Cultus engine and body overhaul and rebuild

[amansoor]

Friends today i replaced thermostate housing here i attached old housing pics

[agoodfriend]

If your old lappy is heating up then most probably the heatsinks of the fan(s) are blocked with lint and fluff which is causing low air flow across them. Open it up and clean them out.

will do a DIY for servicing it soon ,

[agoodfriend]

damn, i hate you organic chemistry

same here ,,,,,,,,,,,,,

[agoodfriend]

@agoodfriend

no dear car ac gas cant be used in home ac ,,,,,,,,,,,,some old car ac prior to 1994 use R12 which was not environment friendly and very dangerous for ozone ,,,,,,,,another -ve point of it was that its highjly flamable,,,,,,,,so its banned to use all over the world after 1994,,,,,,,,,,its substitute is R134a,,,,,,an environment friendly car refregrant,,,,,,,,,,but it cant be used in home AC,,,,,,,,,,,,fridge , ac , deep freezer they all use R22,,,,,,,,,

R22 available in cans like R134a ?[/QUOTE]

yes its available , you can charge your split unit with that ,,,,,,,,,,,,,,,but you cant charge gas into your fridge , deep freezer and window ac , because you need some gas welding for that ,,,,,,,,,,,,,,,,but you must need a vaccum compressor and manifold guage set for charing gas in any system

[margallar]

same here ,,,,,,,,,,,,,

well i still have to give chem exam, i was pathetic when i tried to learn it at school, lets see what magic sir saad hameed can do at his academy,

btw when you clean ur old lapto remove the heatsink and apply a good quality thermal paste over the processor's face (the metal face where the heatsink rests) and then put the heatsink back, it will improve the heat conduction between processor and heatsink.

[agoodfriend]

well i still have to give chem exam, i was pathetic when i tried to learn it at school, lets see what magic sir saad hameed can do at his academy,

btw when you clean ur old lapto remove the heatsink and apply a good quality thermal paste over the processor's face (the metal face where the heatsink rests) and then put the heatsink back, it will improve the heat conduction between processor and heatsink.

yeah i know that thermal paste , but i dont think its really availabe in market , i was thinking not to remove the heat sink just because i dont want to disturb the thermal paste,,,,,,,,,,,,

[margallar]

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[agoodfriend]

helo PWs , after a littel pause i am here back with the real post,,,,,,,,,,the compressor installing ,,,,,,,,unfortunately i lose some of my very precious data during data transfer from one pc to other , some folder on desktop has been gone, although i always carry a external hard disk with me but dont how how that blunder happens , any how i recover some of that with a data recovery sw,,,,,,,,
here i use pajero mino compressor on cultus ,,,,,,,,,,,,,,first of all you need some very very strong brackets to mount that compressor on ND compressor mountain ,,,,,,,,,,,,these brackets must be strong enough to bear the load and punishment ,,,,,,,,,,other wise they wont work and you end up in total loss,,,,,,,,,,,,,the system of brackets you see in this post may look fragile but infect they are very very strong and i am sure they will with stand all that punishment ,,,,,,,,,,also the belt allighnment must be dead accurate ,,,,,,,,,,,,,the second thing is the alteration in pipe,,,,,,,,,,,,,the new compressor come along with its original half cut pipes , which i use to make new working pipes ,,,,,,,,,,,just check the pic for detail ,,,,,,,,,,,,,,
system is still waiting to get the refregrant ,,,,,,,,,,,

[agoodfriend]

[Xulfiqar]

Friends today i replaced thermostate housing here i attached old housing pics

boys and girls

thats why we do not use neat tap water in our car radiator..

[agoodfriend]

[agoodfriend]

[daniyalahmad]

Excellent!
Lets see how does the AC performs with the new compressor.

[agoodfriend]

[smijaz]

@agoodfriend

I must say you are making a lot of effort on your part for the AC ( Wish it will freeze the passengers ) and more than that by sharing it in such detail.

I must confess that I also do most these things myself but lacks the passion to share it. Like I did the engine overhaul of brother's cultus and also made a commitment with you and myself that I will be taking the pics for sharing it through you. I thought it would be easy like i have to just take picture but it is very very hard once you have to assemble and do the photos with all greasy hands. It is not just hard but also the time factor goes way out of the window. At the end i could just make very few of them which actually are pretty much useless in terms of sharing as rebuild.

So bravo to you dude.

One thing i would like to say about the compressor you opted for, is that it surely puts very minimal load on engine being rotary but at the same time it is very rpm dependent meaning it barely works on idle or higher idle rpms. Higher the rpms better is the cooling simple.

