Daihatsu Charade G10 1977 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Daihatsu Model: Charade Model Code: G10 Year: 1977 Engine Code: CB Type Codes Chassis Code: G10 Engine Family: Daihatsu CB 👋 Introduction Market Position Segment: Compact/Subcompact Hatchback Target Audience: Economical urban transportation, first-time car buyers, small families. Competitive Analysis Key Competitors 1977: Honda Civic, Toyota Corolla, Datsun (Nissan) Sunny, Mitsubishi Lancer, Suzuki Fronte. Key Features Design Philosophy: Compact dimensions, fuel efficiency, simplicity of design, affordability, reliability for its era. Unique Selling Points: Daihatsu's reputation for small, efficient engines; often offered good value for money. Manual Value Proposition Value For Mechanics: Provides authoritative, factory-level information for accurate diagnostics and repairs, reducing guesswork and time. Value For Diy: Empowers owners to perform their own maintenance and repairs, saving money and fostering a deeper understanding of their vehicle. 📋 Manual Details Coverage Areas Primary Coverage: Daihatsu Charade G10 (1977) with CB Type Engine Specific Systems: Engine, Transmission, Fuel System, Electrical System, Chassis, Brakes, Steering, Suspension, Bodywork, Maintenance, Troubleshooting, Specifications Page Count Estimated Pages: 300-500 (typical for factory service manuals of this era) Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Digital (likely PDF), printable pages 📖 Manual Coverage Systems Covered Engine: Complete disassembly, assembly, inspection, repair, and adjustment of the CB Type engine, including cylinder head, block, pistons, crankshaft, camshaft, valve train, lubrication system, cooling system, and ignition system. Fuel System: Carburetor (likely a single-barrel unit) disassembly, adjustment, and overhaul; fuel pump operation and testing; fuel filter replacement; fuel lines and tank inspection. Transmission: Removal, installation, disassembly, assembly, and adjustment of the manual transmission. Includes clutch operation, inspection, and replacement. Electrical System: Wiring diagrams, component testing and replacement for lighting, starting, charging (alternator/generator), ignition, and accessories. Includes fuse and relay identification. Chassis And Suspension: Front and rear suspension component inspection, replacement (shocks, springs, bushings), alignment specifications, steering system overhaul (rack and pinion or steering box), and wheel bearing service. Brakes: Front disc and rear drum brake system inspection, service, adjustment, and overhaul. Includes master cylinder, wheel cylinders, brake lines, and brake pads/shoes. Bodywork And Interior: Door mechanisms, window regulators, seat adjustments, basic trim removal and installation procedures, and perhaps exterior panel alignment guidance. Procedures Included Maintenance: Oil changes, filter replacements, spark plug service, ignition timing adjustment, valve clearance adjustment, coolant flushes, brake fluid changes, lubrication points, belt tensioning. Troubleshooting: Diagnostic procedures for common starting, running, electrical, and braking issues. Likely includes symptom-based fault finding charts. Repair: Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair or replacement of parts, and reassembly. Installation Removal: Detailed procedures for removing and installing major components like the engine, transmission, suspension assemblies, and body panels. Specifications And Charts: Torque values for critical fasteners, engine tune-up specifications (idle speed, ignition timing), valve clearances, fluid capacities, dimensions, and electrical system specifications. Technical Depth Depth: Comprehensive, suitable for both professional mechanics and advanced DIY enthusiasts. Covers detailed internal component repair and overhaul, not just basic maintenance. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) is the standard for scanned factory manuals. Print Quality Scan Quality: High-resolution scans of original factory documentation, ensuring readability of text, diagrams, and illustrations. Binding Type Original Binding: Typically a sturdy, professional binding suitable for workshop use. Paper Type Original Paper: Durable paper stock designed for frequent handling in a service environment. Searchability Text Search: Likely includes searchable text layers (OCR) for easy navigation and quick lookups of specific terms or procedures. ⚙️ Engine Specifications Primary Engine Engine Type: Inline-3 Cylinder, Naturally Aspirated Displacement: 993 cc (60.6 cubic inches) Bore X Stroke: Approx. 70.0 mm x 86.0 mm (typical for CB series) Compression Ratio: Approx. 8.5:1 to 9.0:1 (typical) Valve Train: SOHC (Single Overhead Camshaft) Fuel Delivery: Carburetor (likely a Hitachi or similar single-barrel unit) Performance Horsepower: Approx. 50-55 PS (DIN) at around 5500-6000 RPM Torque: Approx. 70-75 Nm (DIN) at around 3000-3500 RPM Fuel System Recommended Fuel: Unleaded gasoline (research grade varies by market, likely 91 RON or higher) Fuel Tank Capacity: Approx. 30-35 Liters (7.9-9.2 US Gallons) 🔧 Transmission Standard Transmission Type: 4-Speed Manual Optional Transmission Type Optional: 3-Speed Automatic (less common for this model/year) Features Clutch Type: Single Dry Plate, Cable Operated Transmission Fluid Spec: GL-4 Gear Oil, SAE 75W-90 or 80W-90 (consult manual for exact spec) 📐 Dimensions Exterior Length: Approx. 3495 mm (137.6 inches) Width: Approx. 1490 mm (58.7 inches) Height: Approx. 1350 mm (53.1 inches) Wheelbase: Approx. 2220 mm (87.4 inches) Front Track: Approx. 1260 mm (49.6 inches) Rear Track: Approx. 1240 mm (48.8 inches) Weights Curb Weight: Approx. 650-700 kg (1433-1543 lbs) Gross Vehicle Weight: Approx. 1100 kg (2425 lbs) 🛡️ Safety Features Ratings Crash Test Data: No standardized crash test data available from modern agencies for this era and vehicle type. Safety was less regulated. Active Features Braking System: Front Disc Brakes, Rear Drum Brakes....
