Daihatsu Charade G11 1985 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Charade Generation: G11 Year: 1985 Codes Chassis Code: G11 Engine Code: CB Series 👋 Introduction Market Position Category: Subcompact hatchback Target Audience: Economy-conscious urban commuters and small families. Competitive Analysis Key Competitors Era: Suzuki Swift, Honda City, Nissan Micra/March, Toyota Starlet, Ford Fiesta. Key Features Design Philosophy: Compact, fuel-efficient, practical, and reliable transportation. Engine Type: Small displacement, inline-three or inline-four gasoline engines. Drivetrain: Front-wheel drive (FWD) was standard. Body Styles: Typically offered as a 3-door or 5-door hatchback. 📋 Manual Details Coverage Areas Primary Coverage: Daihatsu Charade G11 with CB Series Engine Secondary Coverage: 1985 Model Year Page Count Estimated Pages: Approximately 300-500 (typical for comprehensive factory service manuals of this era) Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed overhaul, repair, and troubleshooting of the CB Series engine (e.g., CB23, CB50, CB60, CB70, CB80, CB90 variants depending on market and trim). Engine Performance: Ignition timing, fuel mixture, emissions control systems (e.g., EGR, air injection). Fuel System: Carburetor (e.g., Mikuni, Hitachi) disassembly, cleaning, adjustment, and troubleshooting; fuel pump, fuel lines, and fuel tank service. Cooling System: Radiator, thermostat, water pump, cooling fan, hoses, and coolant specifications. Lubrication System: Oil pump, oil filter, oil pan, lubrication passages, and oil specifications. Ignition System: Spark plugs, ignition coils, distributor, spark plug wires, and ignition timing procedures. Transmission Manual: Manual gearbox overhaul, clutch service, gear shift linkage, and transmission fluid specifications. Transmission Automatic: Automatic transmission (if applicable for specific markets/trims) service, fluid, and adjustment procedures. Drivetrain: Front-wheel drive system, differential, driveshafts, CV joints, and axle service. Suspension Front: MacPherson strut assembly, control arms, bushings, ball joints, and wheel alignment specifications. Suspension Rear: Torsion beam, trailing arms, shock absorbers, bushings, and rear axle geometry. Steering System: Steering rack, tie rods, steering column, and power steering system (if equipped). Brake System Front: Front disc brake service, caliper, rotor, brake pads, and brake fluid specifications. Brake System Rear: Rear drum brake service, wheel cylinders, brake shoes, drums, and brake fluid specifications. Parking Brake: Parking brake mechanism, cable adjustment, and operation. Electrical System Charging: Alternator, voltage regulator, battery, and charging circuit testing. Electrical System Starting: Starter motor, starter solenoid, and starting circuit troubleshooting. Lighting System: Headlights, taillights, turn signals, interior lighting, and bulb specifications. Instrument Panel: Gauges, warning lights, and indicator functions. Wiper Washer System: Wiper motor, linkage, blades, and washer fluid system. HVAC System: Heating, ventilation, and air conditioning system (if equipped) components, operation, and basic service. Body Exterior: Door panels, hood, trunk lid, bumpers, body panel alignment, and glass service. Body Interior: Seat removal, interior trim, dashboard assembly, and soundproofing. Chassis Frame: Frame construction and underbody components. Torque Specifications: Comprehensive torque values for critical fasteners across all systems. Wiring Diagrams: Detailed electrical schematics for various circuits and options. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, air filter replacement. Engine Repair: Top-end overhaul (cylinder head), bottom-end overhaul (crankshaft, pistons), valve adjustments, timing belt/chain replacement, gasket replacement. Fuel System Repair: Carburetor rebuilding, fuel pump replacement, fuel filter replacement. Transmission Service: Clutch replacement, transmission fluid change, clutch linkage adjustment. Suspension Repair: Strut replacement, ball joint replacement, bushing replacement, wheel bearing replacement. Brake System Overhaul: Brake pad/shoe replacement, caliper/wheel cylinder rebuilding, rotor/drum resurfacing or replacement, brake fluid bleeding. Electrical Diagnostics: Troubleshooting common electrical faults using multimeter and wiring diagrams. Body And Trim Work: Door handle replacement, mirror replacement, interior trim panel removal and installation. Troubleshooting Guides: Diagnostic charts and symptom-based troubleshooting for various systems. Specifications And Tolerances: Precise measurements for engine components, bearing clearances, and critical tolerances. Technical Depth Depth: Comprehensive, covering complete engine rebuilds, transmission overhauls, and detailed electrical system diagnosis and repair. Diagnostic Capability: Advanced diagnostic procedures and troubleshooting for complex issues. Repair Level: Suitable for professional mechanics and experienced DIY enthusiasts. 📊 Manual Specifications File Format File Type: PDF Searchable Text: Likely Yes (common for scanned factory manuals) Resolution: High-resolution scans for clear diagrams and text. Print Quality Quality: Excellent (designed for clarity of technical diagrams and text) Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Family: Daihatsu CB Series Engine Configuration: Inline-3 cylinder, SOHC (Single Overhead Camshaft) Displacement Cc: Approximately 993 cc (common for CB23/CB50 variants) Bore X Stroke Mm: Detailed specifications available in manual (e.g., 70.0 x 64.0 mm for CB23). Performance Horsepower Ps: Typically 45-55 PS (for naturally aspirated versions) Torque Nm: Typically 70-80 Nm (for naturally aspirated versions) Fuel System Induction Type: Carbureted (e.g., single-barrel or two-barrel carburetors depending on market/spec). Fuel Type: Unleaded Gasoline (typically 87 octane or higher, consult manual for specific grades) Cooling System Cooling Method: Water-cooled Lubrication System Oil Capacity Liters: Approximately 3.0 - 3.5 liters (including filter), check manual...

