F300-GI-General_Information-Part1

F300-GI-General_Information-Part1.pdf

PART 1 - PART 2 - PART 3 - PART 4 - PART 5 - PART 6

DAIHATSU

GENERAL INFORMATION

1. IMPORTANT SAFETY NOTICE GI- 2 2. CHASSIS SERIAL NUMBER &

MANUFACTUREITS PLATE GI- 5 3. ENGINE NUMBER AND

ENGINE TYPE GI- 6 4. BODY COLOR INFORMATION GI- 6 5. VEHICLE 4-PLANE DIAGRAMS GI- 7 6. PERFORMANCE DIAGRAMS GI-11 7. SPECIFICATIONS GI-14 8. SUMMARY OF ENGINE

CONSTRUCTION GI-17 9. SUMMARY OF BODY AND OTHER

CONSTRUCTIONS GI-26 10. SUMMARY OF POWER TRAIN

CONSTRUCTION GI-34 11. SUMMARY OF CHASSIS

CONSTRUCTION GI-40 12. SUMMARY OF BODY ELECTRICAL GI-44

This Service Manual applies to those vehicles with the following chassis numbers onward and with the owner's manual F270-9008-E1, FG1, S1 or A1 fur- nished.

GENERAL INFORMATION

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 concerned properly. Furthermore. he must assume responsibility 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 and/or if 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 possibility of damage to the component being repaired if the operator fails to follow the operating prooedure prescribed in this manuai.

NOTE: To accomplish the operation in an efficient manner, additional instructions oonceming the operation are given in this section.

The following list describes general WARNINGS:

o Always wear safety glasses for eye protection. 0 Use safety stands whenever a procedure requires you to be under the vehicle. o Be sure that the ignition switch is always in the OFF position, unless otherwise required bythe

procedure. 0 Set the parking brake when working on the vehicle. 0 Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide. v Keep yourself and your clothing away moving parts, when the engine is running, especially

from the fan and belts. o To prevent serious burns, avoid contact with hot metal parts such as the radiator. exhaust

manifold, tail pipe, catalytic converter and muffler. 0 Do not smoke while working on a vehicle. o 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 to operate in anytime during the 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.

GENERAL INFORMATION

W 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 WARNWG

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 grinding brake linings drilling 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 safe 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.

DON’T blow dust out of brake drums or clutch housings with an airline. DO use properly designed drum cleaning equipment which prevents dust escaping 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 linings 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 a special vacuum cleaner to remove dust. DO wet dust thoroughly and scrape it up if you haven’t got a vacuum. DO wear the protective clothing, such as overalls, provided by your employer. DON’T take the protective clothing home. lt should be cleaned by your employer. DON’T use equipment if it is not main- tained and checked. Ask to see the examination reports for ventilation sys- tems.

GENERAL INFORMATION

1. VEHICLE MODELS

Model code

Destination Engine

. W. ..., Catalyzer canister

Fuel system

General HD-C

Canister (Only G.C.C.)

Carburetor

Europe HD-C

Carburetor

Europe HD-E

3-WAY Canister

Australia HD-E

3-WAY Canister

Note: (1) Electronic Fuel Injection

EXPLANATION OF VEHICLE MODEL CODE

F300RC-FMDEW

General specifications (GE) European specifications (EC) Australian specifications (AUS)

EFI-equipped engine Carburetor-equipped engine

Dx grade A EL grade

5-speed manual transmission

Resin Top Soft Top

Convenible

Left-hand drive Right-hand drive

:Vehicle mounted with HD engine

Daihatsu 4-wheel drive

GENERAL INFORMATION

2. CHASSIS SERIAL NUMBER &

MANUFACTUREFPS PLATE

FIRST CHASSIS SERIAL NUMBER

F300LC- FBOOLG

CHASSIS NUMBER & MANUFACTURER’S PLATE

1. Position

The chassis number is stamped on the crossmember at the front section of the vehicle. Manufacturer's plate is attached on the cowl panel.

2. Cantents of manufacturefs plate

Built date

00000

(1) General & Australian Specification

nm coue (2) European Specification Engine fwmbef

G ENERAL IN FORMATION

3. ENGINE NUMBER AND ENGINE TYPE

The gnging type and serjal number is stamped on the place |

The engine type and serial number is stamped on the place i as shown in the illustration. X( J

-A 3 s% /t /Seri

4. BODY COLOR INFORMATION

Serial number stamped posin' on

Stripe color

Red Gray M.

San Remo green/Grey M.

Body color l Daihatsu color code

Green Dark blue M. Black M. Red mica/silver M. Dark blue M./silver M Black M./silver M. White/silver M. White

Dark Gray Metallic

Silver Metallic

Dark Blue

Gray Metallic

A B C

Silver Metallic Dam l

ly Metallic

Gray Metallic Re

Red

COLOR CODE OF THE WORLD

COLOR & DUPONT l.C.| SPIES HECKER STANDOX

WHITE

16067

RED

GREEN

GRAY, M

168

DARK BLUE. M

BLACK. M

TWO TONE

NAS

TWO TONE

GENERAL INFORMATION

5. VEHICLE 4-PLANE DIAGRAMS

version: A (Resin top)

GENERAL IN FORMATION

Version: B (Soft top)

I LIES’

nde

Version: C (Soft top)

GENERAL INFORMATION

3820

GENERAL INFORMATION

Version: D (Soft top)

M I

3820

F300-GI-General_Information-Part1

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