Cultus engine and body overhaul and rebuild

[agoodfriend]

Well I was waiting for the Sunday to come and take out the blower from car to take pics for you,Now you are at it I took the help from the Photoshop to show how and where I have introduced DIY cabin filters.
The to side which fit with the car body for fresh air I removed the foam seal which was broken any way. cut a piece of window Jally overlapping the edges of the hole on the blower.The Jally was only put to hold the AC foam filter otherwise it would not stay I put some glue on the edges of the jally and the blower to fix .Then I made a new foam seal cut from a one inch foam sheet and fixed it on top of jally.After that I cut a piece of filter foam sheet to the size of the opening and just placed it on top of jally,The top side is done .For the cabin inlet I simply cut a foam filter piece little larger than the inlet and with a small samad bond on the edges fixed it to the blower .Thats job done and fixed the blower back to the car. Fresh air is dust free and the cabin recirculating aire is also free of dust . spray air freshener on the cabin filter and enjoy clean and fresh air from the vents.

can you tell me the air flow after installing the air filter ?,,,,,,,i guess it may reduce to some extent

[agoodfriend]

no one interested in cultus manual i guess. yesterday i pasted a link of uploaded file, no feed back. how it was.
is
well i guess it was wrong file uploaded. i m uploading it again and this time all three files will be uploaded.

if some one interested can down load one file so far uploaded at suzuki cultus manual-1.PDF - 4shared.com - document sharing - download

well i guess many PWs has downloaded it silentelly,,,,,,,,,i havent down laod it yet because of load shading issue ,,,,,,,,,,

[shazaryab]

can you tell me the air flow after installing the air filter ?,,,,,,,i guess it may reduce to some extent

There is a minute difference in air follow which is to compromised for clean air.The split AC foam filter does not block so much air if you use normal foam sheet that may decrease air flow significantly.

[Xulfiqar]

yeah you are right , its obvious that the multi flow is batter but our ac mechanics dont know much ,,,,,,,,,,,,,,none of them know about the ambient temperature,,,,,,,,,,they never check the outside temp,,,,,,,,,,,,,all they check is the vent out air after charging gas ,,,,,,,,,,,,
,,,,,,,,can you tell me about fitting the balleno multi flow conderncer in cultus,,,,,,,,its longer in length so will it give some batter efficency,,,,,,,,,,,,,,i guess that that condencer and evaporator are selected in some proper proportion , mean i cant install a bigger evaporator with smaller evaporator,,,,,,,,,,,,,,

slightly larger condenser will enhance performance and the TX valve would do the regulation of the liquid refrigerant so dont worry about additional volume - you are not doubling the system, you would obviously not follow the recommended weight of the refrigerant becuase the condenser is now larger and holds more.

Measure the ambient, line and vent temperature to determine the correct charge load.

[mazamwarraich]

This is great this is THE manual I have downloaded, it its 349 pages, are there more?

yes their r two more parts. i will upload today.

[Xulfiqar]

agoodfriend

may I suggest you throw away this junk scrap excuse of a fan that is placed on the condenser and use a proper SPAL, GATE or Bosch high CFM fan.

You can find a lot of them in old parts. The only thing required would be to install a second relay for it as it consumes very high amps when it starts.

[mazamwarraich]

2nd part of manual SF-310

suzuki cultus manual-2.PDF - 4shared.com - document sharing - download

[agoodfriend]

agoodfriend

may I suggest you throw away this junk scrap excuse of a fan that is placed on the condenser and use a proper SPAL, GATE or Bosch high CFM fan.

You can find a lot of them in old parts. The only thing required would be to install a second relay for it as it consumes very high amps when it starts.

now i need to post pone gas charging and get back on drying board again ,,,,,,,,need to upgrade,,,,,,,i guess the baleno condencer comes with high CFM fan but not sure ,,,,,,,,,,,,,,,will check it tomorrow

[agoodfriend]

agoodfriend

may I suggest you throw away this junk scrap excuse of a fan that is placed on the condenser and use a proper SPAL, GATE or Bosch high CFM fan.

