Daihatsu Charade 1983–1987 Type CB & Chassis Manual Set

The chassis foreword calls for using that volume with the appropriate engine workshop manual. Here, the Type CB material provides the engine procedures, while the chassis volume covers the drivetrain, running gear, body and body electrical systems.

Check chassis applicability: The transmission-tool instructions reference Charade G100/G101; match the chassis procedures to the vehicle configuration. Full CB-80 engine-control troubleshooting is covered by a separate publication, and the Type CB/Type CL wiring sheets listed after the chassis System Index are not included in this PDF.

PDF Search, Bookmarks and Circuit Detail

Search and diagram detail: Text search is available in much of the chassis volume, but not in the engine material or its appendix. Embedded bookmarks link the engine sections and the chassis volume as a whole. Small circuit labels require zooming; some densely packed junction-block codes remain difficult to distinguish.

The ZIP contains one printable, 821-page PDF. The engine material precedes the chassis volume, with its 13-page appendix at the end. That appendix, the section-title pages and five blank pages are already included in the total.

Engine Overhaul, Drivetrain Repair and Chassis Diagnosis

These selected coverage highlights summarize the main repair areas. Other topics include heater-unit service and radio antenna replacement; this is not a complete contents list.

• Engine repair: Step-by-step procedures for engine removal and installation, cylinder-head and cylinder-block overhaul, timing-belt service, oil seals, head gaskets and CB-80 injector replacement.

• Tune-up and fault finding: Compression and valve-clearance checks, distributor and ignition adjustment, idle-speed and CO checks, choke, fast-idle and dashpot testing.

• Fuel and turbo systems: Carburetor inspection and adjustment, fuel-line and pump checks, turbocharger lubrication checks, wastegate testing, boost-pressure tests and CB-61 troubleshooting charts.

• Lubrication and cooling: Oil-pump inspection and assembly, oil-cooler installation, cooling-system leak tests, radiator-cap and thermostat checks, fan-switch testing and water-pump overhaul.

• Clutch and transmissions: Clutch diagnosis and cable adjustment, manual transmission and differential overhaul, automatic transmission testing, control-system diagnosis and internal repair.

• Chassis and brakes: Axle, suspension, drive-shaft and wheel-alignment service, steering-gear repair, brake bleeding, master-cylinder and booster work, and front and rear brake service.

• Body and electrical systems: Body alignment, panels, glass, doors, sunroof, exhaust and fuel-tank service, plus ignition, starter, alternator and body-circuit inspection.

This material is suited to mechanics familiar with workshop measurement and component overhaul; it assumes standard shop equipment and identifies the special tools needed for individual operations.

Type CB Engine Service and Overhaul

Engine identification and tune-up: Engine-type embossing and engine-number stamping references help distinguish the applicable procedures before service data or parts are selected. Carbureted CB-23/CB-61 instructions are separated from CB-80 EFI material, including its instrument connections, diagnosis-code check and shim-type valve adjustment.

Internal inspection: The overhaul chapters detail valve and guide work, rocker gear or CB-80 lifters and shims, camshaft journals, pistons, pins and rings, connecting rods, crankshaft, flywheel and balance shaft. Bearing-clearance measurements and selection information support decisions about component reuse or replacement.

The manual specifies that undersize main bearings are unavailable for CB-61 and CB-80 engines.

The in-vehicle chapter distinguishes work that can be done with the engine installed from the deeper disassembly covered under Engine Mechanicals. Timing-mark diagrams, engine sectional views and exploded cylinder-head and cylinder-block layouts support those procedures.

Fuel, Turbocharger and Engine Electrical Service

The carburetor section goes into float-level adjustment and individual jet, needle-valve, solenoid and diaphragm checks. CB-61 fuel-pressure regulation and emergency fuel-stop testing provide fault-isolation detail beyond a component list.

Turbocharger component views accompany the pressure tests and CB-61 fault charts. The unit itself is not to be disassembled or adjusted. Intake coverage includes air-cleaner service, the CB-61 surge tank and CB-80 intercooler; destination-specific emission schematics distinguish the related control systems.

Distributor and ignition checks, starter-variant disassembly and performance tests, and alternator inspection, assembly and in-vehicle load tests complete the engine electrical coverage.

Chassis Transmission, Brake and Body Details

Manual transmission instructions cover the housing, input and output shafts, fifth gear, differential and control linkage. The chassis specifications also distinguish CL-11 and CL-61 diesel transmission configurations; Type CL engine overhaul belongs to a separate engine manual.

Automatic transmission coverage includes stall, time-lag and hydraulic-pressure tests, electronic-control checks, troubleshooting charts, oil-pump repair, forward and direct clutch work, valve-body inspection and final assembly. Transmission sectional views show the internal arrangements.

Brake coverage distinguishes rear drum and rear disc assemblies, including the parking-brake mechanism. Body electrical material supplies switch-continuity tables and circuit diagrams for systems such as front wipers, power windows and central door locking.

SSTs, Reference Tables and Repair Cautions

The reference sections collect component-specific torque tables, capacities, pressure and electrical test data, clearances and wear limits. The engine appendix lists the 09219-87202-000 engine overhaul stand, 09219-87701-000 attachment, 09248-87703-000 valve-clearance tool, 09992-87704-000 turbocharger pressure gauge and 09842-87704-000 EFI computer check subharness.

The manual warns that oil-pan deformation can cause engine seizure, while CB-80 shim-tool use at top dead center can damage valves and pistons. Raising engine speed before a replacement turbocharger receives its initial idle lubrication can damage its bearings.

Vehicle support, battery isolation, hot cooling and turbocharger components, fuel pressure, and rotating machinery require the precautions and test equipment specified in the manual.

A Preview of CB-80 Spark-Plug and Valve-Clearance Data

The CB-80 tune-up section specifies a spark-plug gap of 0.9–1.0 mm, alongside plug selection and inspection information.

For its warmed-engine valve-clearance check, with coolant at 75–85°C, the specified clearances are 0.27 ±0.05 mm for intake valves and 0.32 ±0.05 mm for exhaust valves. The accompanying shim-selection material explains how adjustment is handled.