WORKSHOP MANUAL DAIHATSU CHARADE Chassis FOREWORD “This workshop manual contains essential information regarding the construction, Gisassemblyreassembly procedures and servicing methods of the power tain, Suspension, brake system, steering system, body and electrical system of the DAIHATSU CHARADE. We hope that this. workshop manual i consulted to the fullest extent, in Combination with the workshop manual ofthe Type CB Engine. Type CL Engine, fad Trouble shooting for Engina contro! system of Type C8-80 Engine so that ‘Quality servicing may be assured at al imes. Furthermore, due i contnuing improvements in the design, contents end speciicatons in this workshop manual may be parly revised without advance notice and without incuring any obligation to us. Published in April, 1987 DAIHATSU MOTOR CO., LTD.SECTION INDEX NAME SECTIOL GENERAL INFORMATION CLUTCH | MANUAL TRANSMISSION Coote NOES COLe INS j_— | AUTOMATIC TRANSMISSION [eee | FRONT AXLE & SUSPENSION REAR AXLE & SUSPENSION ‘STEERING BRAKES BODY | BODY ELECTRICAL ar) ‘APPENDIXDAIHATSU CHARADE Chassis SECTION 1 GENERAL INFORMATION HOW TO READ THIS BOOK (CONTENTS OF EXPLANATION 1 Schematic Diagram of Ce 2 Servicing Procedure 4. Trouble Shooting 1 Table of SSTs Used 5 Table of Service Speciications 6: Table of Tightening Torque 7 Wing Diagrams DEFINITIONS OF TERMS ABBREVIATION CODES. ‘SERVICING OPERATIONS. {JACKING POINTS AND SUPPORTING POINTS OF SAFETY STANDS ‘SUPPORTING POINTS OF TWGENERAL INFORMATION HOW TO READ THIS BOOK CONTENTS OF EXPLANATION 4. Schematic Diagram of Components (f) The schematic diagram of components that appears atthe beginning of each secon describes the nomenclature and installed conditions o each component. Futhermare, the tightening torque is posted in the foure (2) Those parts whose reuse isnot permitted bear a “k* mark for an identfication purpose, Be certin to replace these parts with new ones during the assembly (Example) By: pemrgroe oe Neon parts 8 = Rese cap soacee @Rewewor suprragn {@ Seach operating tose Bilan ojan sor se Samp = Serose ODeme, Seat => 29 a Sanne e0¢e it eying reat i aoe 2. Servicing Procedure (@) Inprincible, the servicing procedure is described inthe folowing sequence given below: Removal —+ Inspection “> Insialation, and Disassembly — Inspection —» Assembly. (2) The explanation covers detaled servicing methods, spectfiations and notes. (@) The main pont of each item explains the servicng section and senicing procedure, using llustations. (example) What do Howiodot [aaeaoiniaten Ci 7 3. Brake tube ination (G) Insta the rake tube fo the wheel cinder temporary by hands. (2) Rohn the brake tube tothe wheel cylinder, using he folowing SST. , ST. 09751-2601 1-000 one ~ hi Min.(GENERAL INFORMATION cnet eae (@) The inspection section inthis manual deseribes only checking operation. Therefor, if you find any ‘uitnetion race any detective parts with new ones. 3, Trouble Shooting {ty At for the three-speed automatic ransmission, the trouble shoating table is provided in this book 80 that you may reacily locate causes of troubles, 4, Table of SSTs Used (1) The SSTs appearing in tis book are listed in the appendix of the book 5. Table of Service Specitications (iy The service specifications necessary forthe service are summarizes in the appendix of his book 6, Table of Tightening Torque {i As for hose sections wher thet tightening torque must be controled during the service, the tightening torque is speciad inthe appendix of tis Book. 7. Wiring Diagrams. {Gy The vehicle winng diagrams are posted inthe appendix ofthis book separately for Type CB and Type CL engines. DEFINITIONS OF TERMS Specified Value .. A value which represents the allowable range during the inspection and adjustment. Limit ‘A maximum or 8 minimum Imit which the value should not exceed or fal! beow. Nowe ‘an item which requires special alertion or an tem which is prohibited curing the(GENERAL INFORMATION {ABBREVIATION CODES The ebro coon he ope te wen mara etre lois pect Aobregeton Original word i ‘Meaning st Laat oe Bp oe —— [sc rie reread [tan er eee ELS (ana