1983–1987 Daihatsu Charade G11 Service Manual (P/N C4085-91017)

• Engine coverage is organized by Type CB identification: CB-23, CB-61, and CB-80, with the engine-type embossing and engine-number stamping locations shown before service specifications or parts are selected.
• Covers major engine repair operations: engine removal and installation; intake and exhaust assemblies; timing belt and water pump service; crankshaft and camshaft oil seals; camshafts; cylinder-head gaskets; CB-80 injectors; oil pump; and complete cylinder-head and cylinder-block work.
• Separates carbureted and EFI procedures: CB-23/CB-61 and CB-80 receive distinct tune-up, timing, valvetrain, fuel, starter, intake, turbocharger, and engine-mechanical instructions.
• Includes inspection, test, and adjustment coverage: compression and valve-clearance checks, distributor and ignition timing, idle-speed and CO adjustment, choke/fast-idle/dashpot checks, turbocharger pressure and wastegate testing, and CB-61 turbo fault isolation.
• Adds a separate April 1987 Charade Chassis workshop volume: clutch, manual and three-speed automatic transmission, differential, front and rear axle/suspension, drive shafts, wheel alignment, steering, brakes, body, glass, sunroof, exhaust, fuel tank, and body electrical service.
• Provides factory reference data and visual support: service specifications, component-specific torque tables, wear limits, clearances, capacities, pressure and electrical test data, SST listings, sectional views, exploded component layouts, schematics, and troubleshooting charts.
• File structure and scope: the 821-page PDF contains 270 Type CB engine pages, a 538-page chassis volume, and the 13-page Type CB appendix at the end. Full CB-80 engine-control troubleshooting is referenced as a separate publication; the Type CB/Type CL wiring-diagram sheets listed after the chassis System Index are not included.

Type CB Engine Service and Overhaul

The Type CB workshop material goes well beyond a specification summary. The tune-up chapters cover fluid and air-cleaner checks, spark plugs, belt condition, compression, valve clearances, distributor and ignition timing, idle speed, CO adjustment, fast-idle operation, dashpot checks, and choke-opener function. CB-80 has its own instrument-connection notes, shim-type valve-clearance procedure, diagnosis-code check, ignition and idle adjustment, and EFI-related service tools.

The in-vehicle section isolates work that can be performed with the engine installed: timing belt and water pump service, crankshaft oil seal, camshaft, camshaft oil seal, cylinder-head gasket, CB-80 injector, and oil pump. The engine-mechanical section then covers engine removal and installation plus internal teardown. It follows the intake and exhaust assemblies, timing system, cylinder head, and cylinder block through removal or disassembly, inspection, and reassembly. Internal subjects include valves and guides, rocker gear or CB-80 lifters and shims, camshaft journals, pistons, pins and rings, connecting rods, crankshaft, flywheel, main and rod bearings, balance shaft, and oil-clearance or bearing-selection checks.

Fuel, Turbocharger, Electrical, and Emission Systems

The fuel chapter documents carburetor components and inspection for CB-23/CB-61 engines, engine-specific fuel lines, CB-61 and CB-80 fuel pumps, and fuel-tank removal and installation. Lubrication and cooling chapters cover oil-pump inspection and assembly, CB-61/CB-80 oil coolers, radiator and cap checks, thermostat and thermo-switch inspection, and water-pump overhaul.

Turbocharger coverage includes CB-61/CB-80 component identification, handling precautions, lubrication-feed inspection, wastegate actuator testing, a supercharging-pressure running test, and CB-61 troubleshooting charts. Engine electrical service covers distributor and ignition components, starter variants, alternator disassembly and inspection, assembly, performance testing, and in-vehicle checks. Air-cleaner service, the CB-61 surge tank, CB-80 intercooler, and destination-specific emission-control systems complete the engine repair coverage.

Separate Charade Chassis Workshop Volume

The inserted chassis manual is a separate Daihatsu publication dated April 1987. It covers clutch diagnosis and adjustment, release-cable and clutch-unit service; 4- and 5-speed manual transmission removal and internal repair of the housing, input and output shafts, fifth gear, differential, and control linkage; and three-speed automatic transmission basic checks, adjustments, tests, troubleshooting, removal, oil pump, forward and direct clutches, valve body, and final assembly.

Further sections document front and rear axles and suspension, shock absorbers, drive shafts, wheel alignment, steering column and gear, brake-system bleeding, master cylinder and booster work, front and rear brake repair, body alignment, panels, glass, doors, sunroof, exhaust and fuel-tank service, and body electrical diagnosis. A G100/G101 reference appears in the transmission-tool information, so chassis applicability should be matched to the vehicle configuration rather than inferred from the Type CB engine code alone.

Diagrams, SSTs, and Service Data

Representative illustrations include CB-23, CB-61, and CB-80 engine sectional views; timing-belt component and timing-mark diagrams; cylinder-head and cylinder-block exploded layouts; turbocharger component views with CB-61 fault charts; destination-specific emission-control schematics; and manual and automatic transmission sectional views.

The Type CB appendix identifies tools such as the 09219-87202-000 engine overhaul stand, 09219-87701-000 overhaul attachment, 09248-87703-000 valve-clearance tool, 09992-87704-000 turbocharger pressure gauge, and 09842-87704-000 EFI computer check subharness. Related tables collect torque specifications, capacities, pressure checks, electrical test data, clearances, wear limits, and adjustment values for the covered assemblies.

The manual warns that deforming the oil pan while supporting the engine can contribute to engine seizure. During CB-80 valve-clearance work, using the SST with the piston at top dead center can allow valve-to-piston contact and damage both parts. After turbocharger replacement, raising engine speed before initial idle lubrication can damage the turbocharger bearings.

This product description summarizes the publication's repair scope and does not reproduce its working sequences. Vehicle support, battery isolation, hot cooling and turbocharger components, fuel pressure, and rotating machinery require the precautions and test equipment specified in the manual.