Suzuki/Mehran/Maruti 800 ENGINE OVERHAUL

[Shergill]

My friend Jimmy came tome to dispose his 1999 Model Maruti 800 as he has extensively used this car and its odometer showing 1,56,000 kms.

The car body line is in mint condition and I found that all what the car demanded was an engine overhaul as there was back pressure from the tappet cover pipe. Also in the mornings the car emitted white smoke ( signs of engine oil residue on the pistons ).

As he was planning another Maruti 800 again, It occured to me that why he is going to spend Rs. 1,78,000/- on a new car ( Cost - 1.94 lacs - discounts of Rs. 16,000/- ). This car could fetch him around Rs. 65000/- to 80,000/-.

Then we decided to go for an engine overhaul and Jimmy made his mind to shell out Rs. 5 to 8 thousands bill on the engine overhaul.

However, when we got the engine opened we found that everything was all right except for some Engine Head job and replacing the piston rings only. Jimmy ended up spending only Rs.2900/- for the whole job

We closly photographed the whole process from Jimmy's Nokia 6681 cellphone.

Let us have gilmipse of the engine in opened condition, while cleaning, spare parts, re assembling etc.

[Shergill]

The car was taken to Manimajra Motor Market in Chandigarh, where a small time workshop being by one Ustaad Amar handled the job for us. He has been repairing Petrol cars, Jeeps ( especially the non MPFI ones ) and diesel jeeps/cars for the last 30 years and is considered one of the coolest mechanic. He has no lust for money and one of the rarest person I have found enjoying his job. His charges are very reasonable and seldom one could find any anomly in his job.

Ustaad Amar as we know him got the engine opened and ordered his Teenaged force to dismentle the motor immiediately. They cleaned all the parts with diesel, Thinner, and even got some parts sand blasted.

This was the first time the car engine was getting an overhaul. Earlier Jimmy got an extended spark plug socket on the Head as some engine oil was coming out from one of the plug sockets. It worked for around 20,000 kms. It is only the idling speed vibrations that made him fed up with the car.

[Shergill]

Everything, like the Head valves, Pistons, crank bearings, connectiing rods, engine oil pump and even the timing belt etc were in very good condition.

Clutch plate ( which was got changed at around 90000 kms ) and the original pressure plate were also in excellent condition

[Shergill]

[Shergill]

[Shergill]

We just needed

1) Piston ring set
2) packing kit
3) Timing seal and other rubber seals.
4) Head valve seal kit.
5) Engine oil
6) Gear oil,
7) Coolant
8) Carburetter venturi kit & float needle.
9) Spark plug set
10) Engine oil filter

[Shergill]

Ustaad Amar pushing the pistons into the Engine block and the boy tightened the connecting rods to the crank.

After fixing all the connecting rods it is now Ustaad Amar's turn to remember his Ustaad/Guru as he is seen remembering him after the main job.

[Shergill]

Now the focus turned towards the engine Head, It was sent to another workshop where the valves were grinded and some finishing was also given to the valve seats.

Check the spark plug extension attached to one of the plugs. They say it checks the oil leakages from the engine Head.

[Shergill]

We missed the final moments of engine assembling as Jimmy insisted to go uphills towards the Shivalik hills. So we left the workshop at around 3 p.m and were back by 8 p.m only. By that time they had already mounted the engine in the engine bay.

I will post another topic covering our small trip towards the Simla Hills ( Shivalik hills ) which are just 25 kms from Chandigarh.

[charterali]

Zabardast, excellent job done. Its quite gudd in ur part as ya convinced ur frnd to go for the overhaul resulting in the saving of money. Mehran is too much economical and reliable car.

I kept my Mehran for more then a yr, which i used to drive till the point petrol got finished in ma car, used by frnds nd us. I had ma engine overhauled for 3 times as I used to drive quite rough.

Btw, its better to change the pressure plate aswell.

Happy driving Maruti/Mehran.

Thnxx..

[sasifh]

So in the end it was a cheap solution for your friend. I must say that the car engine is very clean.

[911]

good coverage (y)

[nightsurfer]

@Shergill

Thanks for another valuable post my friend, excellent coverage, good job (Y)

[Vaqas1]

Hmmz u sure these pics are not taken in Pakistan other then names everything looks so similar

Good Job..

[AbidSiddiqui]

Reply By : Shergill on 9/30/2006 6:41:17 PM

However, when we got the engine opened we found that everything was all right except for some Engine Head job and replacing the piston rings only. Jimmy ended up spending only Rs.2900/- for the whole job

Rs.2900 for whole job

If You were in Pakistan u have to pay Rs.2000/- for overhauling to labor (even if u wanted to replace piston ring only) and 4000-5000 for rest of the engine parts.

[spectra]

Great job with photography paa jee
Well done and congrats on the overhaul. My mechanic demands mithai from customers whenever an engine is overhauled or swapped and started for the first time Whats the norm in India?

@Abid bhai a ring replacement with valve job and kharad work for mehran costs Rs. 4000 including good quality parts.
u must be talking about your charade

[Shergill]

Thanks for the encouragement from all my friends there.

@ abidsiddiquee

Indeed, spare parts are very cheap here ( Rs.550/- including VAT for the Original Piston rings USHA maKe and Rs. 350/- for general purpose Delhi made rings bearing various names like RIK, RIKON, REKEN ( duplicates of RIKEN of Japan )

@ Spectra

Yes here also we need to bring a Mithai kaa Dibba and the Mistri Sahib would offer one piece of Burfi or Ladoo to the Engine tappet cover for a good running life. Rest of the Dibba is distributed among the Teenaged Force of the workshop and people sitting close. We brought burfi for the occasion.

To all

While the engine was getting overhauled, we went to Simla Hills on my Motor Bike ( Just a road trip for 30-40 kms ) and photographed the road, the traffic, the people and adjoining places. I am posting a separate topic for the same under

" TOWARDS SIMLA HILLS ON A BULLET "

"

[imranbhatti]

@shergill

Nice job done.
BTW car engine & hood was realy clean.

[Shergill]

@ Imranbhatti

Thanx brother.

Almost all the cars in Chandigarh boast of such neat and clean engine bays.

Actually, most of the Service stations here charge Rs. 20/- to 40/- extra for spraying a mixture of Petrol+ Thinner+ brake oil + Diesel+ coolant over the engine bay so that this alchemy reaches out everywhere ( where usually your hand cannot reach ). Then they leave it for 10-20 minutes before applying a solution of strong detergent with a brush and used nylon socks.

After the water pressure cleaning the engine bay looks as clean as one finds on opening a mechnical watch.

Thereafter, they apply dashboard sprays over all the rubber and PVC made parts. Some use Keo-karpin hair oil for this purpose.

A few service stations here gurrantee full money return if you can point out any grease, dirt in the enginebay after such a wash.

So. It is a common sight among all the Chandigarh cars and this is also one of the reasons why Chandigarh cars commands 20% extra resale value over the cars of other regions from Punjab and Haryana.

[humy]

nice stuff man, great going, 11/10