ELSA RET ITARRERSe eee aT eR aI os ows ERaip ea eae ceamencen ‘She at pa may oe Siswo ure agus “Over Sued pars ance ose sain brotindaceeecta ose Terenas mats corer pe (aromas us| ose Sie eee aver oe oars Sapna eae ce nee alee | RRS RAT a, magw te in ‘Sone of ‘Rese daagatinmurbarhane Coos sfc by Sosy errs oka ESSreaere sea eee nares see Sige ea uae ean mea snae Ger Ene naue esas ieee DiS ERR aaa ea ce Epeily secre pocwecmemcmsh oe ein \nhbrees engine ale wr Gove ens ae Casslid es CC, CO and 80.08 Seaton oer nv errs ct er restos Seon ma eer 2 vemety ‘else ial or suse to extn fof a sie compere. eee SESE perer ereweronetir ror tare eaT ww ere ae koing parle ac of [Sra at in a sear ae co | Seth ers an convene one Sides | RSE ‘The abbreviation codes that appear in the figure stand forthe following, respectively. @ | Bot © | Sew @ [rs << hi Iti. a(GENERAL INFORMATION Ee ee SERVICING OPERATIONS 11. Jacking up iy When ony the front section o rear section of the vehicle is jacked up, be sure to place checks at the wheels 60 as to insure safe operations, (@) When tne vehicle nas baen jacked up, be sure to support the vehicle at the specified sectons using safety stands. 2. In the case of repairs on the electrical system or the removal/nstallation of the engine, first disconnect the negative © terminal of the battery. Then, proceed to the operations. (On ‘lock-equipped vehicles, set the time of the clock after the negative ©) terminal of the battery is connected.) {3 Repairing fuel system of Type CB-80 engine ‘Type €8-80 engine employs a high fuel pressure. Therefore, the folowing notes should be observed UF When the union bois removed, take a measure to prevent the fuel fom splashing with a cloth a the like, Siacken the union bolt gradual (@) Tiahten each connecting section to the speciied torque. (6) Atach the specified clip fo each connecting section. 4. For increased work efficiency and improved accuracy, be sure to utilize the SSTs (Special ‘Service Tools) effectively. ‘5, Removal and disassembly (1) When disassembling complicated components, put stamped marks or mating marks on those sections vanere such marks do not affect ther functions so that the assembling operation may be performed easily (@) Each time a partis removed, check the par for the assembied condition, delormation, breakage, roughness and scratches. {@) Arrange the cisessembied parts In he disassembling order, In addition, separate and arrange those paits to be replaced and those parts to be reused. (4) Thoroughly clean anc wash those pars tobe reused, (6) inspection and measurement of part . PPetiorm thorough inspection and measurement on those parts to be reused, as required 6. Installation and assombly (i) Assemble those satstactory part, folowing the proper procedure and specified standards (acjusing ‘values anc’ tightening torque, et). {g) knsure tnat seal packings an grease we apotied 1 those sections where such spplictionis noodod, {@) Be sure fo use new packings, Gaskets, cater pins and 80 for {@) Encure thatthe spectieg bolts and ruts ony be used, Moreover, where specified, make sure to employ a torque wrench fo lighien bots and nuts to the specified toraus. Make sure to use only genuine parts for every replacement 77._Adjustment and operation chock ‘Adjust he reassembled or replaced components to the servicing specifications, using gauges and testers, as require. 8. Handling of hose, etc. (G) Connect ve! hoses and water hoses, etc. securely so that they exhibit no leakage. {@) When disconnecting fue! noses, make sure thet no ful is splashed around the hose. (Special care must be exercised as to the engine mount rubber, etc, for here isa possibilty thatthe rubber is deteriorated by the pettolbased tquid)GENERAL INFORMATION 8. Touch-up painting i paint fins surfaces ofthe body and bolts should be scratched when Bots, ete. are removes during the ‘ody alignment, ete. touch up the seratch with @ paint ving the same color as that of the Body. JACKING POINTS AND SUPPORTING POINTS OF SAFETY STANDS ‘© Jacking point Front side. Engine mounting canter member (Place the jack below the member, exercsing ‘care ofthe exhaust pipe) Rear side .... Center of rear floor cress member Engi mounting cetarmerer Peer ar rose rember oxen" ener Spgtea sit Baeyeee ‘© Supporting points of safety stands Four supporting points are located atthe right and left sides. (The supporting points have been strengthened by spotweiding reinforcements. Never support the vehicle at points ether than the spectiod pons) nansoomse, . Frntandrearon oor moet 322 /pgar on 3-dor mes rer cd SUPPORTING POINTS OF TWO-POST LIFT [Align the supporting pads ofa two-post it with the suoporing points of safety stands, as indicated in the figure above, a as Mt, “DAIHATSU CHARADE Chassis SECTION 2 CLUTCH DESCRIPTION "TROUBLE SHOOTING : CLUTCH PEDAL ADJUSTNENT ‘CLUTCH PEDAL AND ‘CLUTCH RELEASE ‘COMPONENTS REMOVAL vom INSPECTION INSTALLATIONCLUTCH DESCRIPTION TROUBLE SHOOTING a = = = Gennes |; Eaaeor miniere™ |: Gage [= cea TEgeeas mmr” |: aaa iaeaae 1 SERRA cit nin | «Fas ais n PERC be et a ms seems Term aaeigeiatanta | us angers | 59 a Semenmaeman™ | faiscana a Eero Se. st BREE oey | RBar cs! a ‘Grabbing and challering | © Wom or oly cich dacinngs. | © Check auch dee and replace, as | 2-8 oa mae ¢ Fetvesenreote 1 Selene o TEER ony |] RES zt ibaa | RRS. St Soar fs croeaie fos ear TOERETSERGRE wom SREB | 27 {Bei ecmtmoonenna | ropa enue Tn ed WES | BRE Si + FEES capregn sa. o° | « Fennec = ‘wom tp end ot spr, CLUTCH PEDAL ADJUSTMENT 1. Check the clutch pedi forthe installation height Pedal instalation Peight (Cistance between pedal pad upper surface’s center and ‘dash pane) LHD. vehicle 189.5 - 194.5 mm (7.46 - 7.68 inch) LHD. vehicle 181.5 - 186.5 mm (7-15 - 7.34 inch) 2. Adjust the pega! nstation nelght, as required (2) Slacken the lock nut. Turn the stopper bot unl the Installation height contocms to the specification (@) Tighten the lock nut ed neigh Pi tes. 19¢5 am 749- T35inen) CHD ters. tease (716.73¢mnen)CLUTCH 3. Clutch cable adjustment (G1) Pulthe outer cable ight with a force of 2-5 kg (8.4 411.0 1b). Check the clearance. (2) Ensure that the stopper (protruding portion) is fted securely in the adjusting groove. (@) Adjusting postion of clutch outer cable 3-6 mm (0.12 - 0:24 Inch) 4, Adjust the clutch pedal ree travel. (1) Depress the clutch pedal gradually unt you fee! a resistance ftom tne clutch. Measure the depressing tance upto this point. Pedal Free Travel: 15 ~90 mm (0.59 - 1.18 inch) 5, Adjust the clearance between the cistch pedal and the floor with the pedal fully depressed. (Minimum clearance ‘betwen the dash panel and the pedal arm) Vehicles mounted with Type CB-80 engine: not less than 20 mm (0.79 inch) Vehicle other than those mounted with Type CB-60 ‘engine: not less than 25 mm (0.88 inch 3G mm (012-024 ch) ensure nat stopcerxouldieg pin Jetted imacutong rg soo 5.200 (058-1 ety Clarnce Beean SoeCLUTCH CLUTCH PEDAL AND CLUTCH RELEASE CABLE COMPONENTS: pee Lary een seamen oe = = Ex BE aneeane ras REMOVAL Toone oe py (Oy LHD hn Sen page 8-7) 2. Fits Bo rt wet tts tan See ee cee anna aaa! 2. Faro tng baRemove the bot with washer. Remove the cable brackel attaching bolt. Remove the clutch cable. Remove the clutch pedal assembly. Remove the soring, ‘bush and spacer. INSPECTION Inspect the folowing pats. 1 2 3 4 6 ‘Bush for wear or damage. Pedal spacer for wear or damage. Pedal for damage or deformation, Pedal pad for wear or damage. ‘Spring for flattened conditon. Each section of clutch cableCLUTCH INSTALLATION 1 ‘Apply MP grease tothe following points () Insie of bush and spacer (@) Connecting section of clutch pedal and release cable Install the spring, bush and spacer to the clutch pedal assembly. Then, stall the assembly tothe pedal bracket Inetal the bolt with washer In poston, Insta both ends of the elutch cable, Tighten the bracket withthe bots. “Tightening Torque: 0.4 - 0.7 kg-m (2.95.1 b) Install the adjusting bot. Tighten the nut Tightening Torque: 1.5 - 22 kg-m (11 - 16 b) Depress the clutch pedal to or three times. Proceed to agjst the chitch peda, folowing the procedure at page 2-2. instal the brake pedal Ay. (Only for LH.D. vehicies. See page 8-8) hi Nis. ad Jo Ts-220m (dos 59%)CLUTCH UNIT COMPONENTS: yas gas se — : = on page ) ‘SEE Se Soren 2. Release the lock plate. Proceed to remove the lock pate along with the Bot.CLUTCH 3. Pull out the clutch release fork lover. Remove the bush felease lover yoke, spring, release Deering cip and release bearing hub. 44, Remove the cluich cover from the flywheel. Take out the clutch disc. INSPECTION 4. Check the pressure plate and flywheel surtace for scores, cracks and discoloration. 