[QUOTE=mirzahadi;3244388]OK, from now on I am going to post all my problems here. The ultimate goal being to bring the car to factory settings. Before further elaboration, a little background on my car.
My father bought this 2006 Cultus brand new. I belong to a farming family so this car went through a lot rough time. By the time I got my hands on this car, it had multiple heat issues and horrible suspension noises which it still has. My father didn't find coolant to be a very attractive option so the car was running on water for all these years.,,,,,,,,,,,,,,,fround suspension control arm need to repair or replace ,,,,,,,,,,,,,there is not too much to repair in rear suspension ,,,,,,,,,check the rear suspension spring packing , if found damaged then change it with the original one , local wont work and also local packing effects the car hight ,,,,,,,,,,,
1- The perennial problem of coolant reduction. The coolant reduces slowly to a point that I have to top of the reservoir once every two days. No visible leakage anywhere in the car. No signs of water or milky stuff on the oil check rod. No white smoke in the exhaust. Head gasket was changed about a month ago. I have no idea what kind of job the mechanics did. Maybe the head is warped?? How to check? The car had a lot of rusty stuff when I put a coolant in it. Even the temperature gauge wouldn't work because of the rust deposits formed in front of it. I haven't done a proper flush, so any idea will be really appreciated.,,,,,,,,,,,,,,,,,,you ever notice air bubbles leaking from the radiator cap,,,,,,,,,,,,,,,,to check start the engine , pull the radiator cap off ,,,,,,,,,then check for air bubbles ,,,,,,,,,,,,,,,,if you see air bubbles leaking from head gas kit then it means the gaskit is still leak and this problem can be solved by changing the gas kit alone,,,,,,,,,,you need to resurface the head face ,,,,,,,,,,if you dont see any air bubbles then check the radiator cap and also some sighns of leak on water pump pully ,,
2- Morning starts need a heavy foot on accelerator. There is that dig dig dig noise when car starts. The car drops RPM if I let go of the pedal. The choke, I guess that is what it is called, kicks in after half a minute and the car smooths out. All this on CNG, didn't try on patrol.,,,,,,,,,,,,,,,that dig dig sound is of huudralic lifters,,,,,,,,,,,,,,,that sound goes off after some time or keep comming,,,,,,,,,in normal condition it must vanish with in 10 to 20 seconds ,,,,,,,,,,,,,,,,,,,,,if keep comming then either your oil pump is working on very very low pressure or the hyudralic lifters are lose enough in there bore that they case an oil leak ,,,,,,,,,,,,,,,,,,if they are lose in there bore then you have to change all the head,,,,,,,,,,,oil pump pressure can be checked by a pressure guage ,,,,,,,,,,soon i will post all its process,
3- First gear requires considerable push to engage. Other gears seem fine.,,,,,,,,,,,,,,,this happens when engine is off or happens while its running and car is stationary ? ,if this happens only when you start the engine in morning then its normal ,,,,,,,,,,,,,,if it happens while car is moving then first check the clutch cable tension,,,,,,,,,if not solved then you may need to change the first gear synchronizer ring,,,,,,,,,,,check gear overhalling in my previous post,,,,,,,,,,
4- Heater doesn't work. I guess its clogged because of those years of rust inside the hoses.,,,,,,,,,,,,,yes its all clogged as the whole cooling system ,,,,,,,,,,,,,need to remove all that and flush it check the above post how to remove it,,,,,,,,,,,,,,,,you can use some radiator flushing liquid to flush all the system , there are some imported brands availabe in market , i check last day and found see one in 200 Rs ,,,,,,,,but some times its dangerous and can cause a gas kit leak,,,,,,,
5- There is rattling in the steering.,,,,,,,,,,,,,,repair it from some good "kharadiya" ,,,,,,,,will cost you 400 Rs in total,,,,,,,,,,,,dont replace it with a chinese stearing ,,,,,,,,if need replace then go for a kabli one,,,,,,,,,,,,,,,new/japaese is way toooo expesnive,,,
5- Fan switch will only work on second position. Nothing comes from the vents on the first. Do you think this is the solution: Geometroforum,,,,,,,,,,,,,that can be a problem/solution but i guess the resistance in the blower motors are worn off ,,,,,,,,,they are very sensitive and fragile,,,,,,,,,,,,,,look like a spring , 4 spring in total each for one speed,,,,,,,,check its pic in attachment ,,,,,,,,,,,,may be one of the spring which controls the low speed (which also gets max load) worn off ,
6- Passenger door lock is not smooth. It doesn't go to one side or the other in a click. It has to be pushed on either side, or it remains in the middle.,,,,,,,,,,,,,its a common problem in cultus,,,,,,,,its door locks levers and mirrors are never been smooth as they must be ,,,,,,,,,,,,,any good denter can open/grease them,,,,,,,,,,,,,,,,well check my previous post to lubricate them,,,,,,,,,
I also had a problem with jerks but they went away with the change of plug wires. I have also bought a new distributor cap and rotor which I am going to switch very soon.,,,,,,,,,,,,,you mention head cover is leak ,,,,,,,i guess oil is spilling on plug wires and causes them to malfunction ,its batter that you change it ,,,,,,,,,,,,changing distributer cap and rotor is also a good practice after heavy milage,,,,,,,,,,,,,
I am planning on doing everything myself. This car is not going to be gutted in another repair shop. I am in the process of gathering all the required tools. ,,,,,,,,,,,,,,,some professional hands need for gear job and head gaskit ,,,,,,,,,,,,,,,,,if you can handel then its good ,
There is also signs oil leakage on the head cover. I wonder if its the bolts or the pcv valve?,,,,,,,,,,,,,,,,,there is no oil under the PCV valve,,,,,,,,,,,,,,,,,oil cant come from there,,,,,,,,,,,,,,,,there is a O ring under it and air can leak from it if O ring fails ,,,,,,,,,,,you can check how to change it in my previous post of carb service,,,,,,,,,,,,,,,,,,and head cover mean jan is leak ,,,,,,,,,,,change it ,,,,,,,,,,,,my car also have a leak jan and will replace it soon,,,,,,,,,also check the disributer O ring , some time it leaks but seems like the head jan is leak ,,,,,,,,,,,,,,conform first ,,,,,,,but jan and O ring cost cheap so batter change both ,,,,,,,,,,,,
Question for Xulfiqar - I can't find Threebond 1209. Will 1104 work? How about Permatex Ultra Black? And what is your opinion about seafoam?