Daihatsu CB-23 Instruction manual

DAIHATSU MOTOR COgr LTD.
NO.9173-GE

FOREWORD
This workshop manual contains essential information regarding the construction,
operation, adjustment procedure and servicing method of the Type
CB-23, CB-61
and CB-80 engines which are mounted on the DAIHATSU CHARADE.
The contents and specifications in this manual may be partly revised without
advance notice and without incurring any obligation to us.
Published in June, 1987
DAIHATSU MOTOR CO., LTD.

SECTION INDEX
NAME

TYPE CB
SECTION 1
GENERAL INFORMATION
HOW TO USETHIS WORKSHOP MANUAL ......... 1-2
INSTRUCTIONSON SERVICEOPERATIONS
..... 1-3
JACKING POINTS AND SUPPORTING POINTS
OFSAFETY STANDS
......................................... . 1-5
SUPPORTINGPOINTS OF TWO-POST LIFT ....... 1-5
LOCATIONOF ENGINETYPE AND
ENGINE NUMBER
............................................... 1-6
ENGINETYPE EMBOSSED POSITION ................ 1 -6
ENGINE NUMBER STAMPED POSITION ............ 1 -6
ABBREVIATIONCODES ........................................ 1 -7
MAIN SPECIFICATIONS ....................................... 1-9
WM-01001

GENERAL INFORMATION
HOW TO USE THIS WORKSHOP MANUAL
[Articles To Be Prepared]
As regards general tools (those tools which are normally provided in a service shop), jacks and other
standard equipment, they are omitted in this workshop manual.
As for those Special Service Toois (SSTs) which are necessary for the service operations, they are posted
collective!y in the tables under SECTION 11 APPENDIX. Hence, please prepare them prior to the service
operation.
In respect to instruments, lubricants and so forth, be sure to use those designated by Daihatsu.
WM-C1002
[Composition]
1. The component diagram is provided in the beginning of each section. Refer to this component d.iagram
whenever you want to assure the shape or the part name of each part during the installation operation
or the removal operation.
2. In principle, each section is arranged in the foilowing crder. However, it should be noted that the
composition for the in-vehicle operation differs from this order.
However, instances where the removal or the installation is comparatively easy or no SST or the like is
required, the arrangement is made as follows:
Removal Procedure
3. With regard to the tightening torque specifications, they are indicated in the Engine Components and
Tightening Torque under SECTION 3-10. In addition, they are shown in the tables under SECTION 11
SERVICE SPECIFICATIONS.
However, as for those items where no specific tightening torque is mentioned, perform the operation
referring to the Tightening Torque for Main Components under SECTION
00.
WM-01003
I
Inspection -~lnstallation Procedure
[Numerals]
As regards those numerals which are posted under "Inspection" and under sections other than SECTIOr'
11 SERVICE SPECIFICATIONS, those numerals from the specified values to the allowable limits a*
posted.As for those numerals which are posted under SECTION 11 SERVICE SPECIFICATIONS, those
numerals concerning the specified values and allowable limits are indicated separately.
WM-01004
[NOTE]
1. "NOTES" posted in the main text clearly show those items which need particular attention or prohibited
items which must be avoided during the service operation.
2. Prior to the operation, make certain to take any necessary precautionary measures so as to prevent
personal injury during the removal/installation of parts.
'NM-01005

