1987–1994 Daihatsu Charade G100 (GTTI) Workshop Manual (P/N NO.9173-GE)

• Coverage: Daihatsu Charade applications fitted with the CB-23, CB-61, or CB-80 three-cylinder engine—the carbureted CB-23, turbocharged carbureted CB-61, and DOHC electronic-fuel-injected turbo CB-80.
• Factory document identity: Official Daihatsu Type CB Engine Workshop Manual, publication No. 9173-GE, published in June 1987 and supplied as a 294-page PDF.
• Documents engine removal and installation, in-vehicle timing-belt and water-pump service, crankshaft and camshaft oil seals, camshafts, cylinder-head gaskets, CB-80 injectors, and oil-pump replacement.
• Details cylinder-head and cylinder-block overhaul, including valve-train disassembly, valve-seat and guide work, camshaft inspection, piston and ring service, crankshaft and bearing checks, connecting rods, balance shaft, flywheel, and final assembly.
• Includes CB-23/CB-61 carburetor schematics and adjustments, fuel-line and pump checks, fuel-tank service, CB-61/CB-80 turbocharger testing, waste-gate checks, CB-61 surge-tank inspection, and CB-80 intercooler leak testing.
• Provides distributor and ignition repair, starter and alternator bench tests, destination-specific emission-control schematics, service specifications, tightening sequences, wear limits, SST listings, and hundreds of numbered factory figures.

Engine Coverage and Repair Depth

The CB-23 material covers a carburetor, mechanical fuel pump, and conventional breaker-point distributor. CB-61 sections add turbocharging, pressure-controlled fuel delivery, an electric pump, surge tank, and turbo-related carburetor controls. CB-80 procedures are separated where its DOHC cylinder head, electronic fuel injection, injectors, electronic timing control, turbocharger, and intercooler require different repair methods. Those distinctions carry through the tune-up data, timing layouts, cylinder-head work, starter versions, and emission equipment.

The repair chapters are organized around component diagrams, removal, inspection, and installation. Tune-up coverage includes compression testing, valve-clearance inspection and adjustment, ignition timing and advance checks, idle and CO adjustment, fast-idle and dashpot checks, and CB-80 diagnosis-code reading. Mechanical repair goes well beyond routine maintenance: the manual documents the engine-and-transmission removal sequence, intake and exhaust teardown, timing-belt service, cylinder-head reconditioning, valve-guide replacement, CB-80 shim selection, crankshaft and bearing oil-clearance checks, piston and connecting-rod inspection, balance-shaft timing, and oil-pump installation.

Fuel, Turbocharger, Electrical, and Emission Systems

Fuel-system coverage is divided by engine build rather than treated as one generic system. The CB-23 and CB-61 pages include carburetor component and schematic views, float and secondary-diaphragm checks, fuel-pressure testing, emergency fuel-stop testing, pump inspection, and fuel-tank removal and installation. Turbocharger chapters cover lubrication-feed inspection, turbine and compressor checks, waste-gate actuator testing, road-load boost-pressure testing, and CB-61 troubleshooting flowcharts for low output, knocking or hunting, and oil smoke.

Electrical chapters document breaker-point distributors, CB-80 distributor resistance checks, ignition coils and high-tension leads, two starter constructions, starter performance tests, alternator disassembly, and no-load and load-output testing. Destination-specific vacuum-routing schematics distinguish General, Australian, ECE/EEC, Saudi Arabian/GCC, Singapore, Swedish, Swiss, and West German configurations. Related checks cover blow-by recirculation, choke opener and dashpot operation, evaporative emission control, secondary-air suction, EGR, deceleration fuel cut, the outer-vent system, and ignition-timing control.

Diagrams, Specifications, and Special Tools

Useful drawing sets include CB-23, CB-61, and CB-80 engine sectional views; engine-component torque drawings; separate OHC and DOHC timing-mark layouts; CB-23 and CB-61 carburetor schematics; turbocharger troubleshooting charts; and emission-control vacuum diagrams. The appendix consolidates service limits and main-component torque tables and identifies the required Daihatsu SSTs by number. Listed examples include engine sling device 09090-04810-000, cylinder-head holder 09219-87703-000, CB-80 valve-clearance tool 09248-87703-000, fuel-pressure gauge 09268-87701-000, and turbocharger pressure gauge 09992-87704-000.

Scope and Workshop Cautions

This is an engine workshop manual, not a complete Charade chassis publication. It does not provide body repair, brake repair, transmission overhaul, or complete vehicle wiring coverage. The PDF consists of scanned page images rather than selectable text. Engine-related ignition, charging, starting, fuel, intake, turbocharger, and emission systems are included. Detailed CB-80 engine-control troubleshooting is cross-referenced to a separate factory troubleshooting publication rather than reproduced here as a full EFI diagnostic chapter.

Two factory warnings are especially relevant during repair. After the CB-80 timing-belt tensioner is removed, turning the camshafts or crankshaft independently can bring the valves into contact with the pistons. During CB-80 shim adjustment, using the valve-clearance SST with the piston at top dead center can also damage the valve and piston. Engine lifting, pressurized fuel-line work, cooling-system testing, and hot turbocharger service require proper support equipment and the safety precautions specified in the manual.