DAIHATSU F70,F75,F77 Service manual GENERAL INFORMATION DAIHATSU MOTOR Co., LTD. NO.9703-FEDAIHATSU F70,F75,F77 GENERAL INFORMATION 1. MODEL VARIATION 2, CHASSIS SERIAL NUMBER Ge 4 ‘STAMPED POSITION .. Gh 5 3. MANUFACTURER'S PLATE POSITION Ges - . ENGINE NUMBER AND ENGINE TYPE ‘STAMPED POSITIONS . BODY COLOR INFORMATION |. VEHICLE 4-PLANE DIAGRAMS: PERFORMANCE DIAGRAMS .. . SPECIFICATIONS .. ). SUMMARY OF ENGINE CONSTRUCTION ... 10. SUMMARY OF BODY AND OTHER CONSTRUCTIONS 11. SUMMARY OF POWER TRAIN CONSTRUCTION 12, SUMMARY OF CHASSIS CONSTRUCTION ... 13. SUMMARY OF BODY ELECTRICAL G6 Gl- 6 Gh 8 Ghia GHI6 fanaa we GLAD This Service manual applies to those vehicles with the following chassis numbers anwar ‘and with the owner's manual F215-9011-E1, FGi, St or Af tumiahed, ‘JDADOF70000645700 ‘JDAQOF7S000847032 ‘JDAQOF77000500689 or 00003789 © 1991 DAIHATSU MOTOR Co, LTD. Al rights reserved. This materia! may not be reproduced of copied, in whole or in part, an without the writen permission of Daihaisu Motor Co,, Lt. reo 001GENERAL INFORMATION IMPORTANT SAFETY NOTICE The vehicle is a machine comprising a great number of parts. Basically speaking, the vehicle is potentially hazard. However, one can handle it safely if he has the required knowledge. Correct service methods and repair procedures are very vital for assuring not only the safety and reliability of a vehicle, but also the safety of service personnel concerned. The methods and procedures contained in this manual describe in a general way the techniques which the manufacturer has recommended. Thus, they will contribute to ensuring the reliability of the products. The contents of the servicing operations come in a wide variety of ways. Moreover, techniques, tools and parts necessary for each operation are different widely from each other. This manual does not cover all details of techniques, procedures, parts, tools and handling instructions which are necessary for these operations, for such coverage is impossible. Hence. any ‘one who obtains this manual is expected first to make his responsible selection as to techniques, tools and parts which are necessary for servicing the vehicle concemed properly. Furthermore, he must assume responsibilty for his actions in connection with his own safety. Therefore, one should not perform any service if he is not capable of making responsible selection andor it he can not understand the contents herein described, for this manual has been prepared for experienced service personnel WARNINGS, CAUTIONS AND NOTES All these symbols have their specific purposes, respectively. WARNING: * This symbol means that there is a possibility of personal injury of the operator himself or the nearby workers if the operator fails to follow the operating procedure prescribed in this, manual. CAUTION: + This symbol means that there is a possibilty of damage to the component being repaired it the operator fails to follow the operating procedure prescribed in this manual. NOTI * To accomplish the operation in an efficient manner, additional instructions concerning the operation are given in this section. The following list describes general WARNINGS: Always wear safety glasses for eye protection. Use safety stands whenever @ procedure requires you to be under the vehicle. Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure. ‘Set the parking brake when working on the vehicle. Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide. Keep yourself and your clothing away moving parts, when the engine is running, especially from the fan and belts. To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. Do not smoke while working on a vehicle. To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle. Keep hands and other objects clear of radiator fan blades! The electric cooling fan is mounted on the radiator and can start to operate at any time by an increase in underhood temperature. The electric cooling fan is also mounted on the condenser for air conditioner and start 1o operate in anytime during air conditioner switch “ON". For this reason care should be taken to ensure that the electric cooling fan motor is completely disconnected when working under the hood. Gl2GENERAL INFORMATION = OOOO /"rr—errr vere YOU SHOULD OBSERVE THE FOLLOWING WARNING WHEN WORKING ON THE VEHICLE AS LAID DOWN BY THE HEALTH AND SAFETY EXECUTIVE. ‘THE DANGER ‘Some vehicle parts contain asbestos. Working with them can create dust. Breathing this dust is harmful. Cases of asbestos related cancer have been reported in garage workers. The dangerous jobs are’ cleaning brake assemblies cleaning clutch housings gtinging brake linings iriling brake linings. sweeping floors Brake and clutch linings and disc pads may contain asbestos. If In doubt assume that they do, WHO IS AT RISK? Anyone in the garage could be at risk. There is no known sate level of asbestos dust. But the more dust you breath, the greater the chance of lung damage. The problem is that the dust particles are too small to be seen by the naked eye. And the diseases caused can take years to develop. Don't put the brakes on your life. Avoid breath- ing asbestos dust. Prevent dust getting into the air, Follow the WARNING. WARNING 1. DON'T blow dust out of brake crums or clutch housings with an airline. 2. DO use property designed drum clean- ing equipment which prevents dust es- caping or Use clean wet rags to clean out drums or housings, Put used rags in a plastic waste bag while still wet, DON'T grind or drill inings unless the machine has exhaust ventilation or there is a ventilated booth to do the work in, . DON'T use brushes to sweep up dust . DO use @ special vacuum cleaner 10 remove dust. . DO wet dust thoroughiyand scrape it up if you haven't got e vacuum. . DO wear the protective clothing, such as overalls, provided by your employer. DON'T take the protective clothing home, It should be cleaned by your employer. DONT use equipment if it is not main- tained and checked. Ask to see tho ox- amination reports for ventilation systems.GENERAL INFORMATION 1. MODEL VARIATION Market ‘Australia Mose! Gra Dx BHD From a0a THO BHD HO FracvnaTe| RHD THD Lo Fro uorw RAD FAVED no FroUv-BD Wagon FrLvor of Fre woop RHO. FanewanT [rrsavatsors Tao aLvNaDT| [ranean Soft Frshh Too FSR FTL FRR FTAA Pick TAD | FPP FrTLMP RAD | F7a-PRo Fras chass LAD | ALR —__1__ __ij Ww) Grade Root type Transmission specifications cheats Body specifications Staering wheel pasiton emul Venicle model IPTION OF VEHICLE MODEL CODE Vehicle Specifications Non: General market Mode! O: Australian market Modal W: European market Model T: With turbo R: STD D: Dx HEL P. Pickup B. Resin top (ote: No mark for cools othor than resin top) M: S-speed Non: 4-speed ¥: Hare top Non: Soft top. Pickup Fr Right hand drive L: Left nana drive 70: with DL engine: Short wheel base 75. with DL engine; Long wheel base 77. with DL engine: Pick-upGENERAL INFORMATION 2. CHASSIS SERIAL NUMBER STAMPED POSITION Der ped on the right side member of 3. MANUFACTURER’S PLATE POSITION ‘acturer’s plate is attached on the cowl panel. CONTENTS OF MANUFACTURER'S PLATE (1) General & Australian Specification {DAIHATSU MOTOR CO. LTD. JAPAN type(TTTTITCTIey cuss WoT TTT @-} ENGI LLL ) ,coLorCLI ible front axle weight ium permissible rear axle weight ® Production month-year. (Only for AUS GisGENERAL INFORMATION 4. ENGINE NUMBER AND ENGINE TYPE STAMPED POSITIONS The engine number and serial number is stamped on the place ‘as shown in the illustration, Center of left side Place where of cylinder block engine number samped 5. BODY COLOR INFORMATION Wa olor i Two ane olor Coe Wie O88 Black MetalicfGrey Metalic TS (EAST Red ‘3E7 Dark Blue Metallic/Grey Metallic 26L (864/168) Green os Fed Mica MetalicfGrey Metalic 25 (91/69) Dark Blue Metalic