You can find a lot of them in old parts. The only thing required would be to install a second relay for it as it consumes very high amps when it starts.

i have just check the balleno condencer ,,,,,,,,,,,,i have found that it can be easily fitted in cultus ,,,,,,,,,,infect cultus has option for installing bigger conderncer,,,,,,,,,,,,,,,,as you know condencer fits with just 2 bolts at the upper side and 2 hooks which goes into the cultus frount foundation ,,,,,,,,,,,,,there are space and holes left for bolts and hooks ,,,,,,,,,,,,so it can be easily fitted,,,,,,,,,,,,,,

but 2 things are in my mind,,,,,,,,,,,,first is that the original condernce wont full cover the radiator,,,,,,,,,but this balleno condencer which is longer in length can fully cover the radiator, just like in mehran,,,,,,,,,,which will block the radiator air flow and also the condencer hot air will directelly flow thow radiator ,,,,,,,which can result in engine overheating,,,,,,,,,if its so then we can do 2 things,,,,,,,,,,either instal 2 fans on condencer or make a system so that the radiator fans kicks in when we switch on the,,,,,,,,,,,,check the pic,,,,,,,,,

second this about the fan,,,,,,,,,,,,you can see the balleno conderncer in pic ,,,,,,i take that pic from web but its same as the one availabe in market,......can you tell me is that high cubic feet per minute fan or same as the old style 4 curved shape blade ............

[amansoor]

Today i was fixing my cultus dashbord while i found TAP on passenger side underneth gluve box.but it is not connected with any thing. I saw a spare connector which is used to bypass TAP wirings. Quistion is how i reconnect TAP is there anything to be altered or just reconnect bypassed connector into TAP. Kindly check out following pics

[smijaz]

@goodfriend

As you are going to use R134a then the regular serpentine condenser would do you no good. R12 is not environment friendly but it is more efficient in heat exchange and being heavier than r134a it works with serpentine pretty well but will fail in MFC.
In MFC, the refrigerant (R134a) is forced through very narrow channels to maximize heat exchange surface contact which very easily compensates for the said disadvantage of r134a.

The ND fan (6 Blade pusher) in baleno is better than the one you have (4 blade pusher), and if you are going for the baleno MFC then get one with fan. This way you might get a good deal. Flushing will be mandatory but it would be tricky being multi flow like a radiator.

You dont need to worry about the condenser covering the radiator. In most of the cars like corolla, vitz and many other have one radiator fan which also acts as condenser fan when compressor kicks in as they have condenser/radiator configuration. No need to connect the radiator fan with condenser fan as you will be having a independent condenser (Pusher) fan and if the coolant temperature will rise the radiator fan will kick in.

If the condenser is efficient and keeps the head pressure well in control then you will notice minor load on the engine with AC resulting in better fuel economy, no engine heat up and chilled cabin.

[agoodfriend]

@goodfriend

As you are going to use R134a then the regular serpentine condenser would do you no good. R12 is not environment friendly but it is more efficient in heat exchange and being heavier than r134a it works with serpentine pretty well but will fail in MFC.
In MFC, the refrigerant (R134a) is forced through very narrow channels to maximize heat exchange surface contact which very easily compensates for the said disadvantage of r134a.

The ND fan (6 Blade pusher) in baleno is better than the one you have (4 blade pusher), and if you are going for the baleno MFC then get one with fan. This way you might get a good deal. Flushing will be mandatory but it would be tricky being multi flow like a radiator.

You dont need to worry about the condenser covering the radiator. In most of the cars like corolla, vitz and many other have one radiator fan which also acts as condenser fan when compressor kicks in as they have condenser/radiator configuration. No need to connect the radiator fan with condenser fan as you will be having a independent condenser (Pusher) fan and if the coolant temperature will rise the radiator fan will kick in.

If the condenser is efficient and keeps the head pressure well in control then you will notice minor load on the engine with AC resulting in better fuel economy, no engine heat up and chilled cabin.