300-500 (typical for factory service manuals of this era)
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF), printable pages
📖 Manual Coverage
Systems Covered
Engine:
Complete disassembly, assembly, inspection, repair, and adjustment of the CB Type engine, including cylinder head, block, pistons, crankshaft, camshaft, valve train, lubrication system, cooling system, and ignition system.
Fuel System:
Carburetor (likely a single-barrel unit) disassembly, adjustment, and overhaul; fuel pump operation and testing; fuel filter replacement; fuel lines and tank inspection.
Transmission:
Removal, installation, disassembly, assembly, and adjustment of the manual transmission. Includes clutch operation, inspection, and replacement.
Electrical System:
Wiring diagrams, component testing and replacement for lighting, starting, charging (alternator/generator), ignition, and accessories. Includes fuse and relay identification.
Chassis And Suspension:
Front and rear suspension component inspection, replacement (shocks, springs, bushings), alignment specifications, steering system overhaul (rack and pinion or steering box), and wheel bearing service.
Brakes:
Front disc and rear drum brake system inspection, service, adjustment, and overhaul. Includes master cylinder, wheel cylinders, brake lines, and brake pads/shoes.
Bodywork And Interior:
Door mechanisms, window regulators, seat adjustments, basic trim removal and installation procedures, and perhaps exterior panel alignment guidance.
Diagnostic procedures for common starting, running, electrical, and braking issues. Likely includes symptom-based fault finding charts.
Repair:
Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair or replacement of parts, and reassembly.
Installation Removal:
Detailed procedures for removing and installing major components like the engine, transmission, suspension assemblies, and body panels.
Specifications And Charts:
Torque values for critical fasteners, engine tune-up specifications (idle speed, ignition timing), valve clearances, fluid capacities, dimensions, and electrical system specifications.
Technical Depth
Depth:
Comprehensive, suitable for both professional mechanics and advanced DIY enthusiasts. Covers detailed internal component repair and overhaul, not just basic maintenance.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format) is the standard for scanned factory manuals.
Print Quality
Scan Quality:
High-resolution scans of original factory documentation, ensuring readability of text, diagrams, and illustrations.
Binding Type
Original Binding:
Typically a sturdy, professional binding suitable for workshop use.
Paper Type
Original Paper:
Durable paper stock designed for frequent handling in a service environment.