ace Grey Meaic 168 Black Metalic sae smesia0n 5-1. COLOR CODE IN THE WORLD COLOR One) owrsa) AKZO DUPONT (|__| SPES HECKER | _STaNDOX [were as | _Davous 887 wwe0 16067 045 RED 3e7 DAH3E7 68690 KK26 38299 27 GREEN | Gos DAHGOS | G8691 Kv77_ 68470 GOS DARK BLUE METALLIC | @G4 | DARBGa 9131 caa7e 7300 ace GREY METALLIC 168 DAH168 N8832 89368 97728 | BLACK METALLIC | 6a5 | OARBAS carae 4008 s7a06 as TWO TONE Nas | DAHNAS | araaneese | Aanae@esee | ovecne77es | Nas TWO TONE ae | Danes. | Keisimesse | Cas7ereeaes | ereoam77s | 26: TWO TONE as_[ banast | caraomess2 | Pcecareeaes | ereaoe77e5 | 25: waren GiteGENERAL INFORMATION e 5-2. BODY STRIPE INFORMATION Along with theVersion: B (F70-Soft top) \ | SS } esl Tm Woe te GENERAL INFORMATIONGENERAL INF ‘ORMATION Version: 6 (F2SV-Wagon} @ (eetoleee (\ {i ii as} | | |g if | lal es it (ie‘GENERAL INFORMATIONGENERAL INFORMATION@ 7. PERFORMANCE DIAGRAMS Frov FTORV-MRQ_ 258/70-15 GENERAL INFORMATIONeee GENERAL INFORMATION | Frsv | FISLV.MBHTW. 255770R15 Gii4GENERAL INFORMATION @ [- FITL-PR 215/R15GENERAL INFORMATION 8. SPECIFICATIONS e 8-1. PRE-DELIVERY INSPECTION SPECIFICATIONSGENERAL INFORMATION 8-2. VEHICLE SPECIFICATIONS Specifications el, ining 4 Diesel, Tura charged, é cycle, in-ine ¢ ambustan cher Jeon timing Value machaniem ENGINE Open [Coxe pan | Max. output nom fulton, DIN ‘outpal torque ‘Manual, 407 & forward sp TaaesassinSENERAL INFORMATION AME SUSPENSION F = Rear Type TEERING | Over all gear ral Tye mergency brake sys Hi hanical Dis, ventilate ;cuum booster with vacun Dual hydraulic cir ‘and operationGENERAL INFORMATION 9. SUMMARY OF ENGINE CONSTRUCTION 9-1. INTERCOOLER TURBOCHARGER (DL-52 Engine) The turbocharger is equipped with an air-cooled intercooler, thereby increasing the maximum horsepower and torque output P.C.S. (Power Control System) Ist gear 2 of the air pr is 300 mmHg, par ie by-passed n: 2nd gear to 5th gear + If the supercharging in excess of the specified level is likely to take place, the waste gate valve opens to release the pressure so as to prevent excessively high supercharging,GENERAL INFORMATION 9-2, ENGINE SECTIONAL VIEWS Type DL-42 engineGENERAL INFORMATION Type DL-52 engine sal LeGENERAL INFORMATION 9-3. COOLING SYSTEM In accordance with the employment of the water-cooled turbocharger, the radiator construction has been changed. The radiator reservoir tank has been modified in its shape. Furthermore, the reservoir tank is now attached to the radiator. (DL-52 Only) Radiator reservoir tank Tao Modification has been made so that the bearing of the turbocharger is now cooled by the engine cooling water. } Drain cock (Cylinder block)GENERAL INFORMATION 10. SUMMARY OF BODY AND OTHER CONSTRUCTIONS 10-1. BASIC DESIGN r ‘< sleiaionibal _ SOFT TOP. = (Short & Long) PICKUP Exterior viewGENERAL INFORMATION 10-2. EXTERIOR MODIFICATION jesign with a wider top. been adapted to give the Ro: re tyre posit 30 mm | combina visibility and (4) Electrically oper. is available for optional equipmen board 10-3. INTERIOR MODIFICATION 3-point ELR rear seat belts are availab model (F75L(R)V) for optional. Wher led, the seat back with armr a large seat back without armre: qo] sme |4 noise. formerly standard in the European markets exc ickup models in now standard on 3) In keeping w the intercooler turbocharger modified to include an INTER: skeleton-typ h raints ered, full form type. moved to the rear wheel ), GENERAL INFORMATIONGENERAL INFORMATION 10-5. INTERIOR VIEW —_ Interior View For LH. Drive VehicleGENERAL INFORMATION © [rion we (B: |GENERAL INFORMATION 10-6. PARTS WHERE GALVANIZED STEEL SHEETS ARE USED ; a a eaterGENERAL INFORMATION @ Continues ___ : = —_= @ Bracket, front fender rear lower F/ ® Suppor, apron fe @ Reinforcement, dash to flo ® Panel, cow top outer BOO @ Panel, cow top o. PeSeey eee) eeceeeeGENERAL INFORMATION (Continued — Pickup model)GENERAL INFORMATION @ 10-7. BODY