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Description

🏷️ Basic Information

Identification

Make:

Daihatsu

Model:

Charade

Generation:

Year:

Codes

Chassis Code:

Engine Code:

CB Series

👋 Introduction

Market Position

Category:

Subcompact hatchback

Target Audience:

Economy-conscious urban commuters and small families.

Competitive Analysis

Key Competitors Era:

Suzuki Swift, Honda City, Nissan Micra/March, Toyota Starlet, Ford Fiesta.

Key Features

Design Philosophy:

Compact, fuel-efficient, practical, and reliable transportation.

Engine Type:

Small displacement, inline-three or inline-four gasoline engines.

Drivetrain:

Front-wheel drive (FWD) was standard.

Body Styles:

Typically offered as a 3-door or 5-door hatchback.

📋 Manual Details

Coverage Areas

Primary Coverage:

Daihatsu Charade G11 with CB Series Engine

Secondary Coverage:

1985 Model Year

Page Count

Estimated Pages:

Approximately 300-500 (typical for comprehensive factory service manuals of this era)

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed overhaul, repair, and troubleshooting of the CB Series engine (e.g., CB23, CB50, CB60, CB70, CB80, CB90 variants depending on market and trim).

Engine Performance:

Ignition timing, fuel mixture, emissions control systems (e.g., EGR, air injection).

Fuel System:

Carburetor (e.g., Mikuni, Hitachi) disassembly, cleaning, adjustment, and troubleshooting; fuel pump, fuel lines, and fuel tank service.

Cooling System:

Radiator, thermostat, water pump, cooling fan, hoses, and coolant specifications.

Lubrication System:

Oil pump, oil filter, oil pan, lubrication passages, and oil specifications.

Ignition System:

Spark plugs, ignition coils, distributor, spark plug wires, and ignition timing procedures.

Transmission Manual:

Manual gearbox overhaul, clutch service, gear shift linkage, and transmission fluid specifications.

Transmission Automatic:

Automatic transmission (if applicable for specific markets/trims) service, fluid, and adjustment procedures.

Drivetrain:

Front-wheel drive system, differential, driveshafts, CV joints, and axle service.

