Hyundai Santro Restoration of Engine

[jagger]

the parts bill says 0.25 undersized main and big end shells but the pistons and rings are STD? Did you resleeve the block or were the bores good but pistons broken?

yes the block was resleeved. the previous size was 50 instead for going for 100 size we decided to restore the original size.. i guess in the future it will improve the fuel economy.. correct me if im wrong!!

[jagger]

again the cleaning procedure..

[jagger]

finally we decided to replace the clutch and pressure plate too

[jagger]

[jagger]

[jagger]

[jagger]

[jagger]

[jagger]

During assembling 2 issues have arised.
1. leakage of water from the water body
2. leakage of water from the hose which surrounds the block.. the mechanic calls it "engine ki tikki"

[jagger]

the above ring was inserted in the throttle body to control its leakage!!

[jagger]

that was the "tikki" i was talking about.. it was causing leakage of water from the block of the engine.. it has been replaced now

[jagger]

[jagger]

got beru spark plug wires installed

[Xulfiqar]

yes the block was resleeved. the previous size was 50 instead for going for 100 size we decided to restore the original size.. i guess in the future it will improve the fuel economy.. correct me if im wrong!!

you just wasted all your money, no shop in Pakistan bake the block before pushing in the new sleeves, they press locally diecasted sleeved in a cold block which causes uneven cooling in the block and eventual failure. btw was the bore out of spec?

[Horse_rider]

@jagger

A friendly advice, please do ask experts on pakwheels before starting any work, I did ask when I started work on my santro, and am saved , these local mechanics only know how to replace the things (not properly, but just know their own way), but they can not diagnose the problem or the symptoms, they just love to replace each and every thing to avoid sudden failure.

[Xulfiqar]

those tikki - more properly known as welch plugs are replaced regardless of their outer condition in every overhaul, the block cooling galleries are also acid washed to remove all traces of rust and scale buildup. I always was amazed when mechanics just left the old ones in and installed rusty items back - just waiting for it to leak again.

I think there are about 6 or 8 in total on your engine

[jagger]

@jagger

A friendly advice, please do ask experts on pakwheels before starting any work, I did ask when I started work on my santro, and am saved , these local mechanics only know how to replace the things (not properly, but just know their own way), but they can not diagnose the problem or the symptoms, they just love to replace each and every thing to avoid sudden failure.

you are absolutely right about the mechanic s thinking. and thts the best thing that one should take advice from the experts rather than consulting mechanics. the reason i couldn't consulted the experts was because of the less availability of time as the car was unable to move and the unavailablity was badly affecting our daily routine.
second reason i trusted the mechanic as he was a retd captain from engg core. and all the work was done under his supervision.

[jagger]

those tikki - more properly known as welch plugs are replaced regardless of their outer condition in every overhaul, the block cooling galleries are also acid washed to remove all traces of rust and scale buildup. I always was amazed when mechanics just left the old ones in and installed rusty items back - just waiting for it to leak again.

I think there are about 6 or 8 in total on your engine

yes there were about 8 of these and all of these were replaced. but no acid waahing of cooling galleries.. is there something that i can do now????

[jagger]

you just wasted all your money, no shop in Pakistan bake the block before pushing in the new sleeves, they press locally diecasted sleeved in a cold block which causes uneven cooling in the block and eventual failure. btw was the bore out of spec?

that's scary if everything you stating comes true what else we can do if the khradiyas here do such unstable work. and no idea about the bore

[Xulfiqar]

that's scary if everything you stating comes true what else we can do if the khradiyas here do such unstable work. and no idea about the bore

tell them to do it properly, They know it but are just plain lazy not to do it. For genuine cylinder liners you need to spend about as much as a good set (not chinese) of pistons. The cooling galleries need to be scrubbed with a brass brush and a mixture of oxalic acid then washed with some soda water to neutralize. spray with WD40 to prevent rusting. Its a very dirty and tiring process.

what you can do now is to make a citric acid mixture of 10% strength and fill the system up with it and flush after 20 minutes. Look up how to do it, Ask capt sb - he must know of this process.