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Daihatsu Rocky Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Rocky Chassis Codes: F70, F75, F80 👋 Introduction Market Position Vehicle Segment: Compact SUV / Off-Road Vehicle Target Audience: Enthusiasts seeking rugged, reliable, and capable off-road transportation; utility-focused buyers. Competitive Analysis Key Competitors: Suzuki Samurai/Jimny, Toyota Land Cruiser (smaller variants), Nissan Patrol (smaller variants), Jeep Wrangler (early models). Key Features Off Road Capability: Body-on-frame construction, robust 4WD system, good ground clearance, short wheelbase for maneuverability. Durability: Known for its simple, rugged mechanicals and longevity when properly maintained. Compact Size: Easy to maneuver in urban environments and on tight trails. 📋 Manual Details Coverage Areas Engine Service: Complete Transmission Service: Complete Drivetrain Service: Complete Suspension Steering Service: Complete Braking System Service: Complete Electrical System Service: Complete Body Chassis Service: Complete Heating Ventilation Air Conditioning Service: Complete Diagnostic Troubleshooting: Comprehensive Maintenance Schedules: Included Technical Specifications: Detailed Wiring Diagrams: Included Page Count Estimated Pages: Varies by specific model/engine combination, typically 500-1500+ pages Manual Type Type: Service and Repair Workshop Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, pistons, crankshaft, camshaft, timing, lubrication, cooling Engine Fuel System: Fuel injection (if applicable), carburetor (if applicable), fuel pump, fuel filter, fuel lines Engine Ignition System: Spark plugs, ignition coils, distributors (if applicable), ignition timing Engine Exhaust System: Exhaust manifolds, catalytic converter, mufflers, exhaust pipes Transmission Manual: Gearbox assembly, clutch, shifting mechanisms, maintenance Transmission Automatic: Automatic transmission assembly, torque converter, hydraulic control, maintenance (if applicable) Transfer Case 4Wd: Transfer case operation, maintenance, repair (for 4WD models) Front Axle Differential: Front differential assembly, maintenance (for 4WD models) Rear Axle Differential: Rear axle assembly, differential, maintenance Suspension Front: Springs, shock absorbers, control arms, ball joints, wheel bearings Suspension Rear: Leaf springs, shock absorbers, trailing arms, Panhard rod (typical for this era) Steering System: Steering gear, steering column, tie rods, power steering (if equipped) Braking System Front: Brake discs, calipers, pads, hydraulic lines Braking System Rear: Brake drums, wheel cylinders, shoes, parking brake system Wheels Tires: Wheel specifications, tire pressure recommendations, mounting Body Exterior: Body panels, doors, hood, tailgate, bumpers, glass, trim Body Interior: Dashboard, seats, carpets, headliner, door panels, interior trim Lighting System: Headlights, taillights, interior lights, bulb types Wiper Washer System: Wiper motor, blades, washer pump, fluid reservoir Climate Control System: HVAC unit, blower motor, heater core, A/C components (if equipped) Instrument Panel Gauges: Speedometer, tachometer, fuel gauge, temperature gauge, warning lights Battery Charging System: Battery specifications, alternator, starter motor Starting System: Ignition switch, starter motor, solenoid Wiring Harnesses: Electrical routing, connectors, component location Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks, tire rotation, lubrication points Engine Overhaul: Complete engine rebuild procedures, component tolerances, torque specifications Transmission Repair: Gearbox disassembly, assembly, clutch replacement, seal replacements Suspension Component Replacement: Shock absorber replacement, spring replacement, ball joint replacement, tie rod end replacement Brake System Repair: Brake pad/shoe replacement, caliper/wheel cylinder overhaul, brake bleeding procedures Electrical Troubleshooting: Diagnosis of electrical faults, wiring diagram interpretation, component testing Body Panel Repair: Dent removal, panel replacement, rust repair techniques Diagnostics Fault Finding: Systematic approach to identifying and resolving common and uncommon issues Component Replacement: Step-by-step guides for replacing major and minor parts Fluid Flush Replacement: Procedures for changing engine oil, transmission fluid, brake fluid, coolant Technical Depth Depth: Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds. Diagnostic Level: Advanced, with detailed troubleshooting trees and symptom-based diagnostics. Repair Level: Professional, suitable for independent workshops and skilled DIY enthusiasts. 