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Daihatsu Charade G100 (GTTI) 1994 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Daihatsu Model: Charade Generation Code: G100 Trim Level: GTTI Year: 1994 Codes Engine Code: CB 👋 Introduction Market Position Segment: Subcompact hatchback, known for its sporty handling and performance in GTTI trim Competitive Analysis Key Competitors 1994: Honda Civic, Toyota Starlet, Suzuki Swift/Cultus, Mitsubishi Mirage Key Features Gtti Focus: Performance-oriented variant with enhanced engine, suspension, and braking components over standard models Manual Target Audience: Mechanics, professional technicians, and DIY enthusiasts seeking detailed repair and maintenance information 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Manual Language: English Format: Digital (likely PDF, intended for electronic distribution) Page Count Page Count: Estimated 500-1000 pages (typical for a comprehensive factory service manual) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, cylinder head, block, pistons, crankshaft, camshaft, timing belt/chain, lubrication system, cooling system, fuel injection system (CB engine specifics) Engine Electrical: Ignition system, starting system, charging system, ECU, sensors, wiring diagrams Transmission: Manual transmission (GTTI likely has a manual), clutch, drivetrain components, gearbox overhaul Suspension: Front and rear suspension systems, struts, springs, control arms, bushings, alignment procedures Steering: Steering rack, power steering system (if equipped), tie rods, steering column Brakes: Front and rear disc brakes (GTTI typically), brake calipers, rotors, pads, master cylinder, hydraulic lines, bleeding procedures Fuel System: Fuel tank, fuel pump, fuel filter, fuel lines, fuel injectors, evaporative emission control system Exhaust System: Exhaust manifold, catalytic converter, muffler, pipes, O2 sensors HVAC: Heating, ventilation, and air conditioning system, refrigerant, compressor, evaporator, heater core Body Exterior: Body panels, doors, hood, trunk lid, bumpers, trim, glass replacement, chassis Body Interior: Dashboard, seats, upholstery, interior trim, carpeting, door panels Electrical Components: Lighting system, wipers, horn, power windows, mirrors, central locking Diagnostics: Troubleshooting guides, diagnostic trouble codes (DTCs) if applicable, common fault diagnosis Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspections Disassembly Assembly: Step-by-step instructions for removing and reinstalling all major components and sub-assemblies Repair Rebuild: Detailed procedures for repairing or rebuilding engine, transmission, suspension, and braking components Adjustment: Idle speed adjustment, clutch adjustment, brake adjustment, suspension alignment Troubleshooting: Systematic approaches to diagnosing and resolving common and uncommon faults Wiring Diagrams: Complete electrical schematics for all vehicle systems Torque Specifications: Precise torque values for all critical fasteners Technical Depth Depth Level: Comprehensive (from basic maintenance to major component overhaul and diagnostics) Diagnostic Tools: Mentions diagnostic procedures, likely requiring basic hand tools and possibly a multimeter 📊 Manual Specifications File Format File Type: Likely PDF (Portable Document Format) Searchable: Searchable text content for quick information retrieval Print Quality Printability: Printable pages for use in a workshop environment Binding Type Binding: Not applicable for digital format, but implies a structure suitable for printing and binding Paper Type Paper Quality: Not applicable for digital format, but original factory manuals typically used durable paper ⚙️ Engine Specifications Primary Engine Engine Type: Inline 3-cylinder, naturally aspirated or turbocharged (GTTI typically turbocharged) Engine Code: CB Displacement: 1.0L (993cc) Performance Horsepower Gtti: Approximately 70-85 HP (depending on specific turbo setup and market) Torque Gtti: Approximately 75-85 lb-ft (depending on specific turbo setup and market) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Technical Specifications Bore X Stroke: 67.0mm x 72.0mm (typical for CB) Compression Ratio: 8.5:1 to 9.5:1 (typical, varies with turbo/NA) 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission Optional Transmission Type Optional: 4-speed Automatic Transmission (less common for GTTI) Features Clutch Type: Hydraulically operated, dry single plate clutch 📐 Dimensions Exterior Length: Approx. 