MOUNTSGENERAL INFORMATION (Continued — Pickup model) Front Body Gi-32GENERAL INFORMATION 11. SUMMARY OF POWER TRAIN CONSTRUCTION 11-1. TRANSMI: jer and more quiet shifting. The 5 prevent direct shifting from the Sth to wo speeds gear ratio, high and low with mechanical shifting or power shifting 4 Speed transmissionGENERAL INFORMATION 11-2. POWER SHIFT MECHANISM The shift from the two-wheel drive to the four-wheel drive and vice versa can be performed by me power shift switch which utilizes a negative pre: tuator, The negative pressure been generate he vacuum pump is transmitted to a diaphragm uator provided inside the transfer case. Consequently, the thrust generated by the actuator is transmitted directly to the drive shift fork shaft. In this way, the shift from the two-wheel drive to the four-wheel drive and vice versa is performed. This device is available as optional equipment with 5-speed transmission Power switch operation drive, high speed range he transfer shift lever into 2H position and turn OFF ower switch. 4-wheel drive, high speed rar Shift the transfer shift lever into 2H pi the power switch 4L: 4-wheel drive, low speed range Shift the transfer shift lever into 4L position. even if the turn ON the power switch, do not operate to shift 4H.GENERAL INFORMATION (2) Operation diagram (4) Description High s eed range (2H) ‘A negative pressure is applied to the chamber B of the actuator thro the atmospheric pre Cor gh the VSV No. 1. At this stage, ure is applied to the chamber A of the actuator from the VSV No. 2. applied to the diaphragm, the front drive shift m will be shifted to the four-wheel drive side equently, because of the difference in pressure being hich is connected directly to the diaphi eed range (4L) The negative pressure is transmitted in the as with cases where transfer shift lever is in the Position with the power h turned ON. Since the low switch is tured ON, the VSV No. 2 is OFF ss of the shift switch. As a result, the vehicle is driven on the e of the wheel drive.GENERAL INFORMATION 11-3. AUTOMATIC LOCKING HUB (ALH) (1) Objective of setting The ALH is set for improving the switching o ity from the conventional manual free whee Namely, the ALH is capable of automatic switching by just starting the car while the free to be done manually in the manual free wheel hub. The ALH is mounted the same position as the manual free wheel hub. (2) Outline of structure | | 7) Ti | { ) (j | | | ey SSB Major differences with manual free wheel hub (Assembly parts) (i )A bearing lock nut @is providec )A brake drum ( is not required.) (iii )@and ®are tightened and fixed by t (iv) A knock pin @is se the All of @- are ALH d parts, (V ) Drive shaft is also reguired for automatic locking hub, w m manua 9 locking hub, Gi-36GENERAL INFORMATION @ 2), eration methoa FREE —> LOCK 1. Stop the car and ct ge the T/F to 4WD. iding the steering whee! aight forward tr m or more, and the system will lock automatically 2. Start the car slowly hi 3. Run about lin LOCK ~ FREE top the car and change the T/F to 2WI k up the car slowly holding the steering wheel in a Run about 3 m or more, and the system become free automat Notes 1. It doesn't matter whether forward or backward, 2. Strictly speaking, start the car in the opposite direction to the direction of travelling just before changing the T/F to 2WD. t forward travelling cc cally (4) Operating principle FREE — LOCK g 1. When the car is started after changing the T/F to 4WD, the i i drive shatt ® turns to turn the inner @ and the cam follower iI. @as or d |] f 2. The brake drum ®, which is fixed to another part (bearing > ae lock nut), does not turn. The brake sub-assembly @ is c 2 og suppressed from turning by the frictional force with @. @, 1 > which is engage law of ©, is also suppressed 2 ——F from turning \ 3 sult, G cline of © while turning to dev 8 @ to the right-hand side, the clutch © attach oring ® also moves to engage the — nner teeth to lock t + When locked, @ starts tuning to slide along the frictional face of ©GENERAL INFORMATION LOCK — FREE When the car is backed up after changing the T/F to 2WD, the system is driven backward from the wheel side to turn @, © and the hub joint @, @ backward as one. (@ and @ also turn as one until unlocked.) @, which is pressed ont 1e of @ by the return spring @, goes down the cam incline of @ to move to the left-hand side iagram. 