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Daihatsu Rocky F300 1990 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Rocky Model Code: F300 Series Year: 1990 Codes Chassis Codes: F300 Engine Codes: e.g., HD-C (Diesel), EF-EL (Petrol) - dependent on specific market...
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Sku: 369576
Daihatsu Rocky F300 1990 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Rocky
Model Code:
F300 Series
Year:
1990
Codes
Chassis Codes:
F300
Engine Codes:
e.g., HD-C (Diesel), EF-EL (Petrol) - dependent on specific market variant
👋 Introduction
Market Position
Segment:
Compact Sport Utility Vehicle (SUV) / Off-Road Vehicle
Target Audience:
Enthusiasts, DIY mechanics, professional workshops specializing in off-road vehicles and older Japanese imports.
Competitive Analysis
Key Competitors:
Suzuki Samurai/Jimny, Toyota RAV4 (later generations), Nissan Terrano/Pathfinder, Mitsubishi Pajero/Montero.
Key Features
Vehicle Strengths:
Robust construction, excellent off-road capability for its class, compact size for maneuverability, reliable powertrain options.
Manual Value
Utility:
Essential for owners and mechanics to maintain, diagnose, and repair the Daihatsu Rocky F300, preserving its functionality and value.
📋 Manual Details
Coverage Areas
Primary Coverage:
Mechanical Repair, Maintenance, Troubleshooting, Electrical Systems, Bodywork
Secondary Coverage:
Diagnosis, Specifications, Wiring Diagrams, Fluid Capacities
Page Count
Estimated Page Count:
Varies, typically 500-1000+ pages for a comprehensive factory service manual
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English (typical for international markets/aftermarket documentation)
Format
Format:
Likely PDF, potentially also available in printed format.
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (disassembly, assembly, tuning, diagnostics), Fuel System, Ignition System, Cooling System, Lubrication System, Exhaust System
Drivetrain:
Transmission (manual/automatic), Transfer Case, Driveshafts, Axles, Differentials
Chassis:
Suspension (front/rear), Steering System, Brake System (including ABS if equipped), Wheels and Tires
Electrical:
Battery, Charging System, Starting System, Lighting System, Instrumentation, Powertrain Control Module (PCM), Body Electrical, Wiring Diagrams
Body:
Body Panels, Doors, Hood, Tailgate, Glass, Interior Trim, Seats, HVAC (Heating, Ventilation, and Air Conditioning)
Procedures Included
Maintenance:
Oil Change Intervals, Filter Replacements, Fluid Level Checks, Spark Plug Service, Belt Tensioning, Lubrication Points
Repair:
Engine Component Rebuilds, Transmission Overhauls, Suspension Bushing Replacement, Brake Caliper Reconditioning, Electrical Component Diagnosis and Replacement
Troubleshooting:
Diagnostic Flowcharts, Symptom-Based Troubleshooting, Common Fault Identification
Specifications:
Torque Values, Clearances, Tolerances, Alignment Specs, Diagnostic Trouble Codes (DTCs)
Technical Depth
Depth:
Comprehensive: Covers from basic fluid checks and filter changes to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable (typically)
Print Quality
Print Readability:
High resolution, suitable for printing specific sections or the entire manual.
Binding Type
Binding:
N/A (for PDF), Typically spiral or perfect bound for printed versions.
Paper Type
Paper Quality:
N/A (for PDF), Typically durable, coated paper for printed versions.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Typically a 4-cylinder, SOHC (Single Overhead Cam) or DOHC (Double Overhead Cam) engine. Common options included naturally aspirated and sometimes turbocharged diesel engines.
Displacement:
Commonly 2.0L (e.g., 1998cc) or 2.8L (e.g., 2768cc for diesel variants). Specific displacement depends on the market and engine code.
Bore X Stroke:
Varies by engine code. For example, a 2.0L petrol engine might have specifications around 83.0 mm x 92.0 mm.
Compression Ratio:
Varies by engine. Petrol engines typically 9.0:1 - 10.0:1. Diesel engines typically 20.0:1 - 22.0:1.
Performance
Horsepower:
Petrol: ~80-105 hp. Diesel: ~70-90 hp. Turbocharged diesel variants could be higher.
Torque:
Petrol: ~140-170 Nm. Diesel: ~170-220 Nm. Turbocharged diesel variants could be higher.
Fuel System
Fuel Delivery:
Petrol: Carburetor (early models) or Fuel Injection (later models, e.g., MPI). Diesel: Indirect Injection (IDI) or Direct Injection (DI), often with turbocharging.
Fuel Type:
Unleaded Petrol (Octane rating specified in manual) or Diesel Fuel.
Ignition System
Ignition Type:
Electronic Ignition (Distributorless Ignition System - DIS on later models)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transmission
Optional
Transmission Type:
4-speed Automatic Transmission (less common but available on some variants)
Features
Drive System:
Part-time 4-wheel drive (4WD) with a selectable transfer case (2H, 4H, 4L).
Gear Ratios:
Specific gear ratios for manual and automatic transmissions, and transfer case, will be detailed in the manual.
Fluid Specifications
Manual Transmission Fluid:
API GL-4 gear oil, viscosity typically SAE 75W-90 or SAE 80W-90.