3,720 mm (146.5 in) Width: Approx. 1,600 mm (63.0 in) Height: Approx. 1,365 mm (53.7 in) Weights Curb Weight: Approx. 800-850 kg (1,760-1,870 lbs) 🛡️ Safety Features Ratings Crash Safety Standards: Met Japanese safety standards of the era; international ratings may vary. Active Features Active Safety Features: Four-wheel disc brakes (standard on GTTI), sport-tuned suspension. Passive Features Passive Safety Features: Seatbelts, reinforced body structure. 💡 Technology Features Infotainment Infotainment Features: Basic AM/FM radio with cassette player, optional CD player; manual covers installation/removal of these components. Driver Assistance Driver Assistance Systems: Limited to standard safety features of the era; no advanced driver-assistance systems (ADAS). Connectivity Connectivity Options: None from the factory; potential for aftermarket upgrades. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, whichever comes first. Timing Belt Replacement: Recommended every 60,000-100,000 miles (96,000-160,000 km) or 5-7 years, as per manual recommendations. Spark Plug Replacement: Typically every 30,000-60,000 miles (48,000-96,000 km), depending on plug type. Fluid Specifications Engine Oil Type: API SG/SH, SAE 10W-30 or 10W-40 (refer to manual for exact viscosity based on climate). Engine Oil Capacity: Approx. 3.0 - 3.5 liters (3.2 - 3.7 US quarts) with filter change. Coolant Type: Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Transmission Fluid Type: GL-4 SAE 75W-90 (for manual...
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Daihatsu Charade G100 (GTTI) 1994 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Daihatsu
Model:
Charade
Generation Code:
G100
Trim Level:
GTTI
Year:
1994
Codes
Engine Code:
CB
👋 Introduction
Market Position
Segment:
Subcompact hatchback, known for its sporty handling and performance in GTTI trim
Competitive Analysis
Key Competitors 1994:
Honda Civic, Toyota Starlet, Suzuki Swift/Cultus, Mitsubishi Mirage
Key Features
Gtti Focus:
Performance-oriented variant with enhanced engine, suspension, and braking components over standard models
Manual Target Audience:
Mechanics, professional technicians, and DIY enthusiasts seeking detailed repair and maintenance information
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Manual
Language:
English
Format:
Digital (likely PDF, intended for electronic distribution)
Page Count
Page Count:
Estimated 500-1000 pages (typical for a comprehensive factory service manual)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, cylinder head, block, pistons, crankshaft, camshaft, timing belt/chain, lubrication system, cooling system, fuel injection system (CB engine specifics)
Engine Electrical:
Ignition system, starting system, charging system, ECU, sensors, wiring diagrams
Transmission:
Manual transmission (GTTI likely has a manual), clutch, drivetrain components, gearbox overhaul
Suspension:
Front and rear suspension systems, struts, springs, control arms, bushings, alignment procedures
Steering:
Steering rack, power steering system (if equipped), tie rods, steering column
Brakes:
Front and rear disc brakes (GTTI typically), brake calipers, rotors, pads, master cylinder, hydraulic lines, bleeding procedures
Fuel System:
Fuel tank, fuel pump, fuel filter, fuel lines, fuel injectors, evaporative emission control system
Exhaust System:
Exhaust manifold, catalytic converter, muffler, pipes, O2 sensors
HVAC:
Heating, ventilation, and air conditioning system, refrigerant, compressor, evaporator, heater core
Body Exterior:
Body panels, doors, hood, trunk lid, bumpers, trim, glass replacement, chassis
Body Interior:
Dashboard, seats, upholstery, interior trim, carpeting, door panels
Electrical Components:
Lighting system, wipers, horn, power windows, mirrors, central locking
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs) if applicable, common fault diagnosis
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspections
Disassembly Assembly:
Step-by-step instructions for removing and reinstalling all major components and sub-assemblies
Repair Rebuild:
Detailed procedures for repairing or rebuilding engine, transmission, suspension, and braking components
