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

[Deadly_Flame]

Hi guys,

I've read about the temperature gauge being up to the middle is fine, i recently overhauled my engine and before the temp gauge was similar to what daniyal posted but now normally its way up not even in the middle like others. I told the mechanic and he gave me the same reason your mechanics gave you for it being close to the half point mark.

Also another question i am not happy with the performance of the car before overhauling i was able to go upto 140 kph on cng but now its like impossible to go beyond 110 kph, again i enquired my mechanic he said "thora kharcha kerna paray ga uss k liyae" i already paid 48k for the overhaul also it was not complete engine it was just the upperbody i don't know what its called but its the one with pistons neechla portion engine ka theek tha so pura engine was not needed.

So my problem is i want to get my engine checked, if its good or not? Since i am not satisfied with the performance after spending so much money so before i go ahead and do "thora or kharcha" i want to be sure k engine is ok?

Also recommend anyplace i can get it checked (in pindi or isb) i want a good and honest opinion on the overhaul.

P.S: Sorry about the double post don't know how to delete one.

[speedster_101]

Japanese pair (Brand: NKN) : 4000/- to 4500/-
Chinese pair : 1700/-

I am using chinese ones they have survived 2 years (Price then was 1200/pair) and now they started to give tak tak when i give them a full turn with above normal speed.

Is it the price of the whole axles or just the outer ends?

[cracked]

@Deadly_Flame
how many kms you car has traveled after overhaul/
engine takes some time to SETTLE IN and then would be responsive more... it takes good 5000 to 10000 kms for engine,atleast that was the case with mine khyber's engine after overhaul..and now its running strong after 60k kms run!
how did you complete its running?

[speedster_101]

@Deadly_Flame
You paid 48,000 Rs for half engine overhaul?
The mechanic looted you badly.

[smijaz]

Is it the price of the whole axles or just the outer ends?

Just a pair of outer CV joints with boots and couple of axle grease tubes.

[smijaz]

@deadly_flame

Never ask a shopkeeper to give you the best he got , he will stick you the worst with price tag of more than the best coz he knows if the person is asking for the best then only way he is going to be satisfied would be by paying an insane amount.

Similarly never ask a mechanic to make your car go fast, this exactly what he wants to hear to rip you off. According to you, you already paid 48K for partial overhaul you must be exhausted but he is still hungry for your money.

Share the list of repairs done so far and what more he wants to perform.

AND your car is definitely overheating, no matter how you interpret the gauge, so take care of it immediately.

[Xulfiqar]

what did the overhaul consist of?

[Deadly_Flame]

@cracked

I cannot say really as my speedometer's kilometer gague has not been working properly since the overhaul. Well the mechanic said no running was required you can drive the vehicle whatever way you want, i was confused i asked him how is it possible and he said running wala daur purana tha.
I think its travelled less than 5000 km since the overhaul.

@speedster_101
I paid about 32k for the engine, well the half part i think its called upperbody or something, well the part with the piston chamber. There were other stuff as well for instance original generator etc. i can't really remember everything so the total cost with the extra stuff was 32k.

@smijaz & Xulfiqar
Well my piston chamber got damaged. According to the mechanic when the piston broke it also damaged the oil pipes within the chamber, so although it could be repaired we won't be sure if it'll work properly or not until we get it back in the car. He said it would be risky kharadia would charge you alot and we still won't know if it'll work or not so better option is to go for a new engine. So the upper part of the engine the head part only that was changed.

Engine cost = 32k
Labour and other small parts: 16k

Though the engine bay was very badly damaged so it needed some denting.

So take out 4k from that 16k, In the end total cost on the engine was 44k.

[cracked]

you should have gone for a swap..cultus engine would have been good for the amount you paid!

[Deadly_Flame]

Now i wish i had, well i am hoping with proper tuning and a little money i can get the engine to work efficiently like a good g10, the focus now is to get the paint job done and the denting. After than i'll go for an engine swap.

So anyplace where i can get a good opinion on the current state of engine and good estimate of what needs to be done with the current engine to improve its performance?

[daniyalahmad]

thinking of adding a strut bar on top of front suspension, previously we use to repair chasis every 6 to 8 months.
can anyone quote me the price and its availability.
i also need the accurate dimensions of the distance between the front suspension where strut bar will be added.

Strut bar should be a nice addition.
Dont know about its availibility in Karachi but Im sure a new one according to the measurements can be fabricated.

Yes you are right. The front seats are not so comfortable. I was also thinking of placing some other car's seats. Do you have any idea which car seats can be fitted in Khyber?

Nopes,
No idea reagrding the seats.
Infact if you change the seats of your car then do let us know.

The axles of my Suzuki Khyber are also giving problems. I hear a tuk tuk voice on turnings. The Kabli parts of Suzuki Khyber are very expensive nowadays due to the fact that the production of this car was stopped decades ago, hence the parts are scarce now. Should I go for brand new Chinese ones? Any idea about the cost?

Get new ones.
No guarantee of used parts.
And in case of axels new ones with proper grease is a better choice.

[daniyalahmad]

Now i wish i had, well i am hoping with proper tuning and a little money i can get the engine to work efficiently like a good g10, the focus now is to get the paint job done and the denting. After than i'll go for an engine swap.

So anyplace where i can get a good opinion on the current state of engine and good estimate of what needs to be done with the current engine to improve its performance?