📊 Manual Specifications File Format Format: PDF Compatibility: All versions of Windows, Mac, and Linux Requirements: Adobe PDF Reader Print Quality Printability: Yes, fully printable Binding Type Binding: Digital Download (PDF) Paper Type Paper Type: N/A (Digital) Download Speed Speed: Instant High Speed Download ⚙️ Engine Specifications Primary Engine Engine Code Examples: F20A, F22B, 4ZE1 (Examples, actual codes may vary based on specific market/year) Engine Type: Inline-4 Cylinder, Naturally Aspirated (Gasoline and Diesel variants common) Engine Displacement Displacement Liters: 1.6L to 2.4L (Common displacements include 1.6L, 2.0L, 2.2L, 2.4L) Performance Horsepower Range Ps: Approx. 75-120 PS (Varies significantly by engine and market) Torque Range Nm: Approx. 120-200 Nm (Varies significantly by engine and market) Fuel System Fuel Delivery: Carbureted or Electronic Fuel Injection (EFI) depending on model year and engine. Fuel Type Fuel Type: Unleaded Gasoline (Petrol) or Diesel 🔧 Transmission Standard Transmission Type Standard: 5-Speed Manual Transmission Optional Transmission Type Optional: 4-Speed Automatic Transmission (less common, depending on market/trim) Features Drivetrain Options: Part-time 4-Wheel Drive (4WD) with selectable 2WD/4WD modes and low-range gearing (transfer case). Clutch Clutch Type: Dry Single Plate Clutch (Manual Transmission) 📐 Dimensions Exterior Length Mm: Approx. 3,900 - 4,100 mm (Varies by body style and generation) Width Mm: Approx. 1,600 - 1,700 mm Height Mm: Approx. 1,800 - 1,900 mm Wheelbase Mm: Approx. 2,300 - 2,400 mm Weights...
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Daihatsu Rocky Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Rocky
Chassis Codes:
F70, F75, F80
👋 Introduction
Market Position
Vehicle Segment:
Compact SUV / Off-Road Vehicle
Target Audience:
Enthusiasts seeking rugged, reliable, and capable off-road transportation; utility-focused buyers.
Competitive Analysis
Key Competitors:
Suzuki Samurai/Jimny, Toyota Land Cruiser (smaller variants), Nissan Patrol (smaller variants), Jeep Wrangler (early models).
Key Features
Off Road Capability:
Body-on-frame construction, robust 4WD system, good ground clearance, short wheelbase for maneuverability.
Durability:
Known for its simple, rugged mechanicals and longevity when properly maintained.
Compact Size:
Easy to maneuver in urban environments and on tight trails.
📋 Manual Details
Coverage Areas
Engine Service:
Complete
Transmission Service:
Complete
Drivetrain Service:
Complete
Suspension Steering Service:
Complete
Braking System Service:
Complete
Electrical System Service:
Complete
Body Chassis Service:
Complete
Heating Ventilation Air Conditioning Service:
Complete
Diagnostic Troubleshooting:
Comprehensive
Maintenance Schedules:
Included
Technical Specifications:
Detailed
Wiring Diagrams:
Included
Page Count
Estimated Pages:
Varies by specific model/engine combination, typically 500-1500+ pages
Manual Type
Type:
Service and Repair Workshop Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, pistons, crankshaft, camshaft, timing, lubrication, cooling
Engine Fuel System:
Fuel injection (if applicable), carburetor (if applicable), fuel pump, fuel filter, fuel lines
Engine Ignition System:
Spark plugs, ignition coils, distributors (if applicable), ignition timing
Engine Exhaust System:
Exhaust manifolds, catalytic converter, mufflers, exhaust pipes
Transmission Manual:
Gearbox assembly, clutch, shifting mechanisms, maintenance
