Daihatsu Charade G100 (GTTI) 1990 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Charade Generation: G100 Trim Level: GTTI Year: 1990 Codes Engine Code: CB 👋 Introduction Market Position Vehicle Segment: Subcompact hatchback, popular for its...

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Type: Car

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Sku: 558174

Tags: 1990 Car Cars Charade Charade G100 Daihatsu GTTI

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Description

🏷️ Basic Information

Identification

Make:

Daihatsu

Model:

Charade

Generation:

Trim Level:

Year:

Codes

Engine Code:

👋 Introduction

Market Position

Vehicle Segment:

Subcompact hatchback, popular for its sporty handling and affordability.

Target Audience:

Enthusiasts, DIY mechanics, and owners seeking to maintain or repair their G100 Charade.

Competitive Analysis

Competitors 1990:

Honda Civic, Toyota Corolla AE90 series, Nissan Sentra N13, Ford Festiva, Hyundai Excel.

Gtti Distinction:

The GTTI variant offered a performance edge with its turbocharged engine and sportier tuning, differentiating it from standard models.

Key Features

Performance Focus:

The GTTI model was specifically designed for enthusiasts, featuring a turbocharged engine and refined handling.

Diy Friendly:

The manual is presented as accessible for both professional mechanics and home enthusiasts.

Comprehensive Guide:

Provides detailed step-by-step instructions for a wide range of repair and maintenance tasks.

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Repair Manual

Language:

English

Format:

Digital (likely PDF, searchable text implied)

Page Count:

Estimated 400-600 pages (typical for comprehensive factory manuals of this era)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete disassembly, inspection, repair, and reassembly of the CB engine. Includes cylinder head, block, pistons, crankshaft, camshafts, valve train, timing belt/chain, oil pump, water pump.

Engine Management:

Fuel injection system (EFI), ignition system, emission control systems, sensor diagnostics, ECU troubleshooting.

Transmission:

Manual transmission (likely 5-speed) overhaul, clutch system, gearshift mechanisms.

Drivetrain:

Front-wheel drive system, CV joints, propeller shafts (if applicable), differential.

Brakes:

Front disc brakes, rear drum brakes (typical for the era), hydraulic system, parking brake, ABS (if equipped).

Suspension:

Front MacPherson struts, rear torsion beam or multi-link suspension, shock absorbers, springs, bushings, wheel alignment.

Steering:

Rack and pinion steering system, power steering system (if equipped), steering column.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), lighting system, fuse box, relays, wiring diagrams, body control modules.

Body And Chassis:

Body panel removal and installation, interior trim, door mechanisms, glass, underbody protection, structural components.

HVAC:

Heating, ventilation, and air conditioning system (if equipped), refrigerant handling, components.

Body Electrical:

Power windows, central locking, mirrors, wiper system, horn, warning lamps.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, air filter service.

Troubleshooting:

Systematic diagnostic procedures for common and complex issues, fault code interpretation (if applicable).

Component Replacement:

Step-by-step instructions for replacing individual parts and sub-assemblies.

Rebuilding Procedures:

Detailed instructions for complete overhaul of major components like engines and transmissions.

Adjustments:

Carburetor (if applicable for non-GTTI variant, but GTTI is EFI), ignition timing, idle speed, parking brake adjustment.

Installation:

Instructions for installing new or reconditioned parts and optional equipment.

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle systems.

Special Tools:

Identification and usage of specific tools required for certain procedures.

Technical Depth

Diagnostic Capabilities:

Advanced diagnostics for engine management, electrical systems, and mechanical components.

Repair Scope:

Covers everything from basic fluid changes to complete engine and transmission rebuilds.

Specifications Data:

Detailed torque specifications, clearances, tolerances, and fluid capacities.

Visual Aids:

Likely includes diagrams, illustrations, and exploded views to clarify procedures.

📊 Manual Specifications

File Format

Digital Format:

PDF (assumed for ease of distribution and searchability)

Searchability:

High (text-based PDFs allow for keyword searches)

Print Quality

Layout Clarity:

Designed for clarity, essential for technical repair information.

Illustrations:

Expected to be clear and informative, typical of factory documentation.