Rest I wish it to be a successful project.

[sharicer]

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[Xulfiqar]

I dont intend to burst your bubble but the problem in the A/C system of the cultus is not the compressor but the POS stupid condenser that PS has installed. It does not cool down the R134 to acceptable levels.

The denso A/C compressor is quite powerful and long life, it suffers from high head pressure due to the silly condenser, a very good modification is to install a generic multiflow condenser that can actually cool down the gas.

[xzap042]

I dont intend to burst your bubble but the problem in the A/C system of the cultus is not the compressor but the POS stupid condenser that PS has installed. It does not cool down the R134 to acceptable levels.

The denso A/C compressor is quite powerful and long life, it suffers from high head pressure due to the silly condenser, a very good modification is to install a generic multiflow condenser that can actually cool down the gas.

agreed. both the condenser and radiator are not up to mark for the required job.

[shazaryab]

Let,s wait for the result of compressor alteration. I hope it will work. The small size of compressor fits good any way otherwise the oil filter removing get hard.
agoodfriend you are doing very well I took the courage and did opened all my car AC parts to service them.I did not have vacuum /pressure pump so instead I used normal air compressor to blow pressurised air to clean the pipes , evaporator and condenser with CTC.All processes was very well explained by the poster.

Some compressor job pending last season.I am sharing here the replacement of clutch magnet coil of ac compressor.here are the pics.

The main shaft nut is 12mm.to remove this nut you need to hold the clutch assembly to stop it rotating .I used hand grinder disc tightening tool to do the job.

Used two flat screw driver to put even pressure form both sides to lift the assembly.

These are all parts removed take care of the spacer shims.they to keep the clearance between clutch and the pulley.

Magnet coil cost Rs800/- from Naz cinema AC spare shops.

The specified clearance is 0.4 to 0.8mm mine is 0.5mm.

[agoodfriend]

@agoodfriend

One thing i would like to say about the compressor you opted for, is that it surely puts very minimal load on engine being rotary but at the same time it is very rpm dependent meaning it barely works on idle or higher idle rpms. Higher the rpms better is the cooling simple.

Rest I wish it to be a successful project.

well this thing was in my mind ,,,,,,,,,,,,,came thru this problem many years before in FX and mehran,,,,,,,,,,as you know both have similar engine , but the AC system are different,,,,,,,,,many of you may have forgotten these 2 cars fx and mehran but i still remember the ac experence on these 2 cars,,,,,,,,,,,,,,fx comes with sanden rotary compressor and mehran comes with ND piston compressor ( the same as the one i have grounded and the only difference is with the refregrant) , both the cars have poor AC system as you also have experences or listen ,,,,,,,,,,,,FX has the same problem as you mention,,,,,,,,,,,,,and mehran has high head pressure problem,,,,,,,,,,,mean it wont work once the car cross 100 Km/h ,,,,,,,,,,,,,i fix both of them with a very simple fix ,,,,,,,,,,,,,,you may have noticed the crank shaft pully which runs alternator and compressor ,,,,,,,,,,,,,in FX the originally pully which drive the ac belt is of very small dia,,,,,,,,and in mehran its large , and even larger than that which runs alternator,,,,,,,,,,,i instal a bigger pully in FX and grounded the original one,,,,,,,,,the pully was originally of japan assamble mehran 800cc ,,,,,,,,,ac works fine on low RPM and cooling was all good and obviously it puts load on engine but that was bareable because at that time there is nothing name CNG ,,,,,,,,,,,,later after some time i experenced mehran,,,,,,,,,,,and found that its ac cooling goes off as car crosses 100Km ,,,,,,,,,,at first i though the comp trips off ,,,,,,,,,,,so i by pass every thing but still nothing happens,,,,,,,,,,,,,later found that its because of high head pressure which ND piston compressor creates ,,,,,,,,,also it was fitted with old style condenser the same as fitted right now in my 06 cultus ,,,,,,,,,any how i pull back that pully from my junk yard and instal it in mehran,,,,,,,,,,,problem solved and ac cooling is all ok even at 130km ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,\

i have check the pressure of the compressor which i have installed in 06 cultus ,,,,,,,,,,,,,some how it has that inherated problem but i guess it will work ,,,,,,,,,,,,cooling will be reduces on low rpm but not as much , and second thing is that mostelly car runs on higher RPM above 2K ,,,,,,,i guess it will creat not much problem,,,,,,,,,,,,,,,