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Daihatsu Charade CB-61 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Charade Chassis Code: CB-61 Codes Internal Product Identifier: CB61FSM001 👋 Introduction Market Position Vehicle Segment: Subcompact hatchback, known for affordability, fuel efficiency, and practicality. Target Audience: First-time car buyers, budget-conscious consumers, city dwellers seeking an economical and easy-to-drive vehicle. Competitive Analysis Key Competitors: Suzuki Swift, Nissan March (Micra), Toyota Starlet, Honda City, Mazda 121. Key Features Vehicle Selling Points: Compact dimensions for urban maneuverability, good fuel economy, low running costs, reliable mechanicals, simple design. Manual Value Proposition Diy Repair Empowerment: Empowers owners to perform maintenance and repairs themselves, saving money on labor costs and gaining deeper understanding of their vehicle. Diagnostic Proficiency: Provides the tools and knowledge to effectively diagnose and troubleshoot issues, reducing reliance on external repair shops. 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Manual Language: English Format: PDF Page Count Estimated Page Count: Approximately 800-1200 pages (typical for comprehensive factory manuals of this era) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, camshaft, timing system (belt/chain), lubrication system, cooling system. Engine Electrical: Ignition system, starting system, charging system, fuel injection system (EFI/Carburetor), engine control unit (ECU), sensors, emission control systems. Transmission: Manual transmission (all gears, synchronizers, shift forks, bearings), Automatic transmission (if applicable, torque converter, planetary gear sets, hydraulic control, valve body). Drivetrain: Clutch system, driveshafts, differentials, axles, hub bearings. Suspension: Front suspension (struts, control arms, bushings, springs, shock absorbers), Rear suspension (beam axle, trailing arms, shocks, springs), alignment specifications. Steering: Steering column, steering rack/gearbox, power steering system (pump, lines, reservoir), tie rods, ball joints. Brakes: Front and rear brake systems (disc/drum), master cylinder, brake booster, proportioning valve, ABS (if equipped), parking brake. Electrical System: Battery, alternator, starter, lighting system (headlights, taillights, interior), horn, wipers, washers, power windows, central locking, fuses, relays. Body And Trim: Exterior body panels, doors, hood, trunk, bumpers, interior trim, seats, dashboard, glass. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system components, refrigerant, operation, troubleshooting. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections, brake pad replacement, tire rotation. Troubleshooting: Diagnostic procedures for common drivability issues, electrical faults, starting problems, overheating, braking issues, and more. Includes symptom-based troubleshooting guides. Major Repairs: Engine overhauls, transmission rebuilds, suspension component replacement, brake system overhauls, steering system repairs, electrical component diagnostics and replacement. Component Removal Installation: Detailed step-by-step instructions for removing and installing virtually every mechanical and electrical component. Wiring Diagrams: Comprehensive electrical wiring diagrams for all vehicle systems, facilitating diagnosis and repair of electrical faults. Specifications And Tolerances: Precise torque specifications for fasteners, critical clearances, wear limits, and other important measurement data. Technical Depth Diagnostic Capability: Advanced diagnostic procedures, including symptom analysis and step-by-step troubleshooting flows, enabling technicians to pinpoint root causes of issues. Repair Instructions: Detailed, illustrated instructions for repairs ranging from simple maintenance to complex component overhauls and rebuilds. Rebuild Procedures: Comprehensive instructions for rebuilding major components such as engines and transmissions, including disassembly, inspection, part replacement, and reassembly. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Software Requirements: Adobe Acrobat Reader (or compatible PDF viewer), WinZip (or compatible file compression utility) Platform Compatibility: Compatible with all versions of Windows and macOS Print Quality Text Searchability: Likely searchable text, allowing for quick information retrieval. Image Clarity: High-quality scans or digital reproductions of original factory diagrams and photographs. Binding Type Digital Binding: N/A (Digital file) Paper Type Digital Paper Type: N/A (Digital file) ⚙️ Engine Specifications Primary Engine Engine Code Examples: CB23 (1.0L), G13A (1.3L) - specific to CB61 generation. Engine Layout Configuration: Inline-3 or Inline-4 cylinder, front-engine, front-wheel drive. Performance Displacement Range: Typically 993cc to 1300cc Horsepower Range: Approximately 45-70 hp (depending on engine and market) Torque Range: Approximately 70-100 Nm Fuel System Fuel Delivery: Carburetor or Electronic Fuel Injection (EFI), depending on model year and specification. Fuel Type: Unleaded gasoline Engine Oil Recommended Viscosity: Typically 10W-30 or 10W-40, refer to manual for specific grade based on climate. Oil Capacity: Approx. 3.0 - 3.5 liters with filter change. Cooling System Coolant Type: Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. 🔧 Transmission Standard Type: 5-speed manual transmission Optional Type: 3-speed automatic transmission (availability varied by market and trim) Features Manual Fluid Type: GL-4 gear oil, SAE 75W-90 or 80W-90 Automatic Fluid Type: Dexron-III or equivalent ATF 📐 Dimensions Exterior Length: Approx. 3600-3700 mm Width: Approx. 1570-1600 mm Height: Approx. 1380-1400 mm Weights Curb Weight: Approx. 750-850 kg Gross Vehicle Weight Rating: Typically around 1200-1300 kg 🛡️ Safety Features Ratings Crash Test Performance: Limited official crash test data available from the era, generally reflected the safety standards of the time. Likely to have lower ratings by modern standards. Active Features Braking System: Front disc brakes, rear drum brakes. ABS was an optional feature on...
