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Daihatsu Charade G200 1996 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Charade Generation: G200 Year: 1996 Codes Chassis Code: G200 👋 Introduction Market Position Segment: Subcompact hatchback Target Audience: Budget-conscious commuters, first-time car buyers,...
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Daihatsu Charade G200 1996 Factory Service Repair ManualDaihatsu Charade G200 1996 Factory Service Repair ManualDaihatsu Charade G200 1996 Factory Service Repair ManualDaihatsu Charade G200 1996 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Charade
Generation:
G200
Year:
1996
Codes
Chassis Code:
G200
👋 Introduction
Market Position
Segment:
Subcompact hatchback
Target Audience:
Budget-conscious commuters, first-time car buyers, DIY enthusiasts.
Competitive Analysis
Key Competitors:
Honda Civic, Toyota Corolla, Ford Escort, Mitsubishi Mirage, Suzuki Swift.
Key Features
Value Proposition:
Affordability, reliability, fuel efficiency, compact maneuverability.
Distinguishing Factors:
Daihatsu's reputation for robust and economical small cars, often featuring simple yet effective engineering.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Manual
Language:
English
Format:
PDF (Digital Download)
Page Count:
Estimated 600+ pages (typical for this era's comprehensive factory manuals)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system (injection/carburetion), cooling system, exhaust system, lubrication system, engine management (ECU, sensors, ignition).
Transmission:
Manual transmission (MT) service, Automatic transmission (AT) service, clutch system, drive axles, differentials.
Chassis:
Suspension systems (front and rear), steering system, brake system (front disc/rear drum or disc, ABS if applicable), wheels, tires, chassis lubrication.
Electrical:
Wiring diagrams, starting and charging system, lighting system, instrumentation, audio system, power windows, mirrors, wipers, horn, fuses, relays, ECU pinouts.
Body:
Body panels, doors, windows, locks, interior trim, exterior trim, bumpers, seats, safety restraints (airbags if equipped), HVAC system (heating, ventilation, air conditioning).
Procedures Included
Routine Maintenance:
Oil change, filter replacement, fluid checks and top-offs, spark plug replacement, belt inspection and adjustment, tire rotation.
Troubleshooting:
Diagnostic charts for common symptoms, fault code interpretation (OBD-I/II if applicable), component testing procedures.
Repair And Rebuild:
Engine overhaul, transmission overhaul, brake caliper rebuild, suspension component replacement, steering rack replacement, AC system service.
Component Replacement:
Detailed steps for replacing starters, alternators, radiators, water pumps, fuel injectors, sensors, body panels, interior components.
Specifications And Tolerances:
Torque specifications for all fasteners, engine component clearances, suspension alignment specifications, brake pad thickness, tire pressures.
Technical Depth
Depth:
Comprehensive. Covers everything from basic preventative maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures and electrical system troubleshooting.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable:
Yes (fully text-searchable)
Print Quality:
High-resolution scans, suitable for printing individual pages or the entire manual.
Binding Type
Binding:
Digital Download (no physical binding)
Paper Type
Paper Quality:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Code:
CB23 (most common)
Engine Type:
Inline 3-cylinder, SOHC, 12-valve
Displacement:
1.3 Liters (1300 cc)
Bore X Stroke:
70.0 mm x 84.5 mm
Compression Ratio:
9.5:1
Performance
Horsepower:
Approx. 82 PS (60 kW) @ 6000 rpm (varies slightly by market/tuning)
Torque:
Approx. 106 Nm (78 lb-ft) @ 3600 rpm (varies slightly)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (Octane rating as per manufacturer recommendation)
Ignition System:
Electronic Ignition (Distributor-based or Distributorless Ignition System - DIS depending on specific model)
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual Transmission (5MT)
Optional
Transmission Type:
3-Speed Automatic Transmission (3AT)
Features
Clutch:
Hydraulically operated dry single-plate clutch (for MT)
Gear Ratios:
Specific ratios detailed within the manual, crucial for performance and economy tuning.
Transmission Fluid:
Manual: API GL-4 SAE 75W-90 or SAE 80W-90. Automatic: Dexron III equivalent.