IMO you have already paid alot to your mechanic.
Let the engine complete some miles and then see if there is any improvement.
Get it tuned by Enercon Islamabad.

[Deadly_Flame]

Yeah thats what i think as well.

Where exactly is Enercon? And how heavy should my wallet be for the tune up?

[daniyalahmad]

^ Im not sure about what sector it is.
You must have seen the PSO filling station near the Melody Food Park?
It is situated in that petrol station.
I got my car tuned last month and he charged Rs. 300 for the tuning. (Previously the rate was Rs. 250)
Contact him before going to his shop.
Zahid Mirza: 03335454373

[Potoharian]

1: Thermo switch for radiator: I think the thermo switch is working ok, as they rarely fall bad. But you can check it by running the engine with radiator cap removed. Use normal mercury thermometer or electronic one and put it (incase of electronic one its probe) in the mouth of the radiator. Note the reading when the fan kicks in. It should be around 90C to 95C.

2: E load idle up: There is an electric solenoid valve (2 ports connection) near the upper engine mount alongside timing belt cover. One port is connected to vacuum hub on the intake manifold and the other is connected to a diaphram on the upper right corner of the carb (near brake booster). When ever any of the following are turned on
1. head lights
2. parking lights
3. rear defogger
4. a/c , heater blower
5. radiator fan
The solenoid allows the vacuum to pass and to actuate the diaphram on carburetor which in turn slightly increases (stabilizes) the engine speed (rpm) to compensate for the electrical load on alternator.

3. PCV: I dont think the PCV unit in khyber is repairable. You can spray in carburetor cleaner while the engine is running (with rubber pipes removed along with air cleaner container). You should feel vacuum when you place finger on it while engine running. You may also hear a minor metallic click when you place and remove finger from over it. Other wise replace it. estimated cost of used unit is around 150 and if by chance you find a new OEM one it will be around 800.

4: Ground: Use good quality 60A load capacity copper wire. No specific brand i know of.

5. Ignition Timing: Ignition is set with the help of timing gun. 10-12 BTDC for petrol and 18-20BTDC for CNG. Timing gun is available starting from rs. 1400 in Lahore.

6: Thermostat valve: Is a mechanical valve with a mechanism which allows it to open when the coolant temp reaches a certain limit and makes way for the coolant to pass through the radiator. In closed position it forces the coolant to bypass radiator. It helps in regulating engine temperature with in optimal range and also provide essential resistance in flow which causes a pressure effect making the coolant to properly collect heat from around the combustion camber.

I will explain the installation process in detail later.

Thanks bro for this wonderful explanation. I need some confirmations from you as well. In the below picture can you please let me know which exactly is the PCV valve ? The one I refer to ??? If this is true, why there is oil leakage from it ?

Can you please also let me know what is this closed thing called ?

below is a bit clear picture...

here is the clear picture of the closed thing just below the air Assembly ? whats its purpose? How to bring back this to its original shape, what to tell to the mechanic ??

Need comments from senior members please..

[Deadly_Flame]

Thnx Daniyal. Will surely go there. Hope this all works out.

[smijaz]

@Potoharian

You have identified PCV correctly, the oil you see might be coz of excessive blow from the crankcase through the tappet cover breather pipe or you have over filled the engine with oil. Just confirm its working as described earlier.

The other thing you marked which was closed is intake manifold port and used to operate two idle up diaphragms on the carb through electrical solenoid valves , one is for Air Conditioner and other is for electrical load.

I could see the electrical load idle up solenoid in the third pic, the one with two pipes attached but i wonder how and where they are connected coz the lower one should be connected to one of the ports on the intake manifold.

Will upload the vacuum pipe connections tomorrow, I.A.

[cracked]

yeah ijaz bhai,do post picture of all vacuum lines plz

[Potoharian]

@Potoharian

You have identified PCV correctly, the oil you see might be coz of excessive blow from the crankcase through the tappet cover breather pipe or you have over filled the engine with oil. Just confirm its working as described earlier.

The other thing you marked which was closed is intake manifold port and used to operate two idle up diaphragms on the carb through electrical solenoid valves , one is for Air Conditioner and other is for electrical load.

I could see the electrical load idle up solenoid in the third pic, the one with two pipes attached but i wonder how and where they are connected coz the lower one should be connected to one of the ports on the intake manifold.

Will upload the vacuum pipe connections tomorrow, I.A.

Ijaz bhai, Thanks..
I would check my PCV valve and may replace as told by you in the earlier post.
Kindly note that normally my engine oil is touching the second mark on the oil level checking strip, infact just below the max level mark and never above. Let me replace the PCV valve and may be this issue of excessive blow get resolve, my mechanic told me that my engine is weak that's why giving so much blow.
I really dont know what to do with the intake manifold being closed. Although I have no problem at the moment but want to straighten up things in my car.

[Xulfiqar]

any cars PCV will have some oil seepage becuase of oil vapour leaking past the pipe ends specially in old engines. Why dont you remove and clean the PCV. Now for the little red vacuum manifold, as smijaz said its two pipes go to vacuum solenoids that control idle up on the carburettor. One solenoid is visible - thats the electric load solenoid, the other should be on the bulkhead firewall - thats for the A/C. where are the vacuum lines for it coming from?