GENERAL INFORMATION
STRUCTIONS ON SERVICE OPERATIONS
1. Make sure that only the specified bolts and nuts are used. Also, where specified, be sure to employ a
torque wrench to tighten bolts or nuts to specifications.
2. When tightening or slackening bolts, be sure to progressively tighten or slacken them over several
stages, slightly at a time. This caution must be observed to prevent the tightened parts from being
distortedor damaged.
3. Use only genuine parts for every replacementoperation.
4. For increased working efficiency and improved accuracy, utilize SSTs (Special Service Tools)
effectively.
5. When both front and rear sections of the vehicle or only the rear section thereof is jacked up, make
certain to place chocks at the wheels correctly in order to assure safe operations.
6. When the vehicle is jacked up, make sure to support the vehicle with safety stands positioned at the
specified jacking points.
7. Before any repair work is made on the electrical system or the engine is removed or installed, first be
sure to disconnect the negative
(-) terminal of the battery.
8. Disassembly
(1) When complicated part are disassembled, put stamped marks or mate marks on suitable
non-functional sections of the parts in order that the said parts may be easily assembled in the
correct original positions.
(2) Replacements of the cylinder block or crankshaft, etc. should be carried out after the engine
assembly has been removed from the vehicle.
9. Checks to be performed during disassembly
Each time a part is removed, check conditions under which the part has been assembled. Also, check
to see if the part exhibits any evidence of distortion, breakage,wear or scores, etc.
10. Arrangement of disassembledparts
Put disassembled parts in a good order. Moreover, divide disassembled parts into two groups: those
parts to be replaced and those parts which can be reused.
11. Washing disassembled parts
As for those parts which can be reused, thoroughly clean or wash them. (except grease sealed
bearing)
12. Inspection
Those parts which are to be reused must becarefully inspectedor measured, as required.
13. Those operations specified under "lnspection" are performed, in principle, in combination with the
checks and repairs. It is, therefore, necessary to replace any part which does not conform to the
;pecifications. However, in cases where otherwise specified in the main text, be sure to follow the given
instructions.
14. Assembly of parts
Those satisfactory parts only should be assembled in accordancewith the prescribed standards (e.g.
specified adjustment values, tightening torque and so forth).
Furthermore,seal packing or grease should be applied, as required.
Furthermore,in respect to packings,gaskets,oil seals and similar items, be certainto install new parts.
15. Adjustments and checking of service operations
Service operations must be carried out correctly by means of gauges or testers, if the use of these
instruments is required.
16. Never smoke during the service operation. Also, be sure not to allow any fire to be brought near the
working bay.
17. Under no circumstances should your hand touch with the front side and back sides, the installation
surfaces of each bearing insert. Also, be very careful not to scratch the surfaces. Do not wipe
off the
bearing surfaces with a cloth. Be certain to blow off them, using compressed air:
Protect your eyes with safety glasses during this cleaning.

GENERAL INFORMATION
-
18. The warming-up state of the engine means a state in which the temperature of the cooling wati
reaches at least 75 - 85°C (167 - 185 F) and the temperature of the engine oil reaches at least 65°C
(1 49 F).
These temperatures can be judged by observing a point where the cooling fan motor ceases its
rotation.
NOTE:
When the idle speed is checked on Type CB-80 engine, special warming-up procedure is required.
Hence, be sure to refer to the section under "Checking Idle Speed." 'uVM-01006

GENERAL INFORMATION
ACKING POINTSAND SUPPORTING POINTS OF SAFETY STANDS
I I
Jacking point
Front side ... Engine mounting center member (Place the jack below the member, exercising
care of the exhaust pipe.)
Rear side
..... Center of rear floor cross member
Enginemounting center rcember
\
Rear floor
/
cross member
@
Supporting point
of garage jack
Supporting point
of safety stand
Supportingpoints of safety stands
Four supporting points are located at the right and left sides. (The supporting points have been
strengthened by spot-welding reinforcements. Never support the vehicle at points other than
the specified points.)
SUPPORTING POINTS OF TWO-POST LIFT
-.n the supporting pads of a two-post lift with the supporting points of safety stands, as indicated in the
,,yureabove.
\
I
Fig. 1-2
WR-01008

GENERAL INFORMATION
LOCATION OF ENGINE TYPE AND
ENGINE NUMBER
ENGINE TYPE EMBOSSED POSITION
The engine type is embossed on the power train side of the
cylinder block.
ENGINE NUMBER STAMPED POSITION
1. CB-23 and CB-61
The engine serial number is stamped on the cylinder head
at the front end section.
For the Australian specifications, the engine number is
s;amped also at the side of the embossed engine type.
2. CB-80
The engine serial number isstamped on the cylinder head
at the rear end section