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Daihatsu Charade CB-61 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Charade
Chassis Code:
CB-61
Codes
Internal Product Identifier:
CB61FSM001
👋 Introduction
Market Position
Vehicle Segment:
Subcompact hatchback, known for affordability, fuel efficiency, and practicality.
Target Audience:
First-time car buyers, budget-conscious consumers, city dwellers seeking an economical and easy-to-drive vehicle.
Competitive Analysis
Key Competitors:
Suzuki Swift, Nissan March (Micra), Toyota Starlet, Honda City, Mazda 121.
Key Features
Vehicle Selling Points:
Compact dimensions for urban maneuverability, good fuel economy, low running costs, reliable mechanicals, simple design.
Manual Value Proposition
Diy Repair Empowerment:
Empowers owners to perform maintenance and repairs themselves, saving money on labor costs and gaining deeper understanding of their vehicle.
Diagnostic Proficiency:
Provides the tools and knowledge to effectively diagnose and troubleshoot issues, reducing reliance on external repair shops.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Manual
Language:
English
Format:
PDF
Page Count
Estimated Page Count:
Approximately 800-1200 pages (typical for comprehensive factory manuals of this era)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, camshaft, timing system (belt/chain), lubrication system, cooling system.
Engine Electrical:
Ignition system, starting system, charging system, fuel injection system (EFI/Carburetor), engine control unit (ECU), sensors, emission control systems.
Transmission:
Manual transmission (all gears, synchronizers, shift forks, bearings), Automatic transmission (if applicable, torque converter, planetary gear sets, hydraulic control, valve body).
Drivetrain:
Clutch system, driveshafts, differentials, axles, hub bearings.
Suspension:
Front suspension (struts, control arms, bushings, springs, shock absorbers), Rear suspension (beam axle, trailing arms, shocks, springs), alignment specifications.
Steering:
Steering column, steering rack/gearbox, power steering system (pump, lines, reservoir), tie rods, ball joints.
Brakes:
Front and rear brake systems (disc/drum), master cylinder, brake booster, proportioning valve, ABS (if equipped), parking brake.
Electrical System:
Battery, alternator, starter, lighting system (headlights, taillights, interior), horn, wipers, washers, power windows, central locking, fuses, relays.
Body And Trim:
Exterior body panels, doors, hood, trunk, bumpers, interior trim, seats, dashboard, glass.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system components, refrigerant, operation, troubleshooting.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections, brake pad replacement, tire rotation.
Troubleshooting:
Diagnostic procedures for common drivability issues, electrical faults, starting problems, overheating, braking issues, and more. Includes symptom-based troubleshooting guides.
Major Repairs:
Engine overhauls, transmission rebuilds, suspension component replacement, brake system overhauls, steering system repairs, electrical component diagnostics and replacement.
Component Removal Installation:
Detailed step-by-step instructions for removing and installing virtually every mechanical and electrical component.
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all vehicle systems, facilitating diagnosis and repair of electrical faults.
Specifications And Tolerances:
Precise torque specifications for fasteners, critical clearances, wear limits, and other important measurement data.
Technical Depth
Diagnostic Capability:
Advanced diagnostic procedures, including symptom analysis and step-by-step troubleshooting flows, enabling technicians to pinpoint root causes of issues.
Repair Instructions:
Detailed, illustrated instructions for repairs ranging from simple maintenance to complex component overhauls and rebuilds.
Rebuild Procedures:
Comprehensive instructions for rebuilding major components such as engines and transmissions, including disassembly, inspection, part replacement, and reassembly.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format)
Software Requirements:
Adobe Acrobat Reader (or compatible PDF viewer), WinZip (or compatible file compression utility)
Platform Compatibility:
Compatible with all versions of Windows and macOS
Print Quality
Text Searchability:
Likely searchable text, allowing for quick information retrieval.