Transmission Automatic:
Automatic transmission assembly, torque converter, hydraulic control, maintenance (if applicable)
Transfer Case 4Wd:
Transfer case operation, maintenance, repair (for 4WD models)
Front Axle Differential:
Front differential assembly, maintenance (for 4WD models)
Rear Axle Differential:
Rear axle assembly, differential, maintenance
Suspension Front:
Springs, shock absorbers, control arms, ball joints, wheel bearings
Suspension Rear:
Leaf springs, shock absorbers, trailing arms, Panhard rod (typical for this era)
Steering System:
Steering gear, steering column, tie rods, power steering (if equipped)
Braking System Front:
Brake discs, calipers, pads, hydraulic lines
Braking System Rear:
Brake drums, wheel cylinders, shoes, parking brake system
Wheels Tires:
Wheel specifications, tire pressure recommendations, mounting
Body Exterior:
Body panels, doors, hood, tailgate, bumpers, glass, trim
Body Interior:
Dashboard, seats, carpets, headliner, door panels, interior trim
Lighting System:
Headlights, taillights, interior lights, bulb types
Wiper Washer System:
Wiper motor, blades, washer pump, fluid reservoir
Climate Control System:
HVAC unit, blower motor, heater core, A/C components (if equipped)
Instrument Panel Gauges:
Speedometer, tachometer, fuel gauge, temperature gauge, warning lights
Battery Charging System:
Battery specifications, alternator, starter motor
Starting System:
Ignition switch, starter motor, solenoid
Wiring Harnesses:
Electrical routing, connectors, component location
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks, tire rotation, lubrication points
Engine Overhaul:
Complete engine rebuild procedures, component tolerances, torque specifications
Transmission Repair:
Gearbox disassembly, assembly, clutch replacement, seal replacements
Suspension Component Replacement:
Shock absorber replacement, spring replacement, ball joint replacement, tie rod end replacement
Brake System Repair:
Brake pad/shoe replacement, caliper/wheel cylinder overhaul, brake bleeding procedures
Electrical Troubleshooting:
Diagnosis of electrical faults, wiring diagram interpretation, component testing
Body Panel Repair:
Dent removal, panel replacement, rust repair techniques
Diagnostics Fault Finding:
Systematic approach to identifying and resolving common and uncommon issues
Component Replacement:
Step-by-step guides for replacing major and minor parts
Fluid Flush Replacement:
Procedures for changing engine oil, transmission fluid, brake fluid, coolant
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds.
Diagnostic Level:
Advanced, with detailed troubleshooting trees and symptom-based diagnostics.
Repair Level:
Professional, suitable for independent workshops and skilled DIY enthusiasts.
📊 Manual Specifications
File Format
Format:
PDF
Compatibility:
All versions of Windows, Mac, and Linux
Requirements:
Adobe PDF Reader
Print Quality
Printability:
Yes, fully printable
Binding Type
Binding:
Digital Download (PDF)
Paper Type
Paper Type:
N/A (Digital)
Download Speed
Speed:
Instant High Speed Download
⚙️ Engine Specifications
Primary Engine
Engine Code Examples:
F20A, F22B, 4ZE1 (Examples, actual codes may vary based on specific market/year)
Engine Type:
Inline-4 Cylinder, Naturally Aspirated (Gasoline and Diesel variants common)
Engine Displacement
Displacement Liters:
1.6L to 2.4L (Common displacements include 1.6L, 2.0L, 2.2L, 2.4L)
Performance
Horsepower Range Ps:
Approx. 75-120 PS (Varies significantly by engine and market)
Torque Range Nm:
Approx. 120-200 Nm (Varies significantly by engine and market)
Fuel System
Fuel Delivery:
Carbureted or Electronic Fuel Injection (EFI) depending on model year and engine.
Fuel Type
Fuel Type:
Unleaded Gasoline (Petrol) or Diesel
🔧 Transmission
Standard
Transmission Type Standard:
5-Speed Manual Transmission
Optional
Transmission Type Optional:
4-Speed Automatic Transmission (less common, depending on market/trim)
Features
Drivetrain Options:
Part-time 4-Wheel Drive (4WD) with selectable 2WD/4WD modes and low-range gearing (transfer case).