.BBREVIATIONCODES
The abbreviationcodes that appear in this workshop manual stand for the following, respectively.
Abbreviation Original word
Meaning
code
j
RH 1 Right Hand Refersto rrght s~de.
LH 1 Left Hand Refersto left s~de.
FR 1 FRont ,
Refersto front side.
R R ' ReaR
Refers:o rear side.
STD StanDard When referringto automotiveparts, "standard" represents those parts which have been
insta!ledoriginally by the manufacturerand which i-iave standard dimensions.
I InIcstanceswhere fitting becomes too loose d~e:o wear resulting from use for a long
period of time or due to frequent removaliinstallat~o~operations.
~f fitting part (e.5. piston)is
CIS Over Size
, replacedwith a part having larger dimensions,the other mating par: may be put into use
1 again. "Over sized" parts denote Pose parts having larger dirnensior,~compared with
i s:andard park.
1 Inthe same manner as with the "oversized" par:s. if fitting part (e.g. bush and bearing)is
UiS ; Under Size
! replaced with a part having smaller bore dimensicns,the other mating part may be put into
i use again. "Under sized" part denore those ?arts having smal!erdimensions compared
1
! with standard pat%.
ATDC
BTDC
IN
EX
After Top
1 Refersto positionof pision in cylinder where Psionis near but has passed over :he top of
Dead Center
/ the stroke.
BeforeTop
1 Refersto positionof piston in cylinder where pisicn is near but has not reached the top of
Dead Center
INtake
Exhaust
PR I Pry Rating
Society of
the stroke.
Refersto intake system.
Refersto Exhaustsystem.
Representsstrengtfi of tires.
The larger the pry rating number,the stronger the tire strength.
For example, automotiveoils are designated as SAE so and so number.These designation
SAE
API
SST
T
SIA
Ay;Assy
Wi
. .
i:
Mfl
Automotive
, numbers have been set forth by the Society of Automotive Engineersin the UnitedStates of
Engineers America (SAE).The larger the SAE number,the higher the oil viscosity.Conversely, the
I smailerthe SAE number,the lower the oil viscosity.
American The standards set forth by the American Petroleuminstitute (abbreviated as AP!
Petroleum
/ Classification)have beenemployed to evaluate and classify properties of various oils.
Institute Englneoils for gasoiineengines are classified as
SD, SE and so on, whereas engineoils for
1 diesel engines are classifiedas CC. CD and so on.
Speciai Serv~ceTocl
' Refersto a tool designed tor a specific purpose.
Torque
' Refersto tightening torque.
Sub-Assembly
, Refersto a component comprising morethan two s~ngleparts which are welded, s:aked, or
i studded to each other to form a single component.
Assembly Refersto an assembiedcomponent compr~singmore than two sirgle pacsor sub-
assembiy parts.
With i Denotesthat the foliowing part is attached.
Less Denotesthat the following part is not attached.
ManualTransmission Refersto maruai type transmissron.
A'T / Au:omatic Transmissian Refersto automarlc transm:ssion.
TC 1 Turbo Charger
1
W,'G I Waste Sate Refersto exhaust by-pass.
KC i Air Cieaner

GENERAL INFORMATION
. .
List of Abbreviated Component Names of Exhaust Emission Control System
t.
The table below shows abbreviated component names of the exhaust emission control system. The
components of the exhaust emission control
system are described in this manual in their abbreviated
forms.
-
Abbreviat~on Component name
1
BVSV B~rnetalVacuum Switching Valve
2 I C/O ' Cho~eopener
3
DP Dashrsot
4 vn/ 1 Vacuum Transmitt~ngValve
5
I
I
VS Vacuum Swltch
1
6 AD I Advance
7 TP Throttle Pos~trover
8 1 NSV Thermostat~cVacuum Switch~ngValve
9 EG R Exhaust Gas Rec~rculation

