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Thread: Charade G30 Turbo Diesel Engine Non responsive

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    Default Charade G30 Turbo Diesel Engine Non responsive

    Salam to all pakwheels fellows.

    We have Charade G30 (1986) Turbo diesel with our family. From the past few weeks it has been facing startup problem specially in the morning despite the fact that it was summer season. But now engine has denied startup not only in the morning but at any given time in the whole day.

    Engine condition was below average but not weak 5 year ago when we bought. But from the past few months engine is generating huge thick cloud of black smoke when revved high on neutral. Moreover, oil leakage from seals has also increased. Considerable quantity of thick black oil is observed above exhaust manifold and turbo during the past 20 days or so.

    Does above signs are indicators of dead engine which needs overhauling and which course of action should we adopt to get the car back on road.

    (Further, we are very satisfied with performance and reliability of this diesel engine. Not a single engine related breakdown in the past 5 years except now and would like to keep this car with diesel engine)
    -

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    I think you are mistaken that mechanics install new bolts. They are living in stone ages and reuse the old stretched bolts which then causes other painful failures. The new bolts are required becuase they are torque to yield bolts.
    ZRS - Zulfiqar Racing Systems ..... - professionals at work - at crackwheels.com

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    The main thing here is to source all the parts needed yourself. The mechanic will either get the parts from where he gets the most cut OR he won't bother finding "rare" things such as the head bolts. IMO, you should start the job only once you have all the parts at hand.
    to give you an idea, you can't get new head bolts for MEHRAN in Lahore, not sure about other cities. But I wasted like 2 to 3 days and a lot of fuel to go into every corner of Lahore but couldn't find new head bolts.
    https://www.facebook.com/OsamaAbbasPhotography

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    Quote Originally Posted by Xulfiqar View Post
    I think you are mistaken that mechanics install new bolts. They are living in stone ages and reuse the old stretched bolts which then causes other painful failures. The new bolts are required becuase they are torque to yield bolts.
    For that i will supply these things to mechanics my self. I know mechanics make these costly 'savings'. I have experience the same on my corolla 1.6Gli
    -

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    Quote Originally Posted by syncview View Post
    The main thing here is to source all the parts needed yourself. The mechanic will either get the parts from where he gets the most cut OR he won't bother finding "rare" things such as the head bolts. IMO, you should start the job only once you have all the parts at hand.
    to give you an idea, you can't get new head bolts for MEHRAN in Lahore, not sure about other cities. But I wasted like 2 to 3 days and a lot of fuel to go into every corner of Lahore but couldn't find new head bolts.
    Means khawari to fit kr k hoge engine overhaul karanay main
    -

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    It always is wise to measure twice and cut once - applies to everything in life. To get the best result heres a breakdown.

    1 - collect parts costings
    2 - locate the parts - including all the proper glues/pastes/assembly lubes etc.
    3 - look for a proper diesel service facility for calibrating the pump and nozzles like Toyota/daihatsu did when new
    4 - gather all special required tools (either cut a deal with the mechanic or simply consider it as investment)
    5 - make other plans to repair the engine room whilst the engine is out - e.g. repairing the whole wiring harness, repairing the sound deadening batting, repairing any missing clamps/clips etc, taking care of rust.

    Remember that a car is a machine for transport, if you cheap out on repairing the machine the transport will not be reliable - Spooky.

    To get a costing analysis - dont judge it by the current value of the car but by the value when it was brand new. Makes sense if the car is worthy to be rebuilt, otherwise scrap it.


    the last paragraph may show you the problem with upkeep of these JDM orphan cars, people assume they are at correct full pricing and their spare parts should be cheaper than that, which is laughable, the spares pricing does not consider devaulation.
    ZRS - Zulfiqar Racing Systems ..... - professionals at work - at crackwheels.com

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    Quote Originally Posted by Xulfiqar View Post
    It always is wise to measure twice and cut once - applies to everything in life. To get the best result heres a breakdown.

