Daihatsu Feroza 1991 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Feroza Year: 1991 Engine Code: HD-C (or similar HD variant) Codes Platform Code: F300 series 👋 Introduction Market Position Vehicle Segment: Compact SUV...

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Sku: 558184

Tags: 1991 Car Cars Daihatsu Feroza Wiring Diagrams

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Description

🏷️ Basic Information

Identification

Make:

Daihatsu

Model:

Feroza

Year:

Engine Code:

HD-C (or similar HD variant)

Codes

Platform Code:

F300 series

👋 Introduction

Market Position

Vehicle Segment:

Compact SUV / Sport Utility Vehicle

Key Target Audience:

Enthusiasts seeking to maintain and repair their Feroza, DIY mechanics, and professional workshops.

Competitive Analysis

Primary Competitors Era:

Suzuki Vitara, Toyota RAV4 (early models), Mitsubishi Pajero Mini, Nissan Rasheen.

Key Features

Vehicle Design Philosophy:

Lightweight, off-road capable, compact SUV with body-on-frame construction for durability.

Manual Value Proposition:

Provides authoritative, factory-correct information for accurate and efficient repairs, saving time and preventing costly mistakes.

📋 Manual Details

Coverage Areas

Primary Coverage:

Daihatsu Feroza HD Engine

Secondary Coverage:

Vehicle systems related to engine operation and maintenance

Page Count

Estimated Page Count:

Likely 500-800 pages (typical for factory service manuals of this era)

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English (assumed based on product description)

Format

Format:

Print (implied by 'handy, easy to read reference book')

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, repair, inspection of cylinder head, block, pistons, crankshaft, camshafts, timing system.

Engine Fuel System:

Fuel injection system (EFI), injectors, fuel pump, fuel filter, pressure regulator, throttle body, intake manifold.

Engine Cooling System:

Radiator, water pump, thermostat, coolant hoses, fan, cooling system troubleshooting.

Engine Lubrication System:

Oil pump, oil filter, oil pan, oil passages, oil pressure checks.

Engine Ignition System:

Ignition coils, spark plugs, ignition timing, distributor (if applicable), ECU control.

Engine Exhaust System:

Exhaust manifold, catalytic converter, muffler, emissions control systems.

Engine Electrical System:

Alternator, starter motor, battery, engine sensors (MAP, TPS, ECT, Crankshaft Position), wiring diagrams specific to engine control.

Transmission Interface:

Engine-to-transmission mounting, clutch operation (if manual), torque converter (if automatic) relating to engine.

Chassis Interface:

Engine mounts, accessory drive belts, engine bay layout and component identification.

Procedures Included

Routine Maintenance:

Oil and filter changes, spark plug replacement, air filter replacement, coolant flush, drive belt inspection/replacement.

Disassembly Assembly:

Complete engine disassembly and reassembly with torque specifications and component orientation.

Repair Rebuild:

Cylinder head gasket replacement, piston ring replacement, bearing replacement, valve seat grinding, complete engine overhaul.

Diagnostics Troubleshooting:

Step-by-step procedures for diagnosing engine performance issues, misfires, starting problems, and emissions faults.

Inspection Checking:

Compression testing, oil pressure testing, ignition timing verification, sensor output checks.

Special Tools:

Identification and usage of specialized tools required for specific repair procedures.

Technical Depth

Depth:

Comprehensive - covers everything from basic adjustments and routine maintenance to complete engine rebuilds and advanced diagnostics.

📊 Manual Specifications

File Format

File Format Details:

Print format, likely with clear diagrams, illustrations, and exploded views. (If digital, expect PDF with searchable text and image quality.)

Print Quality

Print Quality:

Factory OEM quality (assumed) - clear text, high-resolution diagrams, durable paper.

Binding Type

Binding Type:

Perfect bound or spiral bound (common for service manuals to lay flat).

Paper Type

Paper Type:

Durable, coated paper to withstand shop environment and repeated use.

⚙️ Engine Specifications

Primary Engine

Engine Family:

Daihatsu HD Series (e.g., HD-C)

Engine Configuration:

Inline 4-cylinder

Displacement:

1.6 Liters (1589 cc)

Valve Train:

SOHC (Single Overhead Camshaft)

Bore X Stroke:

Approximately 76.0 mm x 87.1 mm (typical for HD-C)

Compression Ratio:

Around 9.3:1 (typical for HD-C)

Performance

Horsepower:

Approximately 70-90 PS (51-66 kW) at 5000-5500 rpm (depending on exact variant and emissions equipment).