GENERAL INFORMATION
AIN SPECIFICATIONS
,edishand Norwegianspecificat~ons.
-
-
- Enginetype
Item
Type
Mountlngloca:ion
!
CB-23 CB-61
i
CB-80
Petrol,4-cycle
i 'etrol, 4-cycle
Front Front
I
CylinderNo. and arrangement 3-cy~incer-ln-line.mounted transve!se!y 3cybr.de,-l~-i~ne,mccntedtransverselv
Com~ust~oncham~ertype Multi-spneretype
Multi-sphere type
Pe!ro:. 4-cycle
Front
3-cylinder-in-Ice,
mclinted trarsversely
?en: roct type
Valve mechanism
i
Belt-drivenoverhead camshaft aelt-driven overhead camshaf: I Belt-driven(D3t!C)
Bore x stroke rnm(inch) ' 76 x 73 (2.99 x 2.87) i 76 x 73 (2.99 x 2.87) 76 x 73 (2.99 x 2.87)
Compressionatio 9.5
1 8.0 I
I
7.8
Corpress~onsressure kg:cm2-rpm (psi-r2mj 12.5 - 350 (177 8 - 350) 1 72.0 - 350 (170.7 - 350) 10 5 - 200 (7A9.3 - 300)
I
/ Maximum
I outpc:
I
I
1
I Maxinum
1 torque
Engine
SAE net kw/rpm
1
General
38!5.600 5015.500
specifica:ions
!
74'6,500
563
x 52C x 632
1
576 x 573 x 624
(22.17
x 20.47 x 24.88)
1
(22.68 x 22.56 x 24.57)
96 (212)
I 105 (233.7)
Enginedimensions
[Length
x width x height] mrn (inch)
j Serviceengineweight kg
(lb)
EEC
I kw!rpm
EEC DIN kwirpm
I
Australian 38:5.600
specifica:ions
SAE net i Nmirpm 1
I
75.5:3.200 1 106:3,200
i
i 3013.560
j specifications
I
566 x 530 x 636
(22.28
x 20.87 x 25.04)
92 (202.9)
50i5.5CO
j
j
-
-
EEC
EEC 'IN
ECE & EEC I
I
soec~ficamns ,
315.600 I 5015.500 i 74:6,500
!
' of
1 piston rings
j
1
/ Valve timing
!
j
Nmirpm Australian 75.5i3.200
1 specifications ,
1 ECE & EEC i
Nmirpm 1 specifications 1
75.5i3.200
I
2 2 2
1
:S0BTDC
5l0ABDC
5l0BBDC
19"ATDC
[Hot] 0.20 (0.0079)
[Hot] 0.20 (0.0079)
Com~ressionring
Oil ring
I
! Open
Intake
1 close
Blow-bygas recirculating sysfem
I
Closed type 1 Closed type
1
Closedtype
I
1C613.200
I
-
r
Exhaust
Valve clearance mrn (inch)
idling speed
rpm
Lubricatingmethod
Oil "ump ;ype
106i3.500
I
1 ! 1
: 1"BTDC 1 23"BTCC
4g0ABDC I 5l0ABDC
Ooen
Close
Intake
Exhaust
I Manual!ransrnission
Automaric
transmission
Fully-forcedfeed method
1 Fully-forcedfeed rnerhod ! Fully-forcedfeed method
i
Trochoidtype Trochoidvpe Trochoid type
1301?,.500
49"SBDC
11"ATDC
800 i 50 (-1000 ? 50) / 800 + 50 ('1000 + 50) I 950 50
49"BBDC
1PATCC
850 F 50 ('1000 k 50)
I Oil filter type
( Fsll-flowfilter type.filter paper tyae Full-flowfilter type,filter paDer ;ype 'i~ull-flowfilter type. filter paper type
[Hot] 0.25 (0.0098)
j [Hot] 0.27 (0.0101)
[Hot]
0.25 (0.0098) ! [Hot] 0.32 (0.0126)
- -
L~ori-
I
I
-mng 1 mole
System Lubrrcaaonoil 1 When
is cha,,sed
I
capacity
1 When oil and oil filter are changed
Oil cooler type
Super chargertype
3.2 3.2
I
i I
3.3
2 7 1 2.7 j 2.7
3.0 3.0
i
.I
3.1
I
Wateracled ty3e (only for trcplcal spec.j! Water-cooled type / Water-cooled type
-
Turbocharger Turbocharger

