Repairing the exhaust manifold on a Daihatsu Charade G100 GTTI involves several steps. click here for more details on the download manual…..

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Below is a detailed guide that includes descriptions of the components involved, tools required, and step-by-step instructions.

### Components Involved

1. **Exhaust Manifold**: A metal component that collects exhaust gases from the engine’s cylinders and directs them to the exhaust system.
2. **Gaskets**: Sealing components that prevent exhaust leaks between the manifold and the engine block and the manifold and the turbocharger (if applicable).
3. **Bolts/Nuts**: Fasteners that secure the manifold to the engine block and other components.
4. **Heat Shield**: A protective cover that shields components from heat generated by the exhaust manifold.
5. **Turbocharger (optional)**: In the GTTI version, the turbocharger is mounted on or near the exhaust manifold.
6. **O2 Sensor**: An oxygen sensor may be located in the exhaust system, which needs to be removed during repairs.
7. **Exhaust System**: The piping and components that carry exhaust gases away from the engine.

### Tools Required

– Socket set (metric)
– Wrenches (metric)
– Torque wrench
– Screwdrivers (flathead and Phillips)
– Pliers
– Gasket scraper or razor blade
– Clean rags
– Engine degreaser
– New exhaust manifold gaskets
– New nuts and bolts (if necessary)
– Anti-seize compound (optional)
– Safety gloves and goggles

### Step-by-Step Instructions

#### 1. Preparation
– **Safety First**: Park the vehicle on a flat surface, turn off the ignition, and disconnect the battery.
– **Allow Cooling**: Ensure the engine is cool before starting the repair.

#### 2. Remove the Heat Shield
– **Locate the Heat Shield**: If your model has a heat shield, it will be above the exhaust manifold.
– **Remove Fasteners**: Use a socket wrench to remove the bolts securing the heat shield. Keep the fasteners in a labeled container to avoid losing them.

#### 3. Disconnect Components
– **Remove the O2 Sensor**: If equipped, use an O2 sensor socket or a wrench to carefully unscrew the O2 sensor from the exhaust manifold.
– **Disconnect the Turbocharger (If Applicable)**: If your model has a turbo, disconnect the intake and outlet pipes and any electrical connections. Carefully unbolt the turbo from the manifold. Take note of the order and orientation of the bolts.

#### 4. Remove the Exhaust Manifold
– **Unbolt the Manifold**: Use the appropriate socket to remove the bolts securing the exhaust manifold to the engine block. There may be several bolts in different locations, so take your time and keep track of each one.
– **Carefully Remove the Manifold**: Once all bolts are removed, carefully pull the exhaust manifold away from the engine. Be cautious of any remaining gaskets and ensure they don’t fall into the engine.

#### 5. Inspect and Prepare
– **Inspect the Manifold**: Check for cracks or warping. If the manifold is damaged, it may need to be replaced or repaired by a professional.
– **Clean the Surface**: Use a gasket scraper to remove any remnants of the old gasket from the engine surface and the manifold. Ensure the surfaces are clean and free from debris.

#### 6. Install New Gaskets
– **Position New Gaskets**: Place the new gaskets onto the engine block and the manifold (if applicable). Make sure they align properly.

#### 7. Reinstall the Exhaust Manifold
– **Position the Manifold**: Carefully position the exhaust manifold back onto the engine block, ensuring the gaskets stay in place.
– **Bolt It Down**: Hand-tighten the bolts first, then use a torque wrench to tighten them to the manufacturer’s specified torque settings (consult a service manual for the exact torque specs).

#### 8. Reconnect Components
– **Reattach the Turbocharger**: If applicable, bolt the turbocharger back onto the manifold and reconnect any hoses and electrical connections.
– **Install the O2 Sensor**: Reinstall the O2 sensor, ensuring it is securely tightened.

#### 9. Reinstall the Heat Shield
– **Secure the Heat Shield**: If removed, reinstall the heat shield using the original bolts. Ensure it is secured properly.

#### 10. Final Checks
– **Double-Check Connections**: Ensure all connections, bolts, and components are secure.
– **Reconnect the Battery**: Reconnect the battery terminals.

#### 11. Test the Repair
– **Start the Engine**: Start the engine and let it idle. Check for any exhaust leaks or unusual noises.
– **Take a Test Drive**: If everything seems normal, take the vehicle for a short test drive to ensure proper operation.

### Conclusion
Exhaust manifold repair on a Daihatsu Charade G100 GTTI requires attention to detail and proper tools. Always refer to a repair manual for specific torque specifications and additional procedures that may be unique to your vehicle. If you’re unsure or uncomfortable with any part of the process, it’s advisable to consult a professional mechanic.
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