Suspension Front:

MacPherson strut assembly, control arms, bushings, ball joints, and wheel alignment specifications.

Suspension Rear:

Torsion beam, trailing arms, shock absorbers, bushings, and rear axle geometry.

Steering System:

Steering rack, tie rods, steering column, and power steering system (if equipped).

Brake System Front:

Front disc brake service, caliper, rotor, brake pads, and brake fluid specifications.

Brake System Rear:

Rear drum brake service, wheel cylinders, brake shoes, drums, and brake fluid specifications.

Parking Brake:

Parking brake mechanism, cable adjustment, and operation.

Electrical System Charging:

Alternator, voltage regulator, battery, and charging circuit testing.

Electrical System Starting:

Starter motor, starter solenoid, and starting circuit troubleshooting.

Lighting System:

Headlights, taillights, turn signals, interior lighting, and bulb specifications.

Instrument Panel:

Gauges, warning lights, and indicator functions.

Wiper Washer System:

Wiper motor, linkage, blades, and washer fluid system.

HVAC System:

Heating, ventilation, and air conditioning system (if equipped) components, operation, and basic service.

Body Exterior:

Door panels, hood, trunk lid, bumpers, body panel alignment, and glass service.

Body Interior:

Seat removal, interior trim, dashboard assembly, and soundproofing.

Chassis Frame:

Frame construction and underbody components.

Torque Specifications:

Comprehensive torque values for critical fasteners across all systems.

Wiring Diagrams:

Detailed electrical schematics for various circuits and options.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, air filter replacement.

Engine Repair:

Top-end overhaul (cylinder head), bottom-end overhaul (crankshaft, pistons), valve adjustments, timing belt/chain replacement, gasket replacement.

Fuel System Repair:

Carburetor rebuilding, fuel pump replacement, fuel filter replacement.

Transmission Service:

Clutch replacement, transmission fluid change, clutch linkage adjustment.

Suspension Repair:

Strut replacement, ball joint replacement, bushing replacement, wheel bearing replacement.

Brake System Overhaul:

Brake pad/shoe replacement, caliper/wheel cylinder rebuilding, rotor/drum resurfacing or replacement, brake fluid bleeding.

Electrical Diagnostics:

Troubleshooting common electrical faults using multimeter and wiring diagrams.

Body And Trim Work:

Door handle replacement, mirror replacement, interior trim panel removal and installation.

Troubleshooting Guides:

Diagnostic charts and symptom-based troubleshooting for various systems.

Specifications And Tolerances:

Precise measurements for engine components, bearing clearances, and critical tolerances.

Technical Depth

Depth:

Comprehensive, covering complete engine rebuilds, transmission overhauls, and detailed electrical system diagnosis and repair.

Diagnostic Capability:

Advanced diagnostic procedures and troubleshooting for complex issues.

Repair Level:

Suitable for professional mechanics and experienced DIY enthusiasts.

📊 Manual Specifications

File Format

File Type:

Searchable Text:

Likely Yes (common for scanned factory manuals)

Resolution:

High-resolution scans for clear diagrams and text.

Print Quality

Quality:

Excellent (designed for clarity of technical diagrams and text)

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Family:

Daihatsu CB Series

Engine Configuration:

Inline-3 cylinder, SOHC (Single Overhead Camshaft)

Displacement Cc:

Approximately 993 cc (common for CB23/CB50 variants)

Bore X Stroke Mm:

Detailed specifications available in manual (e.g., 70.0 x 64.0 mm for CB23).

Performance

Horsepower Ps:

Typically 45-55 PS (for naturally aspirated versions)

Torque Nm:

Typically 70-80 Nm (for naturally aspirated versions)

Fuel System

Induction Type:

Carbureted (e.g., single-barrel or two-barrel carburetors depending on market/spec).

Fuel Type:

Unleaded Gasoline (typically 87 octane or higher, consult manual for specific grades)

Cooling System

Cooling Method:

Water-cooled

Lubrication System

Oil Capacity Liters:

Approximately 3.0 - 3.5 liters (including filter), check manual for exact capacity.

