1983–1993 Daihatsu Charade Workshop Manual (P/N WR-00000)

• Official 538-page factory publication (P/N WR-00000, first published April 1987)
• Covers 1983–1993 Daihatsu Charade configurations equipped with CB, CL, and CB-80 engines
• Details 3-speed automatic, 4-speed, and 5-speed manual transmission variants, alongside chassis and electrical specifications
• Includes over 100 exploded-view diagrams, 15 torque specification tables, and 10 troubleshooting flow charts to streamline workshop diagnostics
• Features comprehensive wiring diagrams, schematic diagrams of components, shift point characteristics diagrams, electrical circuit diagrams, continuity tables, and sectional views
• Explores complete teardown procedures for the steering gear assembly, brake booster, front suspension, power glass sunroof, and body electrical system

Drivetrain and Transmission Architecture

This factory PDF manual thoroughly details the construction and disassembly of both manual and automatic transmission systems found in the Daihatsu Charade. It offers a deep dive into the clutch pedal assembly, clutch release cables, and internal transmission components. Mechanics will find extensive documentation on input and output shaft maintenance, 5th gear assemblies, and differential cases. The text provides the exact gear end-play measurements and synchronizer ring inspection criteria required for a reliable rebuild and repair. You will also find manufacturer recommendations regarding the proper application of bonding agents during case reassembly.

Advanced Chassis and Electrical Servicing

Eliminating the need to outsource complex jobs to expensive specialty shops, this guide delivers precise step-by-step instructions for complete front and rear wheel alignment calibrations, 6-inch and 7-inch brake booster overhauls, and steering rack rebuilds. Having this level of verified factory geometry and electrical pinout data directly on your workstation eliminates trial-and-error testing. This specific advantage drastically reduces vehicle downtime, empowering technicians to efficiently verify sensor voltages and execute a heavy repair without relying on outside help.

When servicing these specific models, professionals must navigate unique mechanical pitfalls. For instance, if the automatic transmission valve body is separated with the upper half facing upwards, the internal check balls will drop and become permanently lost. Furthermore, when reassembling the manual transaxle casing, the specified Three Bond 1216 liquid gasket begins curing immediately upon atmospheric exposure, meaning component mating must be perfectly executed within a strict five-minute window to avoid severe fluid leaks.

Specification Highlights

Accurate data is critical for any drivetrain overhaul. This guide supplies the exact specifications needed for rigorous inspection and assembly operations. For example, the 4-speed unit requires 1.9–2.0 liters of transmission fluid, while the 5-speed unit takes 2.1–2.2 liters of SAE 80 GL-3 oil. High-performance variants specify a differential ring gear tightening torque of 8.0–9.0 kg-m (58–65 ft-lb). To ensure proper disengagement, clutch pedal free travel is strictly documented at 15–30 mm. The automatic transmission stall speed sits at 2100–2300 rpm under standard operating temperatures of 70–80°C. Always cross-reference these figures with the specific vehicle VIN and adhere to standard shop safety practices before initiating any heavy mechanical work or drivetrain drops, as improper handling of transmission assemblies poses significant physical risks.