This dedicated engine service repair manual covers the Daihatsu CB series engines (CB-23, CB-61, CB-80) as used in the Daihatsu Charade. Complete engine assembly overhaul, cylinder head service, fuel system and carburetor rebuilding, cooling system repair, alternator and starter diagnostics. Includes detailed engine electrical wiring diagrams, tightening torque specifications, special tool identification, and maintenance schedules. The essential workshop reference for Daihatsu engine technicians and experienced DIY mechanics.
Daihatsu CB Series Charade CB-23 CB-61 CB-80 Engine Service Repair Workshop Manual PDF
VEHICLE/EQUIPMENT INTRODUCTION:
The Daihatsu CB series engines power the popular Daihatsu Charade subcompact car across multiple generations and markets. These compact inline-three and inline-four cylinder engines are renowned for their remarkable fuel efficiency, lightweight construction, and straightforward mechanical design that makes them exceptionally serviceable. The CB-23, CB-61, and CB-80 engine designations cover specific variants within this engine family, each optimized for different market requirements and emissions standards. Daihatsu's engineering philosophy for these engines emphasizes simplicity, reliability, and economic operation, making the Charade one of the most affordable vehicles to own and maintain in its class worldwide. These engines have been particularly popular in Asian, European, and Australian markets where compact dimensions and low running costs are highly valued.
SERVICE & REPAIR SCOPE:
- Complete engine identification and variant specification lookup
- Engine body disassembly and reassembly including block inspection
- Piston and connecting rod removal, ring replacement, and cylinder wall honing
- Cylinder head removal, valve guide inspection, and valve seat cutting
- Camshaft bearing clearance measurement and cam lobe inspection
- Crankshaft journal micrometer measurement and bearing shell selection
- Fuel system servicing including carburetor overhaul and fuel line inspection
- Carburetor float bowl cleaning, jet replacement, and idle mixture adjustment
- Cooling system thermostat testing, water pump seal replacement, and radiator flush
- Complete exhaust system inspection and manifold gasket service
- Alternator bench testing, brush replacement, and diode array testing
- Voltage regulator function verification and output voltage adjustment
- Complete electrical wiring diagram analysis for engine-related circuits
- Ignition system distributor servicing with timing specification
- Starter motor solenoid testing, brush inspection, and armature diagnosis
- Engine special tool identification and usage instructions
- Maintenance checklist and scheduled service interval reference
- Tightening torque specifications for all critical engine fasteners
TECHNICAL SPECIFICATIONS:
- Engine family: Daihatsu CB Series (Charade application)
- Variants: CB-23, CB-61, CB-80
- Configuration: Inline-3 and inline-4 cylinder, 4-stroke
- Valve train: SOHC overhead camshaft
- Fuel system: Carburetor (model-specific)
- Cooling: Water-cooled with thermostat-controlled circulation
- Lubrication: Full-pressure force-feed with oil filter
- Ignition: Electronic distributor ignition
- Special tools: Model-specific engine service tools identified
DIAGNOSTIC INFORMATION:
- Engine oil pressure warning light on: Check actual oil pressure with mechanical gauge, inspect oil pump pickup screen for sludge blockage, verify oil viscosity matches ambient temperature specification, examine main and connecting rod bearing clearance
- Engine overheating: Test thermostat opening temperature in boiling water bath, inspect water pump for impeller slippage on shaft, verify cooling fan belt tension, flush radiator of scale deposits, bleed air from cooling system
- Excessive fuel consumption: Inspect carburetor float level and needle valve condition, check air filter element for restriction, verify ignition timing with timing light, test engine compression on all cylinders against specification
- Engine misfire on acceleration: Test ignition coil output voltage, check distributor cap for carbon tracking or moisture, inspect spark plug wires for resistance within specification, verify carburetor accelerator pump discharge
- Blue exhaust smoke during operation: Check valve stem oil seal condition, inspect piston ring end gap and side clearance, examine cylinder wall cross-hatch pattern, verify PCV valve is not restricted
- Difficult cold starting: Check choke operation (manual or automatic), verify spark plug heat range suitability, test starter motor cranking speed, inspect fuel delivery from tank to carburetor, check for vacuum leak at intake manifold
- Abnormal engine noise: Knocking suggests main or connecting rod bearing wear; ticking may be valve clearance out of adjustment; rattling could be timing chain tensioner failure; whining from front suggests water pump bearing wear
- Alternator not charging battery: Test alternator output at B+ terminal with engine running (should read 13.5-14.5V), inspect drive belt condition and tension, check voltage regulator function, test battery terminal connections for corrosion
ILLUSTRATIONS & DIAGRAMS INCLUDED:
- Complete engine cross-section with CB series component identification
- Cylinder head assembly showing valve, spring, and camshaft arrangement
- Piston and connecting rod assembly with ring groove detail
- Crankshaft main bearing housing and thrust bearing arrangement
- Carburetor exploded view with jet sizing and float height specifications
- Cooling system water pump assembly with seal identification
- Alternator cross-section showing brush holder and diode layout
- Complete engine electrical wiring diagram with ignition circuit detail
- Distributor assembly with advance mechanism cross-section
- Starter motor exploded view with solenoid detail
- Exhaust manifold attachment and gasket specification
- Special tool identification drawings with usage references
- Maintenance check list with service interval schedule tables
COMPATIBILITY:
- Daihatsu Charade CB-23 engine
- Daihatsu Charade CB-61 engine
- Daihatsu Charade CB-80 engine
- English language edition
- PDF format, fully searchable and printable
FILE PROPERTIES:
- Format: Searchable PDF
- Language: English
- Delivery: Instant digital download
- Access: Download anytime after purchase
Daihatsu CB Series Charade CB-23 CB-61 CB-80 Engine Service Repair Workshop Manual PDF
VEHICLE/EQUIPMENT INTRODUCTION:
The Daihatsu CB series engines power the popular Daihatsu Charade subcompact car across multiple generations and markets. These compact inline-three and inline-four cylinder engines are renowned for their remarkable fuel efficiency, lightweight construction, and straightforward mechanical design that makes them exceptionally serviceable. The CB-23, CB-61, and CB-80 engine designations cover specific variants within this engine family, each optimized for different market requirements and emissions standards. Daihatsu's engineering philosophy for these engines emphasizes simplicity, reliability, and economic operation, making the Charade one of the most affordable vehicles to own and maintain in its class worldwide. These engines have been particularly popular in Asian, European, and Australian markets where compact dimensions and low running costs are highly valued.
