Cultus engine and body overhaul and rebuild

[syncview]

At high revs the water body also spins faster hence the increased water flow

Did you replace the cap?

You cannot just test these caps that way, you need a radiator cap tester tool or make one

It looks like you need to replace your cap and also make SURE that the pipe that goes to coolant reservoir is not damaged. If it's damaged, it will only pull air back in the system instead of the coolant in the reservoir.

[syncview]

The bubble appearing after a lot of idling are due to the fact that the water is boiling.

To check for air in the system you need to perform this test with a dead cold engine

Xulfiqar suggests to raise the front of the car so that the rad cap is considerably higher than the rest of system, makes it easier for hot air to exit the system.

Also if the fan starts late as you mentioned in one of your posts it may be a bad thermo switch or a bad temperature gauge.
Either confirm this by using an external temperature gauge on the radiator or replace the thermo switch to eliminate a possibility

[syncview]

Thanks! Need a brand name of a better than OEM boot for Cultus 2001 and also a brand name for the CV Joint grease. Also is there a different grease for inner and outer or same grease can be applied for both?

By the way there is no sound yet.

Can't say anything about brand names of boots but there are none better than OEM

Liqui moly LM 47 is a good cvj grease to be used in six ball cv joints (rzeppa joints)
If you can't find LM47 then get the usual 90gm packs from any good auto parts shop. . They are mostly available in toothpaste like tubes

If the inners are a tripod cv joint then you need NLGI2 WHEEL bearing grease.. one of the best available here is Mobil XHP222.

Cv joint boots need to be installed carefully making sure that the correct amount (about 90 grams) goes in and that the air is released before locking the boot. . Also make sure that the boot is not in a twisted position it should sit flush and straight

[Xulfiqar]

Thanks! Need a brand name of a better than OEM boot for Cultus 2001 and also a brand name for the CV Joint grease. Also is there a different grease for inner and outer or same grease can be applied for both?

By the way there is no sound yet.

are the boots torn?

[Xulfiqar]

@Xulfiqar @agoodfriend

Dear Guys, serviced the radiator my self using tartari then radiator flush and then baking soda in the end and then rinsing with water and then coolant before finally putting coolant in the car, thermostat is at the moment removed. Facing one problem.

During extended driving (more than 10 kilometers) too much coolant goes into the reservoir bottle which gets full and if I don't put it back in the radiator in time then the bottle over flows and coolant is wasted. Don't know why it is happening. Have detected one thing that fan starts when the needle goes at 60 to 70% mark and not exactly half mark.

My query does the coolant expands if heated so much that it over fills the reservoir bottle. Mechanic is telling me that engine or head bolts need to be tightened. please help me right now I am going through the inconvenience of putting coolant from reservoir bottle back into the radiator every 10 to 15 kilometer drive and at least purchase 1 liter bottle of coolant every week. Coolant is Osaka. (I will only change to a better coolant once this problem is solved)

Also when the car is idling temperature needle reaches 70 to 80% mark and if I drive fast it quickly comes to middle mark.

Another thing I have noticed that from a cold start (overnight) even with thermostat removed car reaches half mark in like literally 2 minute of driving even with the thermostat removed when previously it took at least 5 to 7 minutes with the thermostat inside. My guess is that probably before radiator flush too much mineral / rust deposit on the sensor reduced the sensitivity which is now better as I replaced it with a new one.

your system has an air leak in it, - the coolant does expand and gets transported to the overflow tank, it is sucked back to the system under vacuum as the coolant cools down, this action sucks down the vacuum valve in the cap which then allows liquid to be filled back in. If there is even a pin hole leak anywhere in the system including the pipe and nipple going to the overflow tank - the system will suck air from it and you will see it as "low coolant"

your car has an overflow tank with two pipes on it, the pipe from the radiator overflow nipple should lead all the way down - if its not all the way down it will not function. If there is a pin hole leak in the pipe - it will allow air to be sucked instead of liquid.

[nasirjavaid]

Lots of rain drops after the first ....

Well, I read somewhere that the rubber washer of radiator cap is larger than the metal part just behind it then the cap needs to be replaced. as Metal part should be visible. Mine metal part isn't visible so do I have to replace it too? Also as explained in detail in previous post radiator to bottle pipe has all air while driven on motorway after 200Km when engine is hot and pushing coolant to bottle. Bottle spilled out extra coolant. While radiator is full of coolant till the neck. And after engine is cold, the next day, Level is again till neck of radiator .... from where this air is coming in the pipe .... Pressing upper pipe while engine is cold shows coolant+air movement in the pipe connected to bottle from radiator... this also show there is some issue with cap or radiator neck ....am I right?

[syncview]

Lots of rain drops after the first ....

Well, I read somewhere that the rubber washer of radiator cap is larger than the metal part just behind it then the cap needs to be replaced. as Metal part should be visible. Mine metal part isn't visible so do I have to replace it too? Also as explained in detail in previous post radiator to bottle pipe has all air while driven on motorway after 200Km when engine is hot and pushing coolant to bottle. Bottle spilled out extra coolant. While radiator is full of coolant till the neck. And after engine is cold, the next day, Level is again till neck of radiator .... from where this air is coming in the pipe .... Pressing upper pipe while engine is cold shows coolant+air movement in the pipe connected to bottle from radiator... this also show there is some issue with cap or radiator neck ....am I right?

If you follow the rubber washer larger method you'd end up with a ****** and then some and then some and then some and then some radiator cap

If the cooling system has no leaks and it doesn't exchange coolant with the reservoir correctly, it's the radiator cap that is bad

Let's summarize

Engine hot - reservoir overflows
After engine has cooled down - coolant level in radiator is low

Right?