well unfortunattely i am not going for any mod in AC system , i discuss with my brother he is saying its all useless as he is getting keen to dispose off this car soon as posible , so that all will be waste of time and energy ,,,,,,,really i want to go for that mod and really love to do that but thats a desperate end , but i tell you guys on PWs that surelly its posible that you can instal balleno condencer on cultus , today i have check its feasibility and found that there will be no alteration needed to instal the balleno condencer in cultus , every thing is already there , may be this same car comes with bigger condencer in some part of the world ,,,,,,,,,,,,,,i have also noticed that those cars which is already fitted with sanden units need no modification in condencer pipes , but for those cultus which comes with ND units (like my 06 cultus) , in that you have to alter the condencer inlet and outlet pipes , but thats not a big deal , you will get the inlet and outlet pipes along with the old balleno condencer , just 2 welds cost not more than 100 Rs ,,,,,,,,,,,,,,,,,means its all posible and not so difficult ,,,,,,,,,,,,,,,,,,,

any how tomorrow will charge the system with its original condencer ,
thanks

[agoodfriend]

Today i was fixing my cultus dashbord while i found TAP on passenger side underneth gluve box.but it is not connected with any thing. I saw a spare connector which is used to bypass TAP wirings. Quistion is how i reconnect TAP is there anything to be altered or just reconnect bypassed connector into TAP. Kindly check out following pics

is it originally installed by paksuzuki ? ,,,,,,,,,,,installed by factory and disconected by previous owner of car ? ,......,,,,,,,,,,,get it fixes ,,,,,,,,,,,but its not installed in my FF CNG cultus

[agoodfriend]

@goodfriend

As you are going to use R134a then the regular serpentine condenser would do you no good. R12 is not environment friendly but it is more efficient in heat exchange and being heavier than r134a it works with serpentine pretty well but will fail in MFC.

well in normal condition you cant charge R12 into R134a unit and vice versa , system and compressor is all same , no difference,,,,,,,,,,,,only difference is that of the oil ,,,,,,,,,,,,,both refregrant have different oils which cant be mixes with each other ,,,,,,,,,,,,,you can charger R134a into R12 after flushing each and every part including compressor ,,,,,,,,,,,,,

[smijaz]

well in normal condition you cant charge R12 into R134a unit and vice versa , system and compressor is all same , no difference,,,,,,,,,,,,only difference is that of the oil ,,,,,,,,,,,,,both refregrant have different oils which cant be mixes with each other ,,,,,,,,,,,,,you can charger R134a into R12 after flushing each and every part including compressor ,,,,,,,,,,,,,

Yes, well i am saying that R134a can work (barely) in R12 system i.e serpentine condenser BUT R12 cannot in r134a system i.e. MFC.

the r12 lubricant (mineral) doesnt mix with PAG (glycol based) oil of r134a. Creating undesired pressure surges in the system

[amansoor]

is it originally installed by paksuzuki ? ,,,,,,,,,,,installed by factory and disconected by previous owner of car ? ,......,,,,,,,,,,,get it fixes ,,,,,,,,,,,but its not installed in my FF CNG cultus

yes it is installed by paksuzuki and
disconnected by previous owner or some mechnic because they dont know the function of such devices.i think ignation timing is advanced by shifting distibuter right now insted of using TAP. Is it possible to set timing with out timing gun and then introduce this TAP for further advance on cng. I have checked it wiring which seems complete to me and also ff. Just need to replace bypass connector

[mazamwarraich]

3rd and final part of manual SF310

suzuki cultus manual-3.pdf - 4shared.com - document sharing - download

[agoodfriend]

helo PWs , so finally today i charge the ac system with refregrant , just for the reference check the pic of thermometer ,,,,,,,,the reading i got while giving a test drive on 6th road Rwp at about 40 to 50 km/h and at around 4 pm ,,,,,,,,i by pass the ac thermostat to put the system on extreme test,,,,,,,,,,one thing i will say that this rotary comp puts very very less load on engine ,,,,,,,,i switch on the comp at about 40 km and hardelly feel any thing ,,,,,,,,,,i must say results are many times batter than the original cultus ac system and also batter than what i have expected ,,,,,,,,,,,later share all process ,

[agoodfriend]

yes it is installed by paksuzuki and
disconnected by previous owner or some mechnic because they dont know the function of such devices.i think ignation timing is advanced by shifting distibuter right now insted of using TAP. Is it possible to set timing with out timing gun and then introduce this TAP for further advance on cng. I have checked it wiring which seems complete to me and also ff. Just need to replace bypass connector

well i suggest leave this thing as it is ,,,,,,,,,,,,,,fixing it may open another "calf",,,,,,,,,,,,,and another problem for you,,,,,,,,,,,,,,,,,

[babarhashmi]

wow thats amazing result (Y)