    1 - collect parts costings
    2 - locate the parts - including all the proper glues/pastes/assembly lubes etc.
    3 - look for a proper diesel service facility for calibrating the pump and nozzles like Toyota/daihatsu did when new
    4 - gather all special required tools (either cut a deal with the mechanic or simply consider it as investment)
    5 - make other plans to repair the engine room whilst the engine is out - e.g. repairing the whole wiring harness, repairing the sound deadening batting, repairing any missing clamps/clips etc, taking care of rust.

    Remember that a car is a machine for transport, if you cheap out on repairing the machine the transport will not be reliable - Spooky.

    To get a costing analysis - dont judge it by the current value of the car but by the value when it was brand new. Makes sense if the car is worthy to be rebuilt, otherwise scrap it.


    the last paragraph may show you the problem with upkeep of these JDM orphan cars, people assume they are at correct full pricing and their spare parts should be cheaper than that, which is laughable, the spares pricing does not consider devaulation.
    I think bolts will be an import.
    @Xulfiqar
    Don't you love us all your brothers here? Cannot you send every now and then a courier to a needy one of those parts that are required badly here. . Of course, we would be spending that money, but at least it would be of great help. Plus it will save us the hassle of recognizing the correct parts.

    Zara Sochiye
    success is the ability to go from one failure to the next without any loss of enthusiasm

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    Quote Originally Posted by Xulfiqar View Post
    It always is wise to measure twice and cut once - applies to everything in life. To get the best result heres a breakdown.

    1 - collect parts costings
    2 - locate the parts - including all the proper glues/pastes/assembly lubes etc.
    3 - look for a proper diesel service facility for calibrating the pump and nozzles like Toyota/daihatsu did when new
    4 - gather all special required tools (either cut a deal with the mechanic or simply consider it as investment)
    5 - make other plans to repair the engine room whilst the engine is out - e.g. repairing the whole wiring harness, repairing the sound deadening batting, repairing any missing clamps/clips etc, taking care of rust.

    Remember that a car is a machine for transport, if you cheap out on repairing the machine the transport will not be reliable - Spooky.

    To get a costing analysis - dont judge it by the current value of the car but by the value when it was brand new. Makes sense if the car is worthy to be rebuilt, otherwise scrap it.


    the last paragraph may show you the problem with upkeep of these JDM orphan cars, people assume they are at correct full pricing and their spare parts should be cheaper than that, which is laughable, the spares pricing does not consider devaulation.
    I think bolts will be an import.
    @Xulfiqar
    Don't you love us all your brothers here? Cannot you send every now and then a courier to a needy one of those parts that are required badly here. . Of course, we would be spending that money, but at least it would be of great help. Plus it will save us the hassle of recognizing the correct parts.

    Zara Sochiye
    success is the ability to go from one failure to the next without any loss of enthusiasm

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    maslann iss list me kiya send kar sakta hoon?
    ZRS - Zulfiqar Racing Systems ..... - professionals at work - at crackwheels.com

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    Quote Originally Posted by Xulfiqar View Post
    maslann iss list me kiya send kar sakta hoon?
    You told yourself that heald bolts are not available in Pakistan, which needs to be put in new. I read that on dani CD20 thread.
    success is the ability to go from one failure to the next without any loss of enthusiasm

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    Lad De ladad de...Ladne wala saath de
    TOYOTA Sprinter 86- AE80 DOHC 20v'D TOYOTA Corolla 98- AE101 4AFE 16v

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    Quote Originally Posted by SER_GTR View Post
    Lad De ladad de...Ladne wala saath de
    You sit tight man You will be seeing a QG swap soon and that too with all mirch masala
    success is the ability to go from one failure to the next without any loss of enthusiasm

