Daihatsu Charade 1977-2000 CB Engine Workshop Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Charade Generation: G100/G101/G102 (Third Generation, 1987-1993) / G200/G201/G202/G203 (Fourth Generation, 1993-2000) Engine Code: CB series (CB23, CB23E, CB50, CB50E, CB60, CB60E, CB90, CB90E,...

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Type: Car

Vendor:

Sku: 566285

Tags: 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 Car Cars Charade Daihatsu Wiring Diagrams

Product variants

Description

🏷️ Basic Information

Identification

Make:

Daihatsu

Model:

Charade

Generation:

G100/G101/G102 (Third Generation, 1987-1993) / G200/G201/G202/G203 (Fourth Generation, 1993-2000)

Engine Code:

CB series (CB23, CB23E, CB50, CB50E, CB60, CB60E, CB90, CB90E, CB100, CB100E, CB110, CB110E, CB120, CB120E, CB200, CB200E, CB210, CB210E, CB220, CB220E, CB230, CB230E)

Codes

Market:

Global (including Japan, Europe, North America, Asia)

👋 Introduction

Market Position

Segment:

Subcompact car, city car

Target Audience:

DIY mechanics, owners seeking to maintain and repair their Daihatsu Charade, automotive enthusiasts.

Competitive Analysis

Competitors:

Honda Civic, Toyota Corolla, Nissan Sentra, Mitsubishi Mirage, Suzuki Swift, Ford Fiesta, Opel Corsa.

Key Features

Manual Value:

Provides factory-level information at a fraction of the cost of dealership repairs, empowering owners to perform extensive maintenance and repairs.

Illustrations:

Detailed illustrations, diagrams, and wiring schematics are integral to the manual's clarity and usefulness.

Step By Step Instructions:

Numbered, detailed steps ensure accuracy and prevent errors during repair procedures.

📋 Manual Details

Coverage Areas

Coverage Years:

1977-2000

Covered Generations:

All generations equipped with CB series engines

Page Count

Estimated Page Count:

Approximately 1500-2500+ pages (typical for comprehensive FSMs of this era)

Manual Type

Type:

Factory Service Manual (OEM-FSM)

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, cylinder head, crankshaft, pistons, connecting rods, camshafts, timing system, oil pump, oil pan, seals, gaskets, torque specifications.

Engine Management:

Fuel injection systems (MPI, DPFI), carbureted systems, ignition systems (distributor, distributorless), sensors (MAP, TPS, O2, ECT, Knock), actuators, ECU diagnostics.

Cooling System:

Radiator, water pump, thermostat, coolant hoses, cooling fan (electric/mechanical), temperature control, specifications.

Fuel System:

Fuel tank, fuel pump, fuel lines, fuel filter, fuel injectors, fuel pressure regulator, carburetor (if applicable), evaporative emission control (EVAP).

Emission Controls:

PCV system, EGR system, catalytic converter, secondary air injection, evaporative emissions.

Transmission Transaxle:

Manual transmission (M/T) and Automatic transmission (A/T) service, clutch operation, gearbox overhaul, shift linkage, torque converter, transmission control units.

Driveline:

Front-wheel drive (FWD) system, CV joints, drive axles, differential service.

Suspension:

Front suspension (MacPherson struts), rear suspension (coil springs, leaf springs depending on model), shock absorbers, springs, control arms, ball joints, bushings, alignment specifications.

Steering:

Steering column, steering rack/gearbox, power steering system (if equipped), tie rods, steering linkage, specifications.

Brakes:

Front disc brakes, rear drum/disc brakes, brake master cylinder, brake lines, brake fluid specifications, ABS system (if equipped), parking brake.

Electrical:

Wiring diagrams for all systems, fuses, relays, lighting (headlights, taillights, interior), power windows, mirrors, locks, horn, wipers, washer system.

Instrumentation Warning Systems:

Instrument cluster, gauges (speedometer, tachometer, fuel, temp), warning lights, diagnostic trouble codes (DTCs).

HVAC:

Heating, ventilation, and air conditioning (HVAC) system, blower motor, heater core, A/C compressor, refrigerant, system charging, controls.

Body Interior Exterior:

Body panels, doors, hood, trunk lid, bumpers, trim, interior components, seats, upholstery, glass, weatherstripping.

Starting Charging System

System:

Starter motor, starter solenoid, battery, alternator, voltage regulator, wiring diagrams, testing procedures.

Procedures Included

Maintenance:

Oil changes, filter replacements, spark plug replacement, coolant flushes, brake fluid changes, belt adjustments/replacements, lubrication points.

Troubleshooting:

Diagnostic procedures for engine, transmission, electrical, and other systems; fault code interpretation; symptom-based troubleshooting guides.

Repair Rebuild:

Detailed step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation of major and minor vehicle systems.

