Leaking Diesel Turbo: Should I Remove or Rebuild it?

[aflatoon210]

We have recently rebuilt a Daihatsu Charade G-30 Diesel Turbo (CL-60) engine with partial success. Everything is changed except for head and crank.
The engineering workshop guy gave its ceased turbo to someone for rebuilding. I trusted him and the result was pathetic. This rebuilt turbo FAILED within 2 hours of idling following first cold start after engine rebuild. Rest is fine, cold and warm starting are good, no heavy smoke at low to moderate RPM and it isn’t consuming engine oil anymore except for leaking turbo.

Now someone has suggested me a workshop on Gawalmandi Road (Rawalpindi) near Kiani Autos who claims to be the specialist of turbo works. ** He told me that finding a new turbo of this engine is next to impossible, so he’d take the **kit from Suzuki Every Turbo variant and use it to rebuild Charade CL-60 Turbo with some alteration. He claims that this turbo would be as good as a new factory specs and would be long lasting.

But the problem is, he is ONLY offering warranty of 2 days, if it fails within this period, it’s on him to redo the job but after that he won’t be responsible for any malfunction.

2nd option I have is to REMOVE this turbo which is going to eliminate the risk of failing turbo again. Since I use this car for shorter trips within city at much lower speed, deleting turbo may not adversely affect engine power and fuel economy. But you know this engine was designed to work with turbo so it may also shorten the engine life.

So what would you suggest? Should this be REMOVED or REBUILT using Suzuki Every’s Turbo again? The latter option is like taking a gamble!

Only professional and sincere advice needed, please don’t suggest me to scrap the engine as it has already been rebuilt and working fine except for this turbo leaking problem.

[Xulfiqar]

You can find a similar turbo cartridge from a lot of engines, a lot of kubota use the same IHI turbo cartridge as this one.

Bigger question here is, during rebuild how did you proceed with the below points

1 did you find a new crank bolt?
2 did you use a torque wrench on that bolt?
3 what tool was used to tighten the head
4 is the pump from a turbo engine? (Has the boost compensation device? - does the pump increase fuelling under boost?)
5 how did you time the pump to the engine?
6 does the pump advance timing at 2000 engine rpm?
7 are the injectors set to pop at the right pressure? They pop at 1700 psi i recall.

Its a 3 cyl diesel - anything causing a slight power problem per cylinder can wreck the engine quite fast.

[sardarg]

sir where you are located in Pakistan.??

[helper_learner]

sir where you are located in Pakistan.??

He(@aflatoon210 ) is in ISL.

@aflatoon210

Visit @dani_kk or @rajaatta.

[aflatoon210]

@Xulfiqar Thank you so much for taking time to reply in detail

Actually I handed over the engine to a repairman who claims to be the specialist in fixing engines in Rawalpindi. I didn't supervise him all the times, just took some video shots for my YouTube channel, yet to produce a video, will share once I compile everything.

And I don't know much about such technical things, but let me try explaining what you want to know:

1 did you find a new crank bolt?
If you mean replacing the crank, then NO, we didn't change the crank as he told me that it was fine.

2 did you use a torque wrench on that bolt?
* Couldn't understand

3 what tool was used to tighten the head
I wasn't there so I couldn't see and record them using the tools

4 is the pump from a turbo engine? (Has the boost compensation device)
I am not sure, showed this to Waris Shah lab in Gawalmandi and he didn't say anything so I assume that it is genuine turbo pump. Here's the picture:

5 how did you time the pump to the engine?

Waseem Diesel lab technician on Tipu road made some adjustments and he told me that pump needs to be repaired but first I needed to fix the turbo or get rid of it. However, starting and overall performance got a lot better after he did something to the pump, the only problem left is bad fuel economy, it isn't giving more than 14 km/l in city traffic. Not too much traffic jam and very low rpm driving.

6 does the pump advance timing at 2000 engine rpm?
He increased the RPM to get rid of rough idling but it remained there and instead worsen the fuel economy (AC has been removed since I got the car). So we reduce the idling speed again by making some adjustments. RPM also fluctuate but overall is okay, no misfiring or giving jerks etc.

7 are the injectors set to pop at the right pressu
re? They pop at 1700 psi i recall.

Injector nozzles are worn out, will replace them once turbo mess is cleared.

White smoke appears during cold start but vanishes as the engine warms up.

And yes, there is NO DIRECT FAN which you normally don't recommend , automatic switch has been installed.
Thanks once again for your time to offer your professional advice!

[aflatoon210]

@helper_learner Thanks for recommending workshops might help me solve the problem. I will contact them, though they're far away from my location. Do you know any reliable professional in Rawalpindi? Preferably near Saddar area

[dani_kk]

Don't get stuck in this juggar thing. It's an obsolete turbo with near to impossible to get it it's rebuild kit.
My friendly advice is to move to Ct9 turbo the one that comes in 4efte and I can do this job of modification of turbo manifold and fitting it near to the factory fitting.

[helper_learner]

Do you know any reliable professional in Rawalpindi?

No, Not other then stated above.

[Xulfiqar]

Oh!!!

Your reply shows that you are relying 100% on usual mechanics to make it work.. its a very grim situation..

These little engines seem easy and simple, and they sort of are but the finer intricacies I mentioned can kill it very quickly.

[aflatoon210]

@dani_kk someone else already has recommended this mod i.e. swapping its genuine turbo by the one comes with a Toyota engine, can't remember if it was a 4efte.

Well, it sounds interesting but could also be quite expensive job. And 4efte is 1.3 petrol engine, so need to make sure that CT-9 turbo works well with 1.0 diesel. All I need is reliability and better fuel economy as this car rarely goes above 100 km/h, there's no need for speed I will contact you soon at given number and may go for this project if my budget allows me and if I feel satisfied.

Thank you all again for offering your valuable suggestions, particularly Professor @Xulfiqar the great

(Can you please share your thoughts about swapping CT-9 in this engine?)

[dani_kk]

Yes performance would be good and you will get a good early spool. A balanced Power. And good reliability.

[Xulfiqar]

as mentioned, the CT9 is pretty nice and suited for this engine, the exhaust manifold will be slightly modified to make it fit along with the oil feed and drain lines.

Once its fit and everything, you need to make 100% sure that your pump is actually increasing fuelling as it hits boost, otherwise the turbo (any kind) will be a showpiece only.