Self Tunning - Khyber G-10 (Plugs, valve clearance, spark gap etc)

[Xulfiqar]

@xulfiqar

I managed to overhaul the distributor of my khyber according to your instructions expecially for the centrifugal advance mechanism.

I was amazed by its effect on vehicles response and acceleration. Thanks for this wonderful tip.

you are most welcome.. This is the first thing I check on all carby cars that have acceleration problems..

This also amazed the Mazda 626 2.0 owner when I tuned his car the same way. It had a 2.0 4 cyl 8 valve engine with a dual throat carby. The centrifugal and vacuum advance were locked solid and his carb was messed up that only one throat operated, valve clearances all over the place, valve seals leaking. After the tuneup/parts O/H and valve seal change, This same car was accelerating like a wildcat ..120 km/h in 2nd gear @ 6800 rpm.

I went against a civic 1.6 vtec and the poor little civic could not keep up with the brutal torque the Mazda FE engine was shoving out.. Not even in first gear could it keep up.

guess what - the owner was told by certain very famous workshops and mechanics that the engine is packed up and needs a rebuild - This same person who owned the car became a very good freind of mine from that day

[Xulfiqar]

My spectacles saves my eyes from dust or other materials.Only backache is the problem after such Job.

If you see me in person, you'll be amazed Im not dead yet..

[Xplorer]

How to clean the fuel tank?
Can it be easily removed and washed with kerosene oil / petrol?

What are these two relays for?

[fas133]

@Xplorer
One relay for AC Compressor and other is for the AC condenser fan.
You can remove the fuel tank easily and for cleaning some people use diesel some water with detergents etc depending on the internal conditions.

@Speedster_101
Thanks for confirming the problem.Please share the expenses as well.

@Smijaz
I took out the diaphragm from the distributor housing and then attached to all the ports of the carb. one by one.At all the other ports (except the port mentioned in the pictures below) the diaphragm arm sucked in at low rpm and comes out at high.
While as far as i know it should happen in reverse because when diaphragm arm is sucked in, it rotates the internal plate in clockwise direction which advances the spark because the distributor rotor is rotating at anticlockwise.So as far as my knowledge it is the correct port for the diaphragm.

Hope Mr.Xulfiqar would correct me if i am wrong.

[speedster_101]

@Speedster_101
Thanks for confirming the problem.Please share the expenses as well.
The cost of the seal was 170 Rs and the shleg costed me 50 Rs. (Its a sticking paste, I don't know the exact name). The labor cost was 1000 Rs. (Gear lever shift was also changed)
The mechanic said that it is a genuine seal, now I don't know whether it is genuine or not.

[smijaz]

How to clean the fuel tank?
Can it be easily removed and washed with kerosene oil / petrol?

What are these two relays for?

Cleaning can be done with soap water and then kerosene with hand through the opening where fuel level sensor is installed.

Are you planning to remove and service the fuel tank for yourself?

The relays are correctly identified by fas133, one is for a/c compressor clutch and other is for condenser fan.

[smijaz]

@Smijaz
I took out the diaphragm from the distributor housing and then attached to all the ports of the carb. one by one.At all the other ports (except the port mentioned in the pictures below) the diaphragm arm sucked in at low rpm and comes out at high.
While as far as i know it should happen in reverse because when diaphragm arm is sucked in, it rotates the internal plate in clockwise direction which advances the spark because the distributor rotor is rotating at anticlockwise.So as far as my knowledge it is the correct port for the diaphragm.

Hope Mr.Xulfiqar would correct me if i am wrong.

Thanks for your help. You are absolutely right about the working and concept of the vacuum advancer. My ride's connections/working are same as shown in the pic shared by you.
I believe you are right But if you are wrong then you are not alone

[smijaz]

@fas133
one more thing. Its quite unusual for the rear crank seal to leak.
Check out for the following possible but unlikely causes
Any rattling from the engine block side at high rpm?
Are you overfilling engine oil > 3.6L?
how is the condition of ring seal, any signs of excessive blow by?
Is PCV not functioning?

[fas133]

@fas133
one more thing. Its quite unusual for the rear crank seal to leak.
Check out for the following possible but unlikely causes
Any rattling from the engine block side at high rpm?
Are you overfilling engine oil > 3.6L?
how is the condition of ring seal, any signs of excessive blow by?
Is PCV not functioning?