Diagnostics:

Component testing, electrical circuit testing, fuel system pressure testing, emission control system testing, scanner data interpretation (for later models).

Specifications:

Torque specifications, fluid capacities, fluid types, clearances, pressures, electrical specifications, diagnostic values.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance and adjustments to complete engine and transmission rebuilds, including detailed electrical troubleshooting.

📊 Manual Specifications

File Format

File Type:

Requirements:

PDF Reader (e.g., Adobe Acrobat Reader)

Print Quality

Printability:

Printable (allows users to print specific sections or the entire manual)

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Quality:

N/A (Digital PDF)

Features

Navigation:

Likely includes internal hyperlinks for easy navigation between sections and topics, bookmarking capabilities.

Searchability:

Text-searchable PDF allows users to quickly find specific terms, part numbers, or procedures.

⚙️ Engine Specifications

Primary Engine

Engine Family:

CB Series (3-cylinder and 4-cylinder, SOHC and DOHC)

Displacement Range:

1.0L (993cc) to 1.6L (1590cc)

Performance

Horsepower Range:

Approximately 55 hp to 110 hp (depending on specific engine variant and tuning)

Torque Range:

Approximately 70 Nm to 140 Nm (depending on specific engine variant)

Fuel System

Fuel Delivery:

Carburetor (early models), Multi-Point Fuel Injection (MPI), Dual Point Fuel Injection (DPFI) (later models).

Fuel Type

Fuel:

Unleaded Gasoline

🔧 Transmission

Standard

Transmission Type:

5-speed Manual (M/T)

Optional

Transmission Type:

3-speed Automatic (A/T) or 4-speed Automatic (A/T) depending on generation and market.

Features

Drive:

Front-Wheel Drive (FWD)

📐 Dimensions

Exterior

Body Styles:

3-door hatchback, 5-door hatchback, 3-door hatchback coupe (G100), 3-door van (commercial variants).

Weights

Curb Weight:

Approximately 750 - 950 kg (depending on configuration)

🛡️ Safety Features

Ratings

Crash Test Data:

Limited official safety rating data for earlier models; later models would have incorporated improvements based on evolving safety standards.

Active Features

Braking System:

Front disc brakes, rear drum brakes standard; optional ABS on some higher trims/later models.

Passive Features

Restraints:

Seat belts, optional driver/passenger airbags on later models.

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM radio, cassette player; optional CD player on later models. Manual covers wiring and speaker systems.

Driver Assistance

Available on select models and trim levels, primarily on later generations.

Connectivity

Power Features:

Power windows, power door locks, power mirrors were optional on higher trims and later models; covered in the electrical section.

🔧 Maintenance

Service Intervals

Oil Change:

Typically every 5,000 - 7,500 km or 6 months, whichever comes first (consult specific model year for exact recommendations).

Spark Plugs:

Replace at approximately 30,000 - 40,000 km or as per manual recommendation.

Timing Belt:

Crucial to replace at specified intervals (e.g., 80,000 - 100,000 km) as these are interference engines; failure can cause severe engine damage.

Fluid Specifications

Engine Oil:

API SG or higher, SAE 10W-30 or 10W-40 recommended (refer to manual for exact viscosity and capacity).

Coolant:

Ethylene glycol based antifreeze, mixed with distilled water (typically 50/50 ratio). Specific coolant type and capacity should be checked in the manual.

Transmission Fluid Mt:

API GL-4, SAE 75W-90 or 80W-90 gear oil (check manual for specific type and capacity).

Transmission Fluid At:

Dexron II or equivalent (check manual for specific type and capacity).

Brake Fluid:

DOT 3 or DOT 4 brake fluid (check manual for exact specification).

Known Issues

Engine Wear:

Oil consumption, piston ring wear, potential head gasket issues on higher mileage engines.

Cooling System:

Thermostat failure, water pump leaks, radiator corrosion.

Ignition System:

Distributor issues (early models), coil pack failure (later models), spark plug wire degradation.

Suspension:

Worn ball joints, tie rod ends, and bushings leading to steering looseness and alignment issues.

Electrical:

Aging wiring harnesses, corrosion in connectors, alternator or starter motor failure.

📚 Vehicle History

Brand Heritage

Manufacturer:

Daihatsu Motor Co., Ltd., a subsidiary of Toyota Motor Corporation.

Model Evolution

Generations:

The Charade has gone through several generations, with the CB engine being prevalent in the G100/G101/G102 (1987-1993) and G200/G201/G202/G203 (1993-2000) series.

Production

Production Period:

1977 - 2000 (for the specific models covered by this manual).

🏆 Awards & Recognition

Recognitions

Market Reputation:

Known for its fuel efficiency, compact size, and reliability, often regarded as a sensible and affordable city car.