2 Check the diaphragm spring tips for wear, rust and breakage. 3. Check the clutch disc for wear and runout ‘Allowable Wear Limit (vet Depth): (08 mm (0.012 inch) Hin. ad i 4CLUTCH ee 4 ‘Alowable Limit of Lateral Runout: 1.34 mm (0.0528 inch) NOTE: Measure the lateral runout with the clutch disc assembled ‘onto a new input shaft Check to see if the release bearing rotates smoothly: Rotate the release bearing by your hand, while appiying a pressure to the beating ina thrust direction. Check to see IFthe Dearing rotates without any abnormal feeling oF binging CCheck the release bearing hub, clp-contacting surlace ‘and hub-teshousing siding section for damage and wear Check to see if the lip has the configuration as show in the figure in its hotzontal pian cus de -Asccelcoiguraion~ reise ‘one Sens SeCLUTCH INSTALLATION 1. Install the clutch aise and cluich cover, using the following SST. ‘SST:_09901-87202.000 Bol Tightening Torque: 1.5 - 2.2 kgm (11 - 16 fb) NOTE: (1) Assemble the clutch disc in the direction as shown in the figure, (2) Tighten the bolts evenly, staring with those bots provided near the locating pin, (2 Arp log le chasis reset the dich dic spines 2. Check the clutch cover diaphragm spring ti fr variation in height. Adjust the ciaphragm spring tips, as required. ‘Check ‘Allowable Limit of Variation in Height (0.7 mm (0.028 inch) SST: 09302-$4701-000 Ben. ‘Adjustment ‘Align the diaphragm spring tips at such a height that ‘makes the number of ps to be adjusted at a minimum umber. SST: 09893-00011-000 3, Assemble the clutch release bearing hub and release ‘beating lip to the clutch release lever yoke (1) Bing the cut-out section of the release lever yoke in contact withthe cp. Under the concltion described in (1), assemble the lever yoke by turning t 180 degrees. NoTE: ‘Apply iong-lte chassis grease to the yokeo- hub sling ‘ection and bearing-to-housing case siding secon, bin, = 1 e® 1 a & rosewood oor erkea00 10° ing (reste aptying ports4. Assemble the bush, dust seal, torsion spring and clutch release lever in positon. 5, Assemble the ott with washer, wih the lock plate interposed Tightening Torque: 3.0 - 4.0 kgem (22 - 29 tb) 6. Check the release hub and yoke for proper operation. ‘Operate the clutch release lever about 50 times. Chack the section A of the clip. f the cip exhibits excessive spread and there is a Ikelinood that the clio may be tached, replace it with # new clo. 7. Install he trenemission assembly to te vehicle (See page 3-7.)DAIHATSU CHARADE Chassis SECTION 3 MANUAL TRANSMISSION ‘SECTIONAL VIEW .. a2 MANUAL TRANSMISSION ASSEMBLY ~.. 3-9 PEMOVAL a3 INSTALLATION 3-7 F DISASSEMBLY, INSPECTION AND ASSEMBLY OF "TRANSMISSION HOUSING, CASE S/A AND CASE COVER ‘COMPONENTS DISASSEMBLY REPLACEMENT INSPECTION ASSEMBLY . ‘APPLICATION POINTS OF GREASE & BOND [AND APPLICATION PROCEDURE woe 3-22 DISASSEMBLY, INSPECTION AND ASSEMBLY ‘OF INPUT SHAFT 3-28 ‘COMPONENTS DISASSEMBLY INSPECTION. ASSEMBLY DISASSEMBLY, INSPECTION AND ASSEMBLY ‘OF OUTPUT SHAFT ‘COMPONENTS DISASSEMBLY INSPECTION .. ASSEMBLY DISASSEMBLY, INSPECTION AND ASSEMBLY OF STH GEAR... 3-38 (COMPONENTS 9-38 DISASSEMBLY = 3-38 INSPECTION "3-40 ASSEMBLY 3-42 DISASSEMBLY, INSPECTION AND ASSEMBLY OF DIFFERENTIAL CASE nee BA COMPONENTS aa DISASSEMBLY 3-45 INSPECTION .. 3-48 SEMBLY . 3-87 DISASSEMBLY, INSPECTION AND ASSEMBLY OF ‘CONTROL LINKAGE-RELATED PARTS... 9-50 3-50 382 3-58 ASSEMBLY . 3-55 SHIFT LEVER & SELECTING ROD encwsccu- 9-59 ‘COMPONENTS 3-59 3-60 361 261 INSPECTION .. 3-63 ‘ASSEMBLY 3-68 INSTALLATION 3-65 i :