Hi, this is my first DIY so kindly bear with me.I must confess that I did not take care lately of my age old Santro 2000 model, mostly because it was with my bro. It clocks at 1,28000 KM, and nothing has been changed accept fuel pump and regular oil changes, it is still going strong. It was converted to LPG.Recently I noticed that it was not accelerating while gear shifting. There was no problem in LPG. Spark plugs were cleaned some time ago. So I thought may be its fuel pump again, I found that tank was clean pump motor was working ok and fuel was returning, so replaced pump sieve with new one but problem kept on. So decided to check injectors. Here some images of my DIY which includes throttle body cleaning, injector cleaning, sludge cleaning off tappets. Images were for future reference later decided to put on forum, so some steps missing, but images explains itself.
Partially clogged fuel rail
this is a severe case of PCV malfunction - check the valve cover baffle and make sure the engine runs at normal temperature with the correct grade oil.
Cleaned parts and cleaning method below. any queries are welcome.Used kerosene+spirit and its thoroughly cleaned.
Don't forget to clean sludge inside injector holes with help of spirited cloth on little finger, works best, don't use sharp tools.FR checked at 40 psi, working okI used kerosene/spirit and brush for cleaning this.
Method : 1. Drill two 10 mm holes in cold drink bottle lid. 2. Insert two clear 10mm tubing and apply some rubber solution like fevibond. One tube goes upto bottom of bottle and other just protrudes lid inside. 3. Cut valve of used bike or car tube. Insert this in Air-in tube as shown in image, it will work as valve so take care that it should not be reversed. 4. Insert inlet of Injector in other tube and secure with wire so that it does not pop off.5. Attach two wires with +ve and –ve terminals of injector. Attach these wires to psu. Check operating current of Injector. I increased current for Injector till it operated which is 6v. Do not operate at 12v,which is too high and may damage injector. 6. Fill bottle with spirit (Methyl Alcohol), as easily available and not too harsh on rubber and plastic item yet works ok. (I cleaned all parts with this, check images). 7. Pressurise bottle up to 40 psi (operating pressure of injector) with foot pump. Check for any leakage of air.8. Now switch on and off psu randomly and collect spray of spirit in other bottle. If it is not uniform, keep switch on till its clean. Also keep air pressure up to 40 psi with foot pump.
Hope this helps
Thanks Xulfiqar bhai for your advice I need lot of these. As you see pcv removed and inlet pipe was byepassed by mechanic to LPG venturi while fitting LPG.I need suggestion for correcting this ?Regards
Edit : I checked underlined part, which was wrong assumption. It was not pcv. Although PCV also cleaned, I'll recheck it. Thanks to Xulfiqar bhai.
thread subscribed, appreciated your efforts.
Thanks bro,With help all of you bro, I will surely rejuvenate my oldy
ps: just translated your signature
Asked here https://www.pakwheels.com/forums/belts-pipes-hoses/211450-santro-rubber-pipe-whats#post3789963
Xulfiqar bhai diagnosed here https://www.pakwheels.com/forums/d-i-y-projects/211384-rejuvenating-santro#post3788500 about PCV problem, I was thinking that it was due to not taken care of for long time. When I cleaned valve cover I found that it was in working order (sucked through pipe and blow from other side). I did not checked it before cleaning valve cover. Which was a mistake. This link was helpful AGCO Automotive Repair Service - Baton Rouge, LA - Detailed Auto Topics - What are the Symptoms of a Bad PCV ValveBut I decided to double check. Below are the images, and believe me it was dirtier inside beyond my thinking.So guys take good care of this valve.
Kerosene spirit and syringe used.
Cleaned from inside also.
Now I have a question regarding pressure [thread=211476]here[/thread]
Thanks a lot! Really helpful.
Thanks for kind words.Next fix - brake fluid bleeding.
^^ I have done the brake fluid bleeding, by not done well, now car pulls to left. waiting for your DIY.
I think this may be due to 1. Left over aiir bubbles in right side tubes or 2. Alignment issue.expert may may tell better.
Excerpt from aa1car :- BRAKES PULL TO ONE SIDE If your vehicle suddenly swerved to one side when you apply the brakes, there is uneven braking side-to-side. This usually means one front brake is not working properly. The pull will be toward the side with the good brake (because it is doing all the work). Brake pull can be caused by brake fluid, oil or grease on the brake pads, a stuck caliper, a blockage in the brake line to one of the front calipers, or sometimes loose wheel bearings. A brake pull can also be caused by different types/brands of brake pads side-to-side on the front brakes. Different friction materials have different friction characteristics, so the brakes will pull toward the side that generates the most friction.
Thanks for pointing that out I'd be more cautious now.
I intended to use this agricultural pump for bleeding brake line, but it was leaking air so left this idea.In past when I bleed my bike I had problem air going back in system and removing it.
This one way valve idea is super duper cheap and ensures no air flow back in system, I am yet to use this. Since brake fluid is thinner it passed through tube valve easily while testing. I am not sure if truck tube valve is more usable, as I have none
Hope this helps someone.
OK I am fed up of not getting simple items like spanner. I never changed engine oil myself, so when I decided do so, I could not find spanner in shops for oil filter opening (bowl type)! Very frustrating.So decided to make one on my CNC.It is combination of pvc bush, mdf and spanner rod (what's its actual name?)It is a perfect fit and removing filter also does not require high torque for opening oil filter- Now it is becoming Hard core DIY
DIY Santro bowl type spannerA perfect fit
Good Going...!
Engine Must Be Breathing Much BetterAfter All The Cleaning
Always Use Good Carb Cleaner For Injector Cleaning And If Clean Using Open/Close Way....Use 6v Supply Instead Of 12v...!
For Brake Bleeder....Simply Pour Some Brake Oil In Bottle And Put The End Of Tube In That Oil.....
This Ensure No Air Suck And Its Way Easy........Check Valves Are No Use Here
@ser_gtr ThanksLike I described my problems above, engine pickup increase was immediately noticed, sluggishness while shifting gears in petrol, gone.Shops owner here does not know what carb cleaner is (quizzical look). 12V can fry you injector( it becomes hot), it operates at 6v so why 12v?When you loosen and tighten bleeder valve while pumping paddle there is always chance of getting air in. Brake bleeder bottle with attached tubes is left over of my HHO project so used here, I also had problems with trapped air in my bike, so this is extra exercise which ensures no back fire.
if you still have pulling while braking, service the brake caliper sliders with fresh silicone grease and replace the rubber pipes too - they swell internally and block flow of fluid - it can sometimes act like a one way valve too.
I think reply is directed to Horse_rider, he has this problem, I've yet to bleed.Thanks for info.
Nice work bro