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    Quote Originally Posted by star2 View Post
    You sit tight man You will be seeing a QG swap soon and that too with all mirch masala
    Kabhi Aao Na Swap Karwake......! Khusbhoo Yahan Lagadeinge
    TOYOTA Sprinter 86- AE80 DOHC 20v'D TOYOTA Corolla 98- AE101 4AFE 16v

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    Quote Originally Posted by Xulfiqar View Post
    before you choose to "repair" your engine, keep these points in mind

    1 you need a brand new genuine crankshaft pulley/timing gear bolt
    2 you need brand new cylinder head bolts
    3 you need new connecting rod cap bolts
    4 you need a dial gauge to adjust the injection timing
    5 you need a proper torque ratchet to tighten all engine fasteners.
    6 you need proper flange sealants to seal down the engine
    7 your engine coolant passages should not be corroded from the cylinder head or block surface - and you should only use a diesel rated coolant in it along with its original thermostat valve.

    you need to follow correct procedure to adjust valve tappets - no grinding etc of the valves or buckets, if the buckets are collapsed you need new buckets (bucket = tappet follower aka dabboo in mechanic terms)

    your injection pump should be tested on a flowbench for correct injection volume and delivery both with and without boost of 8 psi (OE boost pressure)


    Ideally you should test the compression pressure first, diesel compression testers are expensive to buy as they measure near 400~500 psi of compression pressure in the cylinders.

    If you follow the correct procedures the engine will start at a flick, be very reliable, quiet and cheap as a CD70 too.
    Xulfiqar bhai, Charade is with mechanic now and as per initial discussion head bolts, turbo setup and few other internal things will be sourced from so called second hand / scrap market and i am pretty sure that he wont use torque ratchet. In short i am not very much confident that engine would run trouble free after rebuild as it used to be. Mechanic is of the view that these things are not available in new spare parts market. What should i do now, Kindly advise.
    -

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    stop the rebuild now. You need new bolts. Find them. It wont work reliably without them. Your mechanic needs to use a torque ratchet, if he does not own one, locate or buy one yourself. Or at least use a scale type (cheapest type)

    Any person can put it together, but it wont work like it should, a proper repair would make it work like a factory build
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    Quote Originally Posted by Xulfiqar View Post
    stop the rebuild now. You need new bolts. Find them. It wont work reliably without them. Your mechanic needs to use a torque ratchet, if he does not own one, locate or buy one yourself. Or at least use a scale type (cheapest type)Any person can put it together, but it wont work like it should, a proper repair would make it work like a factory build
    what if we are unable to locate bolts and other items that mechanic wants to put from scrap.
    -

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    Quote Originally Posted by sarmadraheem View Post
    what if we are unable to locate bolts and other items that mechanic wants to put from scrap.

    you will end up with a half hearted attempt at rebuilding. At the least get a torque ratchet to do the tightening - and start looking around for such parts. IMO its a waste of money to repair something with no set goal.
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    Quote Originally Posted by Xulfiqar View Post
    you will end up with a half hearted attempt at rebuilding. At the least get a torque ratchet to do the tightening - and start looking around for such parts. IMO its a waste of money to repair something with no set goal.
    So should i go for some swap?
    -

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    your postings make it sound like the car is nearly scrap, swap/repair is your choice, reliability is also your choice. If I were spending money I would make sure I do it correctly.
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    the mechanic who rebuilt my honda had a torque wrench
    (probably someone like u gifted that guy)
    but it was a decoration piece in that work shop
    point is, even if they have it, they dont know how to use it or they are least bothered

    plus according to mechanics the worlds best bolts are in the junkyard taken out of busted jdm cars

    so ur wish list cant be fullfiled in pk that easily specially for such an old car and machine
    swap is better
    Life is short and very unpredictable just like a Quarter mile .....

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    I am now thinking of swapping a good JDM sealed engine coz i am unable to get bolts, turbo and other stuff. Moreover, i cant even get genuine engine mounts for charade and they keep breaking again and again. Swap would at least be reliable as to the condition of engine itself.
    -

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