Automatic Transmission Fluid:
Dexron-II or equivalent ATF (Automatic Transmission Fluid).
Transfer Case Fluid:
API GL-4 gear oil, viscosity typically SAE 75W-90 or SAE 80W-90.
📐 Dimensions
Exterior
Length:
Approx. 3,845 mm (Short Wheelbase/Hardtop)
Width:
Approx. 1,660 mm
Height:
Approx. 1,755 mm (Hardtop), variable for soft-top variants.
Wheelbase:
Approx. 2,300 mm
Ground Clearance:
Approx. 200-220 mm (variable depending on tire size and suspension).
Weights
Curb Weight:
Approx. 1,200 - 1,400 kg (depending on configuration)
Gross Vehicle Weight Rating:
Specific GVWR will be detailed in the vehicle's compliance plate and manual.
Towing Capacity:
Typically in the range of 750 kg (unbraked) to 1500 kg (braked), consult manual for exact figures.
🛡️ Safety Features
Ratings
Crash Test Ratings:
Limited data available for this era and model in formal crash test ratings (e.g., NHTSA, Euro NCAP). Vehicles of this vintage generally had less stringent safety standards compared to modern vehicles.
Active Features
ABS:
Optional on some higher trims, not standard.
Four Wheel Drive:
Standard part-time 4WD system enhances traction and stability, especially off-road and in adverse conditions.
Passive Features
Seatbelts:
Front and rear seatbelts. Lap belts in the rear on some early models, three-point belts on later models.
Airbags:
Not typically equipped with driver or passenger airbags as standard for the 1990 model year.
Body Construction:
Body-on-frame construction, providing robustness for off-road use.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with cassette player. Optional CD player on later/higher trims. Speaker configuration typically 2 or 4.
User Interface:
Analog knobs and buttons for climate control, radio tuning, and volume. Simple dashboard layout.
Driver Assistance
ABS:
Optional, as mentioned in safety section.
Traction Control:
Not available on this model year.
Connectivity
Auxiliary Inputs:
Not typically equipped with auxiliary audio inputs or USB ports. Aftermarket head unit upgrades are common.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000 - 7,500 km (3,000 - 5,000 miles) or 6 months, whichever comes first. Specific interval depends on driving conditions.
Oil Filter Replacement:
At every engine oil change.
Air Filter Replacement:
Every 15,000 - 20,000 km (9,000 - 12,000 miles).
Fuel Filter Replacement:
Every 20,000 - 30,000 km (12,000 - 18,000 miles), especially critical for diesel engines.
Spark Plug Replacement:
Every 30,000 - 40,000 km (18,000 - 25,000 miles) for standard plugs. Platinum or iridium plugs may have longer intervals.
Timing Belt Replacement:
Crucial for petrol engines. Typically every 80,000 - 100,000 km (50,000 - 60,000 miles). Consult manual for specific engine type. Critical to prevent catastrophic engine damage if it breaks.
Fluid Specifications
Engine Oil Specification:
API SG or higher, SAE 10W-30 or 10W-40 for petrol engines. For diesel engines, API CF or higher, viscosity grade varies by temperature, often 15W-40.
Coolant Specification:
Ethylene Glycol based antifreeze, mixed 50/50 with distilled water. Specific Daihatsu or Toyota coolant recommended if available.
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid:
Dexron-II or equivalent ATF, if power steering is equipped.
Known Issues
Common Wear Items:
Clutch wear (manual transmission), suspension bushings, ball joints, steering rack components, exhaust system corrosion, starter motor brushes, radiator and heater core leaks.
Diesel Engine Specifics:
Glow plug issues, injector pump calibration, turbocharger wear (if applicable).
Electrical Gremlins:
Corroded electrical connectors, faulty grounds, aging wiring insulation leading to intermittent issues.
Rust Prone Areas:
Wheel arches, rocker panels, chassis frame (especially in areas with road salt), tailgate.
📚 Vehicle History
Brand Heritage
Daihatsu Focus:
Daihatsu, a subsidiary of Toyota, is known for producing compact, fuel-efficient, and reliable vehicles, often with a focus on practicality and value, particularly in smaller vehicle segments and SUVs.
Model Evolution
Rocky Lineage:
The Daihatsu Rocky, also known as the Feroza in some markets, is a long-standing model in Daihatsu's lineup, originating from earlier compact 4x4s. The F300 series represents a distinct generation of this compact off-roader.
Production
Production Period:
The F300 Rocky was produced from 1989/1990 through the early 2000s, with facelifts and updates occurring during its production run.
Manufacturing Location:
Primarily manufactured in Japan by Daihatsu Motor Co., Ltd.
🏆 Awards & Recognition
Recognitions
Off Road Capability Awards:
While specific awards for the 1990 Rocky are not widely documented, the model consistently received positive reviews for its robust off-road performance and value for money within the compact SUV segment, often being lauded by enthusiast publications for its go-anywhere ability.
Ratings
Reliability Ratings:
Daihatsu vehicles are generally considered reliable. The Rocky's simple mechanicals contribute to its durability when properly maintained, as evidenced by the continued operation of many examples today.
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