GENERAL INFORMATION
'Plunger stroke: 0.87 5 O.C3 mrn (0.035 i 0.0012 inch) WM-01014
Enginetype i
-1 (26-23 ca-6: ca-80
i
Item I
!
Coolingmethod ] Water cooled, e!ectromotor type / Water coo!ed.elec:romotor type Water cooled, elec:romotor type
! Radiator type 1 Corxgatan qp tcrced circulation ; iarmgatlcrtype forced c!rculatbn Corm~atlontype forced circulat~on
I
I ~lanual
Cooling 1 ! :ransm~ssion
System j Coolant capacity
I
3.5 3.9 4.0
, [Including 0.6 for reserve tank] , [Including 0 6 for reservetank] , [Including 0.6 for reservetank]
I
:Iter
Autcmatic
I
! 3.9 - -
! 1 transmission 1 [Inc!uding0.6 for reserve tank] :
i Water ~umptype
/ Centrii~gal ty-. "V belt-ciiver:type . Cenlrlfugai :vpe. 'V' be!t-dr~ventype Centrifugaltype.
"V" belt-criventype
j Thermostat :ype 1 Wax pellet type Wax pelle: type
I
Wax pellet type
1
I
-.
Type -,.ter pacer type Ftiter aaper vpe
Air Filter paper type
cleaner
:
/ Numoer 1 1 1
Capaclty Llter I 40 40
A -
3 1
I Fcei tank I
Location I Moun:ed underneathrear seat flwr / Mounted urderneathrear seat :loor . Mounted uncernea:h rear seat floor
F-el plpemater:al Rubber ano steel tuce I Sieei tube Steel tube
Fuel pump type Diaphra~rntype
I
1 Fuel filtertype Filter ~apertype
E1ec;rcmotor type E!ectromc:or type
Fiiter paper type
! Fiiter paper type
Aisan kcgyo I -
Two-aarrei type !
-
28 (1.10). 32 j1.26) I -
18(0.1,28110 I -
Manufac:urer Aisan kogyo
Type I Two-barrel type
Throttlevaive disme?er mm (inchj
/
28 (1.lo), 32 (I .26)
Venturi diameter mm (inch) 1 18 (0.71). 25 (0.98)
Choke vaive type
I
I Manual Vpe. butterfly-shapedvake
1
1
Manual type, butterfty-shapedvalve
-
-
Injection
pump
Fuel
-
Electronic type
-
-
Carburetor
Fuelinjectionoevice
I
-
!
Piunger diameter mm(incl) / -
!
-
I
-
Cam lift mm(inch) 1 1 - -
Type
injection timing
Type of self-aiigner
!
I Type of inlectlont:ming regula:ing
-
-
1
- ! -
I
-
- I - -
i
/ cevice
!
/ Typecf nozz!e retainer
- -
1 With cushion rubber type
Inlection :
nozzleor ' Nozzle type ! - / E!ec:ronic controlledthrottle type
, Injector
I 1njec:ion pressure kg;cm2 (Psi)
i
- i -
2.55 (18 4)
' 'Joltage J 12 [Negativeground]
/ 12 [hegative ground] j 12V [Negative grounc]
i ' Type Battery ignit~ontype ! Ba~eryignition type { Batteryignitiontype
I
i
I
1 Ipnit~ontiming STDC 5'42911cling / 9T3C 1O042"Idling I BTDC 1O0+2":ldling
1
' Firingc?rc'er I : -2-3
Ewne
elecricai
sys:em
1-2-3 1-2-3
Conventional type
Contact-polnttype
ignition
System Full-trans~storizedtype
-
/
Elec:ron~ctlmlng aovarce
Eiectronictiming advance
I CEr~bl;:or I
) PeCmucecl / Cectnfcga, yw
! i:mlng atiacc:ng
1 ' mecnac~m ! Vacuum type
0°;750 rpm. 10.5":2.800 rpm O0ff5orpm. 13.Y13.000 rprn
0":-100 mmHg. 1l0!-320 rnmhg 00:-60 mm~s,10°/-450 mmHg
Ds:nbutcr type Convenrional?joe
; Breakertype Contacr-po~nttype