Image Clarity:
High-quality scans or digital reproductions of original factory diagrams and photographs.
Binding Type
Digital Binding:
N/A (Digital file)
Paper Type
Digital Paper Type:
N/A (Digital file)
⚙️ Engine Specifications
Primary Engine
Engine Code Examples:
CB23 (1.0L), G13A (1.3L) - specific to CB61 generation.
Engine Layout
Configuration:
Inline-3 or Inline-4 cylinder, front-engine, front-wheel drive.
Performance
Displacement Range:
Typically 993cc to 1300cc
Horsepower Range:
Approximately 45-70 hp (depending on engine and market)
Torque Range:
Approximately 70-100 Nm
Fuel System
Fuel Delivery:
Carburetor or Electronic Fuel Injection (EFI), depending on model year and specification.
Fuel Type:
Unleaded gasoline
Engine Oil
Recommended Viscosity:
Typically 10W-30 or 10W-40, refer to manual for specific grade based on climate.
Oil Capacity:
Approx. 3.0 - 3.5 liters with filter change.
Cooling System
Coolant Type:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water.
🔧 Transmission
Standard
Type:
5-speed manual transmission
Optional
Type:
3-speed automatic transmission (availability varied by market and trim)
Features
Manual Fluid Type:
GL-4 gear oil, SAE 75W-90 or 80W-90
Automatic Fluid Type:
Dexron-III or equivalent ATF
📐 Dimensions
Exterior
Length:
Approx. 3600-3700 mm
Width:
Approx. 1570-1600 mm
Height:
Approx. 1380-1400 mm
Weights
Curb Weight:
Approx. 750-850 kg
Gross Vehicle Weight Rating:
Typically around 1200-1300 kg
🛡️ Safety Features
Ratings
Crash Test Performance:
Limited official crash test data available from the era, generally reflected the safety standards of the time. Likely to have lower ratings by modern standards.
Active Features
Braking System:
Front disc brakes, rear drum brakes. ABS was an optional feature on higher trims or later models.
Passive Features
Seatbelts:
Standard front seatbelts, often lap belts for rear occupants in earlier models. 3-point belts became more common later.
Body Structure:
Reinforced safety cell and crumple zones, though less advanced than contemporary vehicles.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio, optional cassette player. Speakers typically limited to front doors.
Driver Assistance
Active Safety Features:
Limited to ABS on select higher-spec models. Primarily relies on driver attentiveness.
Connectivity
External Connectivity:
None. No provision for Bluetooth, USB, or AUX inputs in original factory configuration.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 - 7,500 km or 6 months, whichever comes first.
Air Filter Replacement:
Every 15,000 - 20,000 km or annually.
Spark Plug Replacement:
Every 30,000 - 40,000 km, depending on plug type (copper vs. platinum).
Timing Belt Replacement:
Crucial interval, typically every 80,000 - 100,000 km or 5 years. Failure can cause severe engine damage.
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4 (refer to manual for exact specification).
Power Steering Fluid:
Specific ATF or power steering fluid as per manual.
Known Issues
Common Wear Items:
CV joints, engine mounts, suspension bushings, exhaust system components, clutch wear.
Electrical Gremlins:
Older vehicles may experience issues with wiring harness degradation, switch failures (e.g., ignition switch, turn signal switch), and grounds.
Cooling System:
Radiator leaks, thermostat failures, and water pump issues can occur due to age.
Carburetor Issues:
Carburetor models may require periodic cleaning and adjustment due to fuel deposits and wear.
📚 Vehicle History
Brand Heritage
Daihatsu Focus:
Daihatsu has a long history as a manufacturer of small, economical, and reliable vehicles, often specializing in Kei cars and subcompacts.
Model Evolution
Charade Generations:
The CB61 represents the third generation of the Daihatsu Charade (launched in 1983, often referred to as the '3rd Gen'). It succeeded the internal designation G11 and was later replaced by the G200 series.
Cb61 Key Changes:
Introduction of more aerodynamic styling, front-wheel drive became standard across most models, updated engine options, and improved interior refinement.
Production
Production Years:
Approximately 1983-1987 for the CB61 generation.
Manufacturing Locations:
Primarily Japan, with some assembly or production potentially occurring in other global markets through licensing or joint ventures.
🏆 Awards & Recognition
Recognitions
Model Specific Awards:
No major widely publicized awards for this specific generation, but the Charade line consistently received praise for its value and economy in its segment.
Ratings
Consumer Reports Or Equivalent:
May have appeared in consumer guides of the era, often highlighting its cost-effectiveness and practicality. Specific ratings not readily available.
Certifications
Emission Standards:
Compliant with prevailing emission standards of its production period for various markets.
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