[siraj_7]

If you follow the rubber washer larger method you'd end up with a ****** and then some and then some and then some and then some radiator cap

If the cooling system has no leaks and it doesn't exchange coolant with the reservoir correctly, it's the radiator cap that is bad

Let's summarize

Engine hot - reservoir overflows
After engine has cooled down - coolant level in radiator is low

Right?

Nops!

At 50% mark, coolant starts to go in the reservoir bottle and keeps going and the bottle (initially at full level) over flows and the radiator gets low on coolant and then the temperature needle keeps going up and then if you keep driving it reaches HOT mark and then you have to stop the car to avoid totaling the engine!

[siraj_7]

@xulfiqar

Do you know of any place where I can get my radiator pressure tested and find any leaks in the system to confirm if its my gasket that is gone or the cooling system which has a leak? I heard even the Suzuki guys here in Defence don't have the machine to check it. When I was in Lahore we knew places where we could get it pressure tested but don't know about Karachi.

Mechanic says the Gasket is gone but then why can't I find any oil in the radiator? Its neck is even not laced with any traces of oil.

By the way car is running on coolant+water so can't see oil visibly.

The problem is that I can see air bubbles constantly in the radiator neck and the car starts to push coolant in the reservoir bottle as soon as the needle reaches 50% and that is the moment when radiator fan comes to life. However it keeps filling the bottle which in the end overflows and all coolant is wasted.

[margallar]

forget about the 3s, those fakeers are just desi mechanics in uniform

[Xulfiqar]

Nops!

At 50% mark, coolant starts to go in the reservoir bottle and keeps going and the bottle (initially at full level) over flows and the radiator gets low on coolant and then the temperature needle keeps going up and then if you keep driving it reaches HOT mark and then you have to stop the car to avoid totaling the engine!

That sounds like a really bad pressure situation in the system, more like a bad headgasket - does the overflow shoot coolant? the expansion should be very gentle - it fills it quite slowly.

[nasirjavaid]

Let's summarize

Engine hot - reservoir overflows
After engine has cooled down - coolant level in radiator is low

Right?

No, the coolant level is full till neck of radiator ( as described in detail in my previous post) ... I am only concerned

1- Why radiator->bottle pipe contains air?
2- When engine is cold why I can see coolant and air movement in same pipe if I press upper radiator hose pipe ?

Thanks for your feedback, please clear my confusion as in above points.

[nasirjavaid]

Nops!

At 50% mark, coolant starts to go in the reservoir bottle and keeps going and the bottle (initially at full level) over flows and the radiator gets low on coolant and then the temperature needle keeps going up and then if you keep driving it reaches HOT mark and then you have to stop the car to avoid totaling the engine!

My needle never crosses middle point and on motorway it even comes down to 10%. But pressure in radiator is there and coolant starts flowing to res. bottle and overspills it..

[nasirjavaid]

forget about the 3s, those fakeers are just desi mechanics in uniform

Any good place for cooling system pressure test to find leakage in Lahore?

[syncview]

No, the coolant level is full till neck of radiator ( as described in detail in my previous post) ... I am only concerned

1- Why radiator->bottle pipe contains air?
2- When engine is cold why I can see coolant and air movement in same pipe if I press upper radiator hose pipe ?

Thanks for your feedback, please clear my confusion as in above points.

this sounds like you either have a bad radiator cap or a bent radiator neck, allowing coolant to move freely between the radiator and reservoir

am I getting it right? - you squish the upper rad hose pipe and you see 'movement' in the cap neck to reservoir pipe - right?

My needle never crosses middle point and on motorway it even comes down to 10%. But pressure in radiator is there and coolant starts flowing to res. bottle and overspills it..

and you also don't have a thermostat valve installed, get a brand new part and install ASAP

and as mentioned above, check your rad cap and neck - or better yet post some pictures for our eyes only

[Xulfiqar]

are you guys in the same city?

are you sure you used the correct cap on your radiator, there are two types of small radiator caps - one is shorter in size which will cause such issues if your radiator neck is the taller one.

as syncview said - if you can hear and see movement of liquid between radiator and overflow tank with engine cold while you press the pipes then you have the wrong cap or really damaged radiator cap neck.

I had a car repaired last week - it was a camry which once had overheated really bad - they already had the head gasket job done and it was also overheating like this - the culprit was a bad radiator cap neck - its plastic had literally melted from overheating and the cap never made a seal on it. New radiator fixed it.

[siraj_7]

@xulfiqar
Yes the overflow shoots all the coolant out as the car gets heated...bubbly situation inside the radiator is also getting worse...
@margallar
3s is hopeless, I went there and was very dishearted to see they did not have machines to properly tune the car and only did by TUQA method. I couldn't see any one with torque wrenches. They just looked like road side mechanics in uniform. Upon enquiry they told me that they take out their torque wrenches only for an engine job. I immediately took my car away as I had gone for a leaked water pump replacement. They were charging much more than the market and I did not see any value for money there...

Guys, Can any one of you recommend some body who can do the gasket replacement job properly with torque wrench?

[margallar]

@ser_gtr, I think you can help

[SER_GTR]

Torque Wrench.....Seriously.....I Am Considering Myself To Get One Of My OWN Because I Don't Know ANYONE Who Use It.......... LOL...

If Anyone Have It.....Its For Either Their Use Or Personal Work....In Commercial Work... I Didn't See Anyone Using It To Torque Head Bolts

[margallar]

If the poster was in lahore, I could have arranged it, I guess he will have to find a workshop willing to use it