Torque:

Approximately 120-130 Nm (89-96 lb-ft) at 3000-3500 rpm (depending on exact variant).

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with multi-point injection (MPI) or single-point injection (SPI) depending on market/trim.

Fuel Type:

Unleaded gasoline

Fuel Octane Rating:

Typically 91 RON (Research Octane Number) or higher.

Engine Characteristics

Engine Type:

Naturally Aspirated

🔧 Transmission

Standard

Transmission Type:

5-speed manual transmission

Optional

Transmission Type:

4-speed automatic transmission

Features

Drivetrain:

Part-time 4-wheel drive (4WD) with manual front hub locking (selectable 2WD/4WD).

Transfer Case:

2-speed transfer case with High and Low range gearing.

📐 Dimensions

Exterior

Length:

Approximately 3,970 mm (156.3 in)

Width:

Approximately 1,690 mm (66.5 in)

Height:

Approximately 1,630 mm (64.2 in) (Hardtop)

Wheelbase:

Approximately 2,300 mm (90.6 in)

Ground Clearance:

Approximately 190-200 mm (7.5-7.9 in)

Weights

Curb Weight:

Approximately 1,200 - 1,350 kg (2,645 - 2,976 lbs) depending on body style and transmission.

🛡️ Safety Features

Ratings

Crash Test Ratings:

Limited safety rating data available for this model/era from official bodies like NHTSA/Euro NCAP. Likely basic for the time.

Active Features

Braking System:

Front: Ventilated disc brakes. Rear: Drum brakes.

Steering:

Power assisted recirculating ball steering (often optional).

Passive Features

Airbags:

Driver airbag typically optional or not available in all markets for the 1991 model year.

Seatbelts:

Front: Three-point with pretensioners (often optional). Rear: Lap belts or three-point belts depending on seating position.

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM radio with cassette player, often with 2-4 speakers. Aftermarket head unit upgrades common.

Driver Assistance

Anti-lock Braking System (ABS) typically optional or not available on base models for 1991.

Connectivity

Connectivity Features:

Minimal to none by modern standards. No Bluetooth, USB, or smartphone integration from factory.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 7,500 - 10,000 km (4,600 - 6,000 miles) or 6-12 months, whichever comes first.

Air Filter Replacement:

Every 15,000 - 20,000 km (9,000 - 12,000 miles) or annually.

Spark Plug Replacement:

Every 30,000 - 40,000 km (18,000 - 24,000 miles) depending on plug type.

Coolant Replacement:

Every 40,000 - 50,000 km (24,000 - 30,000 miles) or 2-3 years.

Fluid Specifications

Engine Oil Type:

API SG or SH, SAE 10W-30 or 10W-40.

Engine Oil Capacity:

Approximately 3.5 - 4.0 Liters (3.7 - 4.2 US Quarts) with filter change.

Coolant Type:

Ethylene Glycol based antifreeze (e.g., Toyota Super Long Life Coolant compatible).

Transmission Fluid Manual:

API GL-4, SAE 75W-90 or 80W-90 gear oil.

Transmission Fluid Automatic:

Dexron II or equivalent ATF.

Brake Fluid Type:

DOT 3 or DOT 4.

Known Issues

Common Wear Items:

Clutch wear, suspension bushings, exhaust system corrosion, radiator hoses, catalytic converter failure due to age.

Engine Performance Issues:

Occasional carburetor issues (if applicable in certain markets) or fuel injector clogging leading to rough idle or power loss.

Electrical Problems:

Aging wiring harnesses, sensor failures (e.g., TPS, MAP), and alternator/starter motor wear.

📚 Vehicle History

Brand Heritage

Daihatsu Specialization:

Known for small, economical, and capable vehicles, particularly compact SUVs and city cars.

Model Evolution

Feroza Introduction:

Introduced in 1988 as the successor to the Daihatsu Taft, positioned as a compact, affordable off-roader.

Feroza Design:

Shared chassis and powertrain elements with the Daihatsu Rocky (Wildcat in some markets). Available in hardtop and soft-top variants.

Production

Production Years:

1988 – 2002

Manufacturing Locations:

Japan

🏆 Awards & Recognition

Recognitions

General Recognition:

While specific awards are not prominently documented, the Feroza was recognized for its ruggedness and affordability in the compact SUV market.