Adjustment:
Idle speed adjustment, clutch adjustment, brake adjustment, suspension alignment
Troubleshooting:
Systematic approaches to diagnosing and resolving common and uncommon faults
Wiring Diagrams:
Complete electrical schematics for all vehicle systems
Torque Specifications:
Precise torque values for all critical fasteners
Technical Depth
Depth Level:
Comprehensive (from basic maintenance to major component overhaul and diagnostics)
Diagnostic Tools:
Mentions diagnostic procedures, likely requiring basic hand tools and possibly a multimeter
📊 Manual Specifications
File Format
File Type:
Likely PDF (Portable Document Format)
Searchable:
Searchable text content for quick information retrieval
Print Quality
Printability:
Printable pages for use in a workshop environment
Binding Type
Binding:
Not applicable for digital format, but implies a structure suitable for printing and binding
Paper Type
Paper Quality:
Not applicable for digital format, but original factory manuals typically used durable paper
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 3-cylinder, naturally aspirated or turbocharged (GTTI typically turbocharged)
Engine Code:
CB
Displacement:
1.0L (993cc)
Performance
Horsepower Gtti:
Approximately 70-85 HP (depending on specific turbo setup and market)
Torque Gtti:
Approximately 75-85 lb-ft (depending on specific turbo setup and market)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Technical Specifications
Bore X Stroke:
67.0mm x 72.0mm (typical for CB)
Compression Ratio:
8.5:1 to 9.5:1 (typical, varies with turbo/NA)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transmission
Optional
Transmission Type Optional:
4-speed Automatic Transmission (less common for GTTI)
Features
Clutch Type:
Hydraulically operated, dry single plate clutch
📐 Dimensions
Exterior
Length:
Approx. 3,720 mm (146.5 in)
Width:
Approx. 1,600 mm (63.0 in)
Height:
Approx. 1,365 mm (53.7 in)
Weights
Curb Weight:
Approx. 800-850 kg (1,760-1,870 lbs)
🛡️ Safety Features
Ratings
Crash Safety Standards:
Met Japanese safety standards of the era; international ratings may vary.
Active Features
Active Safety Features:
Four-wheel disc brakes (standard on GTTI), sport-tuned suspension.
Passive Features
Passive Safety Features:
Seatbelts, reinforced body structure.
💡 Technology Features
Infotainment
Infotainment Features:
Basic AM/FM radio with cassette player, optional CD player; manual covers installation/removal of these components.
Driver Assistance
Driver Assistance Systems:
Limited to standard safety features of the era; no advanced driver-assistance systems (ADAS).
Connectivity
Connectivity Options:
None from the factory; potential for aftermarket upgrades.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, whichever comes first.
Timing Belt Replacement:
Recommended every 60,000-100,000 miles (96,000-160,000 km) or 5-7 years, as per manual recommendations.
Spark Plug Replacement:
Typically every 30,000-60,000 miles (48,000-96,000 km), depending on plug type.
Fluid Specifications
Engine Oil Type:
API SG/SH, SAE 10W-30 or 10W-40 (refer to manual for exact viscosity based on climate).
Engine Oil Capacity:
Approx. 3.0 - 3.5 liters (3.2 - 3.7 US quarts) with filter change.
Coolant Type:
Ethylene glycol-based coolant, typically a 50/50 mix with distilled water.
Transmission Fluid Type:
GL-4 SAE 75W-90 (for manual transmission).
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Common Wear Items:
Clutch wear, suspension bushings, exhaust system corrosion, turbocharger seals (if equipped).
Engine Specific Concerns:
Potential for oil leaks, timing belt failure if not replaced on schedule, injector clogging.
📚 Vehicle History
Brand Heritage
Daihatsu Focus:
Daihatsu, a subsidiary of Toyota, known for small, economical, and reliable vehicles.
Model Evolution
Charade Generations:
The G100 generation (1993-1998) represented a significant styling update and technological improvement over previous generations.
Gtti Introduction:
The GTTI variant was positioned as a 'hot hatch' version, targeting enthusiasts with its performance credentials.
Production
Production Period G100:
1993-1998
🏆 Awards & Recognition
Recognitions
Gtti Performance Reputation:
Generally recognized as a fun-to-drive and capable small hatchback in its segment during its production years.
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