Binding Type

Digital Format:

N/A (digital download)

Paper Type

Digital Format:

N/A (digital download)

⚙️ Engine Specifications

Primary Engine

Engine Family:

Daihatsu CB Series

Engine Code:

CB-series, specifically the turbocharged variant for GTTI

Configuration:

Inline 3-cylinder, DOHC, 12 valves

Displacement:

993 cc (1.0 Liters)

Bore X Stroke:

70.0 mm x 86.5 mm

Performance

Aspiration:

Turbocharged

Horsepower:

Approximately 90-100 PS (varies slightly by market and specific tune)

Torque:

Approximately 120-130 Nm (varies slightly)

Compression Ratio:

Typically around 8.5:1 (for turbo variant)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline

Turbocharger Details:

Small-frame turbocharger, intercooled (typical for GTTI)

🔧 Transmission

Standard

Transmission Type:

5-speed Manual Transmission

Optional

Transmission Type:

3-speed Automatic (less common for GTTI, but possible)

Features

Clutch Type:

Hydraulically actuated single dry plate clutch

Gear Ratios:

Specific gear ratios will be detailed in the manual, crucial for performance tuning.

Fluid Type:

Manual Transmission Fluid (MTF), specific viscosity grade (e.g., GL-4 75W-90) detailed in manual.

📐 Dimensions

Exterior

Length:

Approx. 3,700 mm (G100 body)

Width:

Approx. 1,600 mm

Height:

Approx. 1,380 mm (may vary with suspension)

Wheelbase:

Approx. 2,300 mm

Weights

Curb Weight:

Approx. 750-850 kg (depending on specification)

Gross Vehicle Weight:

Details available in the manual.

🛡️ Safety Features

Ratings

Crash Test Data:

Limited publicly available formal crash test data for this specific model and year from major agencies like NHTSA/Euro NCAP; manual may contain manufacturer internal data.

Active Features

Optional on some GTTI variants, check specific vehicle. Manual would cover its function and diagnostics.

Passive Features

Seatbelts:

3-point front seatbelts, 2-point rear (typical for the era); manual covers adjustment and maintenance.

Crumple Zones:

Designed with energy-absorbing front and rear sections as per contemporary safety standards.

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM radio with cassette player. Manual would cover speaker replacement and head unit removal.

Driver Assistance

Cruise Control:

Rarely fitted on GTTI, typically an aftermarket addition. If equipped, manual would cover its system.

Connectivity

Auxiliary Input:

None present from the factory. Manual would not cover this.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 5,000 km or 6 months, but the manual will provide exact recommendations based on driving conditions. (Example: 5,000 km / 3,000 miles)

Air Filter Replacement:

Recommended at 10,000-15,000 km, or sooner if driving in dusty conditions. (Example: 10,000 km / 6,000 miles)

Spark Plug Replacement:

Typically 20,000-30,000 km for standard plugs, more for performance plugs. (Example: 20,000 km / 12,000 miles)

Timing Belt Replacement:

Crucial for this engine. Usually around 80,000-100,000 km or 5-7 years. (Example: 80,000 km / 50,000 miles or 5 years)

Fluid Specifications

Engine Oil Type:

API SG or higher. Viscosity grade likely 10W-30 or 10W-40, depending on climate. Manual will specify exact grade.

Engine Oil Capacity:

Approximately 3.0 - 3.5 liters with filter change.

Coolant Type:

Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Manual will specify OAT/HOAT requirements.

Brake Fluid Type:

DOT 3 or DOT 4, as specified by Daihatsu.

Known Issues

Turbo Wear:

Early turbocharger failure if not properly maintained (oil changes, cool-down periods). Manual covers inspection and replacement.

Timing Belt Failure:

Catastrophic engine damage if timing belt breaks. Regular replacement is critical. Manual emphasizes this.

Corrosion:

As with many vehicles of this era, rust can be an issue, particularly in the wheel arches, sills, and chassis. Manual may touch on body inspection.

Efi Component Issues:

Sensors (e.g., TPS, MAP) and fuel injectors can fail over time. Manual provides diagnostic procedures.

📚 Vehicle History

Brand Heritage

Daihatsu Reputation:

Daihatsu has a long history of producing small, economical, and reliable vehicles, often with innovative engineering.

Model Evolution

Charade Generations:

The G100 represents the third generation of the Daihatsu Charade, succeeding the G10/G20 and G25/G30 series. It was a significant redesign.

G100 Introduction:

Introduced in 1987, the G100 brought a more modern, rounded design and improved chassis dynamics.

Gtti Variant:

The GTTI variant, introduced later in the G100's lifecycle (around 1989/1990), was the performance flagship, powered by a turbocharged 1.0L engine.

Production

Manufacturing Location:

Primarily Japan, with potential assembly in other regions.

Production Years G100:

1987-1993

🏆 Awards & Recognition

Recognitions

Performance Awards:

While the GTTI itself may not have specific widely publicized awards, it was lauded in period reviews for its spirited performance relative to its size and class.

Ratings

Fuel Economy Ratings:

Excellent for its class, especially the non-turbo variants. GTTI still offered good efficiency due to its small displacement.