components, clutch wear, exhaust systems (rusting), steering linkages.
Common Engine Issues:
Carburetor issues (tuning, leaks), diesel injection pump issues (less common but possible), oil leaks from gaskets and seals.
Common Electrical Issues:
Corroded electrical connections, alternator/starter problems, aging wiring harnesses.
Chassis Corrosion:
Prone to rust, especially in areas with road salt exposure; frame, body panels, and wheel arches are common areas.
📚 Vehicle History
Brand Heritage
Daihatsu Focus:
Daihatsu, a subsidiary of Toyota, historically focused on small, economical, and rugged vehicles, often with a strong presence in off-road and light commercial segments.
Model Evolution
Fourtrak Lineage:
The Fourtrak (also known as the Rocky, Rugger, or Taft in some markets) was Daihatsu's primary offering in the compact SUV segment, evolving from earlier rugged, body-on-frame utility vehicles.
Production
Production Period:
1984-1992 covers the F80/F70 generation. Successor models followed.
Manufacturing Locations:
Primarily Japan, with potential assembly in other international markets.
🏆 Awards & Recognition
Recognitions
Historical Awards:
While specific awards for the Fourtrak F80 might be scarce in widely available English-language sources, Daihatsu vehicles of this era were often recognized for their value, reliability in their segment, and off-road prowess.
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