📐 Dimensions
Exterior
Length:
Approx. 3700 mm (145.7 in)
Width:
Approx. 1600 mm (63.0 in)
Height:
Approx. 1385 mm (54.5 in)
Wheelbase:
Approx. 2300 mm (90.6 in)
Track Width Front:
Approx. 1350 mm (53.1 in)
Track Width Rear:
Approx. 1355 mm (53.3 in)
Weights
Curb Weight:
Approx. 830-900 kg (1830-1984 lbs) depending on equipment.
Gross Vehicle Weight Rating:
Refer to vehicle's compliance plate; typically around 1250 kg.
Cargo
Cargo Volume:
Configurable with rear seats folded; specific figures not readily available but typical for class.
🛡️ Safety Features
Ratings
Crash Test Data:
Limited independent crash test data available for this specific model/year. Expected to be basic by modern standards.
Active Features
ABS:
Optional on some higher trims, not standard.
Traction Control:
Not typically available.
Passive Features
Airbags:
Driver's airbag often standard, passenger airbag optional or absent depending on market and trim.
Seatbelts:
Front: 3-point ELR; Rear: 2-point lap belts (center) and 3-point belts (outboard) depending on seating position.
Body Structure:
Crumple zones, reinforced passenger compartment. Specific structural details covered in manual.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with cassette player, often with 2-4 speakers. Aftermarket upgrades are common.
Climate Control:
Manual HVAC system (heater, fan, A/C if equipped), basic rotary or slider controls.
Driver Assistance
Cruise Control:
Optional on higher trim levels or specific market versions.
Parking Assistance:
No factory-installed parking sensors or backup cameras.
Connectivity
Bluetooth:
Not available from factory; requires aftermarket installation.
Usb Ports:
Not available from factory; requires aftermarket installation.
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, whichever comes first. Refer to manual for specific conditions.
Air Filter Replacement:
Every 15,000-20,000 miles (24,000-32,000 km).
Spark Plug Replacement:
Every 30,000-50,000 miles (48,000-80,000 km), depending on plug type (standard vs. platinum).
Timing Belt Replacement:
Crucial for this engine. Recommended every 60,000-90,000 miles (96,000-144,000 km) or 4-5 years, as failure can cause catastrophic engine damage (interference engine).
Fluid Specifications
Engine Oil Capacity:
Approx. 3.5 - 3.7 Liters (3.7 - 3.9 US Quarts) with filter change. Refer to manual for exact amount.
Coolant Capacity:
Approx. 5.0 Liters (5.3 US Quarts). Use a 50/50 mix of ethylene glycol coolant and distilled water.
Brake Fluid Type:
DOT 3 or DOT 4.
Power Steering Fluid:
If equipped with power steering, refer to manual for specific type (often Dexron II/III or dedicated power steering fluid).
Known Issues
Common Wear Items:
Clutch wear, suspension bushings, exhaust system components, ignition coils (if DIS), wheel bearings.
Engine Specific:
Timing belt tensioner and idler pulley should be replaced concurrently with the timing belt. Overheating can occur if cooling system maintenance is neglected. Some early models might have carburetor issues if not EFI.
Electrical Quirks:
Corrosion on connectors, aging wiring insulation, failure of specific relays or sensors are possible with age.
📚 Vehicle History
Brand Heritage
Daihatsu Focus:
Daihatsu has a long history of producing small, economical, and reliable vehicles, often exported globally.
Model Evolution
Charade Lineage:
The Charade was Daihatsu's flagship small car for several generations, known for its consistent focus on efficiency and practicality.
G200 Generation:
The G200 generation (introduced in 1993 globally) represented a modern styling and engineering update over its predecessor, moving towards more rounded forms and improved interior space.
Production
Production Period:
Globally produced from 1993 to 1998.
Manufacturing Locations:
Primarily Japan, with production facilities in other countries under license or for specific markets.
🏆 Awards & Recognition
Recognitions
Category:
Often recognized for affordability and fuel efficiency in its class during its production years.
Ratings
Reliability Perception:
Generally perceived as a reliable car, especially with consistent maintenance, reflecting Daihatsu's reputation for robust small engines.
Certifications
Emissions Standards:
Meets emissions standards applicable for the 1996 model year in its primary markets.
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