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

This 1983–1993 Daihatsu Charade Chassis Workshop Manual (P/N WR-00000), published in April 1987, covers the drivetrain, suspension, steering, brakes, body and body electrical systems. For engine repair and CB-80 engine-control troubleshooting, the foreword calls for use alongside the separate Type CB, Type CL and CB-80 engine-control manuals. Those publications are not included.

PDF Search, Circuit Detail and Page Count

Search and diagram detail: OCR text supports searches through much of the manual, with gaps in some tables and drawing labels. There are no embedded PDF bookmarks. Small labels in dense circuit diagrams require zooming, and some text at page edges is cropped.

One printable, 538-page PDF in English includes the title/foreword, indexes and appendix. Five blank pages and two repeated rear-axle pages are already included in that total.

Transmission Overhaul, Chassis Repair and Body Electrics

The following selected topics show the main repair coverage rather than the complete contents; additional subjects include heater-control cable adjustment and seat-belt retractor checks.

• Clutch and manual transmissions: Pedal and cable adjustment, clutch inspection, gearbox removal, shaft disassembly, synchronizer checks and differential reassembly.

• Automatic transmission: Stall, time-lag and hydraulic-pressure tests, electrical troubleshooting, valve-body service, oil-pump inspection and clutch overhaul.

• Axles and suspension: Wheel-bearing replacement, drive-shaft and joint service, shock-absorber disassembly, suspension-arm replacement and wheel-alignment checks.

• Steering and brakes: Steering-column and rack service, preload adjustment, master-cylinder and booster overhaul, caliper repair and brake bleeding.

• Body and glass: Door and hatch alignment, windshield installation, window-regulator replacement and power glass sunroof removal, installation and adjustment.

• Body electrical systems: Circuit diagrams, connector views, switch continuity tables and component tests for lighting, instruments, wipers, locks and power windows.

Suited to technicians and experienced owners familiar with presses, measuring gauges and electrical test equipment; the internal overhaul procedures require workshop-level mechanical skills.

Drivetrain and Transmission Servicing

The manual details the construction and disassembly of both manual and automatic transmissions. Clutch coverage extends from the pedal assembly and release cable to the disc, pressure plate, release bearing and operating mechanism.

Manual gearbox procedures cover the input and output shafts, fifth-gear assembly, differential case and control linkage. Gear end-play measurements, synchronizer-ring inspection criteria and SAE 80 GL-3 oil specifications support inspection and reassembly. Case-sealing instructions identify Three Bond 1216 and its curing requirements.

Automatic transmission diagnosis: Test results are linked to possible clutch, brake, torque-converter and line-pressure faults. Electrical checks cover speed sensors, the throttle sensor, neutral-start switch and shift solenoids, helping distinguish control-circuit problems from faults requiring internal transmission work.

Transmission sectional views and the shift-point characteristics diagram support these checks. Valve-body instructions warn that incorrect handling during separation can release and lose the steel check balls.

Transmission removal involves heavy assemblies; follow the manual’s support and lifting precautions.

Suspension, Steering and Brake Repair

Step-by-step procedures cover front and rear suspension work, steering-rack rebuilds, and 6-inch and 7-inch brake-booster overhauls. Wheel-alignment coverage includes front turning-angle, camber, caster and kingpin checks, plus front and rear toe adjustment.

The steering section warns that improper rack removal can damage the rack bushing. Brake instructions distinguish rear drum and rear disc arrangements, including their parking-brake mechanisms and adjustment procedures.

Body, Windows and Sunroof

Body coverage extends beyond panel removal to door and hatch fit, glass sealing, window regulators and fuel-tank removal. The power glass sunroof section covers the drive cable, guide rails, drive gear and alignment, with checks for binding, abnormal noise and water leakage.

Electrical Tests and Circuit Coverage

Connector views, terminal assignments and continuity tables support component-level fault tracing. Examples include the junction-block circuit diagram, front-wiper circuit diagram, power-window circuit diagram and power glass sunroof circuit diagram.

Wiring coverage limit: These individual system diagrams are included, but the separate CB- and CL-engine vehicle wiring sheets listed in the appendix are absent. The PDF ends at the wiring system index on printed page 11-16.

A Preview of Differential Torque and Automatic Clutch Clearances

The manual-transmission differential assembly procedure specifies ring-gear attaching-bolt torque at 8.0–9.0 kg-m (58–65 ft-lb).

For automatic-transmission overhaul, forward-clutch clearance is 0.41–1.08 mm (0.016–0.043 inch), while direct-clutch clearance is 0.89–1.46 mm (0.035–0.057 inch). The associated inspection sections address clutch discs, plates and selective flange thicknesses when evaluating these assembly clearances.