PCV is ok and i have always bought 3L oil can so engine oil cannot be in excess.
Blow by is normal.I just have the vibration issue from left front tire which u have diagnosed to be the inboard CV joint problem.

[smijaz]

PCV is ok and i have always bought 3L oil can so engine oil cannot be in excess.
Blow by is normal.I just have the vibration issue from left front tire which u have diagnosed to be the inboard CV joint problem.

Ok, isnt 3L a bit too less?

I wanted to know is there any rattling sound from the engine block side at high rpm while the car is not moving to rule out excessive main bearing clearance.

If all is well then its just an old worn out seal.

[fas133]

Ok, isnt 3L a bit too less?

I wanted to know is there any rattling sound from the engine block side at high rpm while the car is not moving to rule out excessive main bearing clearance.

If all is well then its just an old worn out seal.

After pouring 3L the dipstick shows oil level between the two marks.I have heard that excess oil is more dangerous than low oil so i remain on the safe side.
No rattling sound at high RPM.

[cracked]

cmy car gives black smoke on petrol n is not stable on petrol,i mean wen i press acclerator,it slowly responces n wen i lift leave paddle,it goes off...do i need carb cleanin/
?
ive tried the carb cleaner spray,worked for cng but no good on petrol!
can tappets adjustemnt b the cause of petrol problem?
tappets make sound on hi rpm so i think they need adjustment n this time ima do it myself,just cudnt find the time!

[cracked]

plus about oil level in khyber..
there r 2 holes on dip stick...full level is wat?
wen the upper hole is filled or wat?

[smijaz]

cmy car gives black smoke on petrol n is not stable on petrol,i mean wen i press acclerator,it slowly responces n wen i lift leave paddle,it goes off...do i need carb cleanin/
?
ive tried the carb cleaner spray,worked for cng but no good on petrol!
can tappets adjustemnt b the cause of petrol problem?
tappets make sound on hi rpm so i think they need adjustment n this time ima do it myself,just cudnt find the time!

Black smoke means engine running on rich fuel mixture ( zayada petrol aa raha hay)
its an issue related to carb mxiture screw, butterfly, slow jet etc. Carb cleaner will not work deep you need a carb service.

Tappets are not involved in this issue.

[cracked]

ok..ill get carb serviced tomorw ...mechanic told me its runnin rich he adjusted the svrew but not of much help...
butterfly is ok as ive changed it recently lyk some months..
chalo open ho ga tou pta chal jaey ga!!!

[cracked]

black smoke cud be due to faulty petrol cleaner?
filter i mean?
maybe its not cleaning the fuel properly?
wat r the symptoms of dirty fuel tank???

[smijaz]

plus about oil level in khyber..
there r 2 holes on dip stick...full level is wat?
wen the upper hole is filled or wat?

According to the workshop manual the total oil capacity including oil pan, oil filter and others is as shown below

Oil pan capacity: 3.1L
Oil filter capacity: 0.2L
Others: 0.3L
Total: 3.6L

Use 3.3L (new oil) on oil change with oil filter coz 0.3L of old oil stays in the engine even after draining.

The top mark is the max (FULL) mark and the lower one is the minimum mark. After oil change the reading should be touching the full mark, not above it.

[smijaz]

black smoke cud be due to faulty petrol cleaner?
filter i mean?
maybe its not cleaning the fuel properly?
wat r the symptoms of dirty fuel tank???

No I dont think so, dirty filter is usually choked and does not allow fuel to flow thru.

Dirty fuel will cause missing / misfiring, plugs will short out, the carb jets and fuel passages will get blocked.

Dirty fuel tank will choke the new fuel filter with rust in few days time.

[Xulfiqar]

I would need to see the workshop manual for the vacuum diagram. I dont recall it over my head. But this type of setup (full vacuum advance at closed throttle) is also acceptable - comes in most engines - what it does it advances the signal plate to max when you change gear, mostly because you also have a dashpot on the carb. Your first repressing of the accelerator would give the engine a nice jumpy and free revving feeling, saving on fuel and enabling to drive smoother at low rpm. It also enables the engine to start easily because its not at full advance and once it gets to idle speed full advance kicks in.

While driving your manifold is the best source to mechanically tell what kind of loads are you placing on the engine, and the distributor advances appropriately to help the centrifugal advance while driving to help the engine accelerate quickly.

[speedster_101]

How to check PCV valve?