SERVICE & REPAIR SCOPE:
- Complete engine identification and variant specification lookup
- Engine body disassembly and reassembly including block inspection
- Piston and connecting rod removal, ring replacement, and cylinder wall honing
- Cylinder head removal, valve guide inspection, and valve seat cutting
- Camshaft bearing clearance measurement and cam lobe inspection
- Crankshaft journal micrometer measurement and bearing shell selection
- Fuel system servicing including carburetor overhaul and fuel line inspection
- Carburetor float bowl cleaning, jet replacement, and idle mixture adjustment
- Cooling system thermostat testing, water pump seal replacement, and radiator flush
- Complete exhaust system inspection and manifold gasket service
- Alternator bench testing, brush replacement, and diode array testing
- Voltage regulator function verification and output voltage adjustment
- Complete electrical wiring diagram analysis for engine-related circuits
- Ignition system distributor servicing with timing specification
- Starter motor solenoid testing, brush inspection, and armature diagnosis
- Engine special tool identification and usage instructions
- Maintenance checklist and scheduled service interval reference
- Tightening torque specifications for all critical engine fasteners
TECHNICAL SPECIFICATIONS:
- Engine family: Daihatsu CB Series (Charade application)
- Variants: CB-23, CB-61, CB-80
- Configuration: Inline-3 and inline-4 cylinder, 4-stroke
- Valve train: SOHC overhead camshaft
- Fuel system: Carburetor (model-specific)
- Cooling: Water-cooled with thermostat-controlled circulation
- Lubrication: Full-pressure force-feed with oil filter
- Ignition: Electronic distributor ignition
- Special tools: Model-specific engine service tools identified
DIAGNOSTIC INFORMATION:
- Engine oil pressure warning light on: Check actual oil pressure with mechanical gauge, inspect oil pump pickup screen for sludge blockage, verify oil viscosity matches ambient temperature specification, examine main and connecting rod bearing clearance
- Engine overheating: Test thermostat opening temperature in boiling water bath, inspect water pump for impeller slippage on shaft, verify cooling fan belt tension, flush radiator of scale deposits, bleed air from cooling system
- Excessive fuel consumption: Inspect carburetor float level and needle valve condition, check air filter element for restriction, verify ignition timing with timing light, test engine compression on all cylinders against specification
- Engine misfire on acceleration: Test ignition coil output voltage, check distributor cap for carbon tracking or moisture, inspect spark plug wires for resistance within specification, verify carburetor accelerator pump discharge
- Blue exhaust smoke during operation: Check valve stem oil seal condition, inspect piston ring end gap and side clearance, examine cylinder wall cross-hatch pattern, verify PCV valve is not restricted
- Difficult cold starting: Check choke operation (manual or automatic), verify spark plug heat range suitability, test starter motor cranking speed, inspect fuel delivery from tank to carburetor, check for vacuum leak at intake manifold
- Abnormal engine noise: Knocking suggests main or connecting rod bearing wear; ticking may be valve clearance out of adjustment; rattling could be timing chain tensioner failure; whining from front suggests water pump bearing wear
- Alternator not charging battery: Test alternator output at B+ terminal with engine running (should read 13.5-14.5V), inspect drive belt condition and tension, check voltage regulator function, test battery terminal connections for corrosion
ILLUSTRATIONS & DIAGRAMS INCLUDED:
- Complete engine cross-section with CB series component identification
- Cylinder head assembly showing valve, spring, and camshaft arrangement
- Piston and connecting rod assembly with ring groove detail
- Crankshaft main bearing housing and thrust bearing arrangement
- Carburetor exploded view with jet sizing and float height specifications
- Cooling system water pump assembly with seal identification
- Alternator cross-section showing brush holder and diode layout
- Complete engine electrical wiring diagram with ignition circuit detail
- Distributor assembly with advance mechanism cross-section
- Starter motor exploded view with solenoid detail
- Exhaust manifold attachment and gasket specification
- Special tool identification drawings with usage references
- Maintenance check list with service interval schedule tables
COMPATIBILITY:
- Daihatsu Charade CB-23 engine
- Daihatsu Charade CB-61 engine
- Daihatsu Charade CB-80 engine
- English language edition
- PDF format, fully searchable and printable
FILE PROPERTIES:
- Format: Searchable PDF
- Language: English
- Delivery: Instant digital download
- Access: Download anytime after purchase
