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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....
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Daihatsu Charade G10 1977 Factory Service Repair Manual
🏷️ 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. 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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