🔧 Transmission

Standard

Type:

4-speed Manual Transmission

Optional

Type:

3-speed Automatic Transmission (market dependent)

Features

Clutch Type:

Single dry plate, hydraulically operated (typically)

Gear Ratios:

Detailed gear ratios for manual and automatic transmissions are in the manual.

Transmission Fluid Type:

Manual: GL-4 gear oil (viscosity typically 75W-85 or 75W-90). Automatic: DEXRON II or equivalent. Consult manual for specific part numbers.

📐 Dimensions

Exterior

Length Mm:

Approx. 3535 mm (3-door model)

Width Mm:

Approx. 1570 mm

Height Mm:

Approx. 1370 mm

Wheelbase Mm:

Approx. 2250 mm

Weights

Curb Weight Kg:

Approx. 700-750 kg (depending on trim and equipment)

Gross Vehicle Weight Kg:

Consult manual for specific GVWR.

🛡️ Safety Features

Ratings

Crash Test Data:

Limited official crash test data available for this era and model globally. European NCAP was not established, and US NHTSA testing was less comprehensive for small imports.

Active Features

Brakes:

Front disc, rear drum (standard). ABS was not typically available on this model.

Passive Features

Seatbelts:

Front lap and shoulder belts, rear lap belts (typical).

Body Structure:

Reinforced passenger cell for its time, but lacks modern crumple zone technology.

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM radio, often with cassette player. Aftermarket head units are common upgrades.

Driver Assistance

Not typically available.

Airbags:

Driver airbag was often an option or not available in many markets at this time.

Connectivity

Bluetooth Usb:

Not applicable; features from a much later era.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 5,000 km or 6 months, whichever comes first (typical for this era; consult manual for specific recommendation).

Oil Filter Replacement:

At every oil change.

Air Filter Replacement:

Every 15,000-20,000 km or as needed based on driving conditions.

Spark Plug Replacement:

Every 20,000-30,000 km. Specific plug type and gap are critical (refer to manual).

Timing Belt Replacement:

Critical. Typically every 60,000-100,000 km or 4-5 years. **Interference engine consideration: Failure can cause severe engine damage. Check manual for exact interval and procedure.**

Fluid Specifications

Engine Oil API Grade:

API SF or SG class. Viscosity typically 10W-30 or 10W-40 depending on ambient temperature. Consult manual.

Coolant Type:

Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio). Check manual for specific OEM recommendations if available.

Brake Fluid Type:

DOT 3 or DOT 4.

Known Issues

Carburetor Issues:

Clogged jets, worn accelerator pump diaphragm, idle speed instability, often requiring cleaning and rebuilding.

Ignition System Wear:

Worn distributor cap and rotor, aging spark plug wires leading to misfires.

Suspension Bushings:

Degradation of rubber bushings in control arms and sway bars leading to clunking noises and poor handling.

Rust And Corrosion:

Common issue on older vehicles, particularly in areas exposed to salt and moisture. Check wheel wells, rocker panels, and underbody.

Cooling System Leaks:

Aging hoses and radiator core support can lead to coolant leaks.

📚 Vehicle History

Brand Heritage

Daihatsu Focus:

Daihatsu's reputation for producing small, economical, and reliable vehicles.

Model Evolution

Charade Generations:

The G11 was the third generation of the Daihatsu Charade, evolving from earlier models. It was characterized by its more modern styling compared to its predecessors.

Production

Production Years G11:

1983-1987

Manufacturing Location:

Japan (primarily)

🏆 Awards & Recognition

Recognitions

General Perception:

Praised for its affordability, fuel efficiency, and maneuverability. It was a practical choice for basic transportation.

Ratings

Consumer Reports Era:

Reviews from this period would have focused on economy and practicality rather than performance or advanced features.

Certifications

Emissions Standards:

Designed to meet the emissions regulations of the mid-1980s for its respective markets. Manual details specific emission control systems and testing procedures.