Clutch
Clutch Type:
Dry Single Plate Clutch (Manual Transmission)
📐 Dimensions
Exterior
Length Mm:
Approx. 3,900 - 4,100 mm (Varies by body style and generation)
Width Mm:
Approx. 1,600 - 1,700 mm
Height Mm:
Approx. 1,800 - 1,900 mm
Wheelbase Mm:
Approx. 2,300 - 2,400 mm
Weights
Curb Weight Kg:
Approx. 1,300 - 1,500 kg (Varies by configuration)
Gross Vehicle Weight Kg:
Approx. 1,800 - 2,000 kg
🛡️ Safety Features
Ratings
Safety Ratings:
Generally basic by modern standards, focused on structural integrity for the era.
Active Features
Active Safety Features:
Limited; primarily effective braking system and robust chassis. ABS was often optional or not available on earlier models.
Passive Features
Passive Safety Features:
Seat belts, sturdy construction. Airbags were not standard or common during the production of these chassis codes.
💡 Technology Features
Infotainment
Infotainment System:
Basic by modern standards; typically a factory-installed radio (AM/FM, cassette), with optional CD players on later models.
Speakers:
Usually 2 or 4 speakers.
Driver Assistance
Driver Assistance Features:
None typical for these chassis codes.
Connectivity
Connectivity Options:
Limited; often an auxiliary input for external devices if equipped with the factory radio.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Typically every 5,000 - 7,500 km (3,000 - 5,000 miles) or 6 months, whichever comes first. Check manual for specifics.
Air Filter Replacement:
Every 15,000 - 20,000 km (10,000 - 12,000 miles) or annually.
Fuel Filter Replacement:
Every 20,000 - 30,000 km (12,000 - 18,000 miles), especially critical for diesel variants.
Spark Plug Replacement:
Every 30,000 - 50,000 km (20,000 - 30,000 miles), depending on plug type.
Coolant Flush:
Every 2 years or 40,000 - 50,000 km (25,000 - 30,000 miles).
Fluid Specifications
Engine Oil Type:
API SG/SH/SJ or equivalent. Viscosity typically 10W-30 or 10W-40 for gasoline, 15W-40 for diesel. Check manual for exact specifications.
Engine Oil Capacity:
Approx. 3.5 - 4.5 Liters (Varies by engine)
Coolant Type:
Ethylene Glycol based, typically Green or Yellow color (ensure compatibility with original spec).
Transmission Fluid Manual:
API GL-4 or GL-5, SAE 75W-90 or 80W-90 Gear Oil.
Transmission Fluid Automatic:
Dexron II or equivalent (if equipped).
Brake Fluid Type:
DOT 3 or DOT 4.
Power Steering Fluid:
Dexron II or equivalent (if equipped).
Known Issues
Common Wear Items:
Clutch wear, brake components, suspension bushings, exhaust system corrosion, clutch slave cylinder leaks, radiator leaks.
Engine Specific Concerns:
Head gasket issues on some older engines, carburetor tuning difficulties on carbureted models, potential for timing belt failure if not replaced per schedule.
4Wd System Concerns:
Wear in transfer case or front axle components if subjected to extreme off-road use without proper maintenance.
📚 Vehicle History
Brand Heritage
Brand Focus:
Daihatsu is known for producing small, fuel-efficient, and rugged vehicles, often with a focus on utility and affordability.
Model Evolution
Model Lineage:
The Daihatsu Rocky (F70/F75/F80 series) is a compact, body-on-frame SUV that evolved from earlier Daihatsu off-road vehicles. It was succeeded by later generations of compact SUVs and crossovers from Daihatsu and Toyota (which owns Daihatsu).
Production
Production Years:
The F70/F75/F80 series was primarily produced from the mid-1980s to the mid-1990s.
Manufacturing Locations:
Japan, and potentially licensed production in other countries.
🏆 Awards & Recognition
Recognitions
Off Road Awards:
While not typically winning formal 'awards', the Rocky gained a reputation among off-road enthusiasts for its capability relative to its size and cost.
Ratings
Consumer Ratings Era:
Generally positive for its intended purpose as an affordable and capable small 4x4. Reliability was considered good for its mechanical simplicity.
Certifications
Emission Standards:
Compliant with prevailing emission standards of its production era (e.g., Euro 1/2, JPN standards).
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