Searchability
Text Search:
Likely includes searchable text layers (OCR) for easy navigation and quick lookups of specific terms or procedures.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline-3 Cylinder, Naturally Aspirated
Displacement:
993 cc (60.6 cubic inches)
Bore X Stroke:
Approx. 70.0 mm x 86.0 mm (typical for CB series)
Compression Ratio:
Approx. 8.5:1 to 9.0:1 (typical)
Valve Train:
SOHC (Single Overhead Camshaft)
Fuel Delivery:
Carburetor (likely a Hitachi or similar single-barrel unit)
Performance
Horsepower:
Approx. 50-55 PS (DIN) at around 5500-6000 RPM
Torque:
Approx. 70-75 Nm (DIN) at around 3000-3500 RPM
Fuel System
Recommended Fuel:
Unleaded gasoline (research grade varies by market, likely 91 RON or higher)
Fuel Tank Capacity:
Approx. 30-35 Liters (7.9-9.2 US Gallons)
🔧 Transmission
Standard
Transmission Type:
4-Speed Manual
Optional
Transmission Type Optional:
3-Speed Automatic (less common for this model/year)
Features
Clutch Type:
Single Dry Plate, Cable Operated
Transmission Fluid Spec:
GL-4 Gear Oil, SAE 75W-90 or 80W-90 (consult manual for exact spec)
📐 Dimensions
Exterior
Length:
Approx. 3495 mm (137.6 inches)
Width:
Approx. 1490 mm (58.7 inches)
Height:
Approx. 1350 mm (53.1 inches)
Wheelbase:
Approx. 2220 mm (87.4 inches)
Front Track:
Approx. 1260 mm (49.6 inches)
Rear Track:
Approx. 1240 mm (48.8 inches)
Weights
Curb Weight:
Approx. 650-700 kg (1433-1543 lbs)
Gross Vehicle Weight:
Approx. 1100 kg (2425 lbs)
🛡️ Safety Features
Ratings
Crash Test Data:
No standardized crash test data available from modern agencies for this era and vehicle type. Safety was less regulated.
Active Features
Braking System:
Front Disc Brakes, Rear Drum Brakes. No ABS or power assistance standard.
Steering System:
Rack and Pinion (typical for G10), Manual Steering.
Passive Features
Seatbelts:
Standard front seatbelts (likely lap/shoulder belts).
Body Structure:
Reinforced passenger cell, crumple zones were basic by modern standards.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio, potentially with an 8-track player or cassette deck as an optional upgrade.
Dashboard:
Simple analog gauges for speed, fuel level, engine temperature, and basic warning lights. No digital displays.
Driver Assistance
Driver Aids:
None. No electronic driver aids like ABS, traction control, or airbags were standard or commonly available.
Connectivity
Connectivity Features:
None. Focus is on mechanical and electrical functionality.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000 km (3,000 miles) or 6 months, whichever comes first.
Oil Filter Replacement:
At every oil change.
Air Filter Replacement:
Every 10,000 km (6,000 miles) or as needed based on conditions.
Spark Plug Replacement:
Every 20,000 km (12,000 miles) or annually.
Ignition Timing Adjustment:
Every 20,000 km (12,000 miles) or if drivability issues arise.
Valve Clearance Adjustment:
Every 40,000 km (24,000 miles).
Transmission Fluid Change:
Every 40,000 km (24,000 miles) or every 2 years.
Brake Fluid Change:
Every 24,000 km (15,000 miles) or every 2 years.
Fluid Specifications
Engine Oil Capacity:
Approx. 3.0 Liters (3.2 US Quarts) with filter change.
Engine Oil Type:
API SF or SG, SAE 10W-30 or 10W-40 (seasonal viscosity may vary, consult manual)
Coolant Type:
Ethylene Glycol based coolant, typically 50/50 mix with distilled water.
Known Issues
Carburetor Issues:
Clogged jets, worn throttle shafts, vacuum leaks, leading to rough idle or poor performance. Requires regular cleaning and adjustment.
Ignition System Wear:
Points, condenser, rotor, and distributor cap wear can cause misfires and poor running. Requires periodic inspection and replacement.
Rust And Corrosion:
Common on vehicles of this age, especially in areas exposed to road salt. Focus on sills, wheel arches, and underbody.
Suspension Bushings:
Rubber bushings in suspension and steering can degrade over time, leading to clunks and imprecise handling. Replacement is common maintenance.
📚 Vehicle History
Brand Heritage
Daihatsu Origins:
Daihatsu Motor Co., Ltd. is Japan's oldest automobile manufacturer, founded in 1907.
Daihatsu Specialty:
Known for producing small, fuel-efficient, and affordable vehicles, including Kei cars and microcars.
Model Evolution
Charade Generation 1 Start:
The Daihatsu Charade was first introduced in 1977 as Daihatsu's first global car.
Charade G10 Significance:
The G10 was designed to compete in the burgeoning small car market, emphasizing economy and practicality.
Subsequent Generations:
The Charade went through several redesigns and generations until production ceased in the early 2000s.
Production
Manufacturing Location:
Japan
Production Period G10:
1977-1982
🏆 Awards & Recognition
Recognitions
Market Reception:
The Charade G10 was generally well-received for its economy and compact size in its target markets, particularly in Europe and Australia.
Specific Awards:
No major formal 'car of the year' awards are commonly associated with this specific early model, but it contributed to Daihatsu's growing reputation for economical transport.
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