3. moves to the Pulled to the left-hand side by @ to free the system, Cautions on user handling [ - In the event of ratcheting, stop the car c nge't WD, and then star ar ¢ ¢ Avoidance of Ratcheting The gear noise that occurs when the clutch and the housing a \ | are about to lock while there is a difference between the } t Prevention of T/F Operation during Travelling Ratcheting x | Dccurs if the T/F is shifted 2WD -» 4WD by mistake while ‘ travelling with the T/F a \d the ALH free 0 In that case, take the disposition ¢ bservance of Straight Forward Starting at ALH Change nen changing the ALH free « lock, hold the steering wheel in a straight forward travelling condition and run pout 3m or more. (If the steering wheel is turned before running a minimum of 3 m, one of the ALH’s on both sides locks while the othe ting.) Gi-s8GENERAL INFORMATION 12. SUMMARY OF CHASSIS CONSTRUCTION 12-1. FRONT AXLE 12-2, REAR AXLEGENERAL INFORMATION 12-3. FRONT SUSPENSION ‘or greater riding comfort ant bilizer, lateral control rods gas-loaded shock absorbe! safety, the front suspension features s 12-4. REAR SUSPENSIONGENERAL INFORMATION 12-5, THREE-STAGE DAMPERS The three-stage dampers al hing the damping force of the shock absorb ing on the road and traveling conditions. It is used in the F70 and F75 as optional equipment. The dampers are operated from the switch in the center console box. OFT end ‘ontrol rod and the shaft align with each other. This increases the 1d, decreasing the damping force. amount of gas whic (2) NORMAL Only one of the two hole align, increasing the damping force to the medium level. (3) HARD Both of the holes are ut of alignment, maximizing the damping force. The damping force is gen valve section ated Condition of gas holes | i | 4 or . afiGENERAL INFORMATION 12-6. FRAMENRE nnn GENERAL INFORMATION e 12-7. BRAKE (1) Brake line The brake line com« icles and the other for the L.H.D. vehicles. 1 all models, the dis: provided at the front wheels, while the drum brake is installed at the rear wheels The rear brake systems are operated through a proportioning valve on General market, a by. valve on AUS and EC market 1g proportioning valve for F77 model. General market RHO (F70/F75) General market LHD (F70/F75) © All market | HD (F77) Worm p41 |GENERAL INFORMATION EC, AUS market RHD (F70/F75) EC market LHD (F70/F75)GENERAL INFORMATION ff the brake fluid nd maintaining casting. The reservoir is a sealed type which s with the diaphragm, thus preventing the fluid from deterior city for long periods of time. high braki Master cylinder specifications e@ Cylinder bore mm Front 185 roke Mes | 2 15 Front cee 14 Reserve tank oa "3 | (Comm fea ' and rearGENERAL INFORMATION 13. SUMMARY OF BODY ELECTRICAL 13-1. FUSE BLOCK & FUSIBLE LINK he fuse block fe of the driv le. Blade type ve been employe the right and left headlamps in order that the load for the instrument panel at the driver’ LHD/European spec. ‘Sub fuse blockGENERAL INFORMATION e 13-2. FUSE CIRCUIT (1) — a _ By [READ FA ; He ( Beam indicatoGENERAL INFORMATION FUSE CIRCUIT (2) r | CIGARETTE] +) LIGHTERGENERAL INFORMATION @ _ USE CIRCUIT (3) (Only for LHD European spec.) [ in [ Alternator ( { Wottage regulator 6 TAIL (LH) 10A 1GENERAL INFORMATION 13-3. INSTRUMENT PANEL Asi mn a f, warnin a in @ combination meter, and volt Triple meter tars waring| [x HAZARD ] on za = ve) | pai z - e (DD Pann tna