GENERAL INFORMATION
"Cption
'2General & Australian specifications mountedwith manualtransmission
'3ECE & EEC specificationsmounredwith manualtransmtssion
*Vehicles mountedwith automatictransmission
'5Norwegianspecificationswith automatic transmiss;onmountedmodel
-
CB-23
Item CS-61 CB-80
DENS0
W20ETR-L
W20ET-L
Manufacturer ! DENSO NGK BOSCH I C:dMFICH DENS0 NGK / BOSCH CHAM?lCN
!
I
Type
Ignition / Spark :
1 system / plug
/
i
~xceptfor ECE ! H16EX-J
25W / 6F19 EIBOC:XY,: N-l!YC
VBM-u 3~5~ ~v~cc(x.? WYC
b EEC tf2Q;)M-lil 3KEY wCC(X.q N.llYC
!
1 I
1 Threaa M14 x 1.25 MI4 x 1.25 / M14x1.25
!
i i
0.7 - 0.8 0.8 - J.J 0.7 - 0.a 1 :.;.06 ; 01-0.a i 0.7 - 0.8 1 0.9 - 1.0
!
mrn :inch) (0.328 - OC3l) NXil - 2.G) I (0.028 - 0.031) :@.%3 - ib?: IC.~ - 031 ' (0.028 - 0.03: ) , (0.035 - 0.039)
!Glow
'
Engine
electr~cal
svstem Ba:tery
-
Tyoe -
-
.
-
I Voi:age, curent \/-A - i -
General speciiications 348; 7L "55824L 1 34Bi71"5532CL I 3BI 7L "55B24L
Type ECE 3 EEC spec:,:caims , 55B24L ! 55324L j 55824L
I
Australian saec~fications : 33817L 1 34317L
j -
27 (5FR). "36 (5HR)
Generalspeciiications ,
27 (5HP:. "36 (5hR) 127 !5hR). "36 (5hR)
1 Caca:z ECE 3 EEC so%~:lcatons 36 (5bR) 36 1:5hR) I 36 (5HR),
I
,
I
Australian soec:ficatrns ' 27 (5PR) 27 (5HR) j -
j Alternator
!
j Starter
I
I 3-Pbase alternating current 1 3-haseil;e!natlng
Type
: 3-PqaseaiterFlat:rgcurrent cornmutating type 1
I c0mmu:aiing iype , c-ner: csm?dal~g Vpe
1
Output V-A : . 12-45."12-50 I 12-45
I
I
12-50
Regulator type Ccntact-po~ntlesstype
1 Contact-pointlesstype 1 Cosia-winlea $e
Type Magnet engaGing type
/ Magnet engaging type 1 kgrdt e~qtg
Output
V-kw '2?2-0.7."12-0.8, &12-1 .O
1 12-0.8. ''i2-l .O / 12-0.8. '312-l.0
Radionoise suppressing device Resistivecord 1 Resistivecord 1 Resistive cord

TYPE CB
SECTION 2
THE ENGINE PROPER
ENGINESECTIONAL VIEWS ............................... 2- 2
CB-23 .................................................................. 2- 2
CB-61 ......................................................... .. 2- 4
CB-80 ..................... ; ....................................... 2- 6
ENGINE COMPONENTSAND
TIGHTENINGTORQUE
........................................ 2- 8
CB-23 and CB-61 ............................................... 2- 8
CB-80 .............................................................. 2- 9
MAINSERVICE SPECIFICATIONS ...................... 2- 10

THE ENGINE PROPER
ENGINE SECTIONAL VIEWS
I
Fig. 2-1 WM-02002