Go Back   Team-BHP > Under the Hood > Modifications & Accessories


Reply
 
Thread Tools Search this Thread
Old 7th November 2008, 15:53   #16
Team-BHP Support
 
bblost's Avatar
 
Join Date: Jul 2007
Location: Hyderabad
Posts: 9,650
Thanked: 6,661 Times
Default

A 5 STAR thread.
Simply amazing.
bblost is offline   Reply With Quote
Old 7th November 2008, 19:26   #17
BHPian
 
Join Date: Nov 2008
Location: New Delhi
Posts: 150
Thanked: 10 Times
Default

Thats just so awesome SirAlec, and doing it yourself! Talk about work satisfaction, this is the number one way to get it . Thanks a lot for sharing these pictures, now i know what the insides of my m800's engine looks like.
eternalck is offline   Reply With Quote
Old 7th November 2008, 19:40   #18
Team-BHP Support
 
Jaggu's Avatar
 
Join Date: May 2004
Location: Bangalore
Posts: 17,743
Thanked: 7,449 Times
Default

Very interesting thread and great job at rejuvenating the engine. Do re torque all the head bolts and reset the tappets after couple of 100 kms.
Jaggu is online now   Reply With Quote
Old 7th November 2008, 19:48   #19
BHPian
 
Join Date: Apr 2008
Location: Bangalore
Posts: 366
Thanked: Once
Default

nice thread! very informative.

a few questions:
1) so are there oversized pistons for the 800? i'm guessing not.
2) basically the lower half was honed - is that right? what's the max that this can be used? i mean doesn't there come a time when this has to be changed as well? i've heard that the limit for the lower half for most cars these days is around 2.4lakh km.

sorry if these questions sound noobish :o
silver_shadow is offline   Reply With Quote
Old 7th November 2008, 20:55   #20
Senior - BHPian
 
Join Date: Sep 2006
Location: zxc
Posts: 3,394
Thanked: 658 Times
Default

Quote:
Originally Posted by Jaggu View Post
Very interesting thread and great job at rejuvenating the engine. Do re torque all the head bolts and reset the tappets after couple of 100 kms.
already done that Covered 280kms. will change oil and coolant at 1000.
thanks for the tip.

Quote:
Originally Posted by silver_shadow View Post
nice thread! very informative.

a few questions:
1) so are there oversized pistons for the 800? i'm guessing not.
2) basically the lower half was honed - is that right? what's the max that this can be used? i mean doesn't there come a time when this has to be changed as well? i've heard that the limit for the lower half for most cars these days is around 2.4lakh km.

sorry if these questions sound noobish :o
1. I guess so. following is the original suzuki data for F8B. I guess it matches that of zen. But i would rather not change the stroke ratio. That will lead to more extra work on tuning. I am very bad with numbers.

2. Yep it was reworked. But if the condition of block is too bad to be rebored, get a half assemlly. its just 9.5k. with crank, connecting rod, pistons, pins. Only head job is left then. Block will last way beyond 2.4lac kms if treated well.

Data Sheet
2lac+ kilometers m800 engine rebuild project.-piston.jpg

Last edited by SirAlec : 7th November 2008 at 20:57.
SirAlec is offline   Reply With Quote
Old 7th November 2008, 21:17   #21
BHPian
 
MalluDude's Avatar
 
Join Date: Aug 2005
Location: Cochin
Posts: 382
Thanked: 28 Times
Default

WOW..great reading, SirAlec.

I suppose you followed a running-in procedure after the work, as with a new car?

Last edited by MalluDude : 7th November 2008 at 21:19.
MalluDude is offline   Reply With Quote
Old 7th November 2008, 22:42   #22
BHPian
 
Join Date: Apr 2008
Location: Bangalore
Posts: 366
Thanked: Once
Default

did i miss it but i can't see the pistons/con rods in your bill? how much did that cost?
silver_shadow is offline   Reply With Quote
Old 8th November 2008, 02:51   #23
Senior - BHPian
 
Join Date: Sep 2006
Location: zxc
Posts: 3,394
Thanked: 658 Times
Default

Quote:
Originally Posted by silver_shadow View Post
did i miss it but i can't see the pistons/con rods in your bill? how much did that cost?
i forgot to upload one more bill. Pistons, rings, bearings, locks, crank bearings totalled rs.1250. con rod were fine.
SirAlec is offline   Reply With Quote
Old 8th November 2008, 02:59   #24
Distinguished - BHPian
 
Mpower's Avatar
 
Join Date: Mar 2005
Location: Bangalore
Posts: 10,432
Thanked: 1,682 Times
Default

Did you do a compression test before or you could feel the power drop off?

Fantastic job.
How was the engine lifted out of the hood.
Did you use 1st oversize piston?
Did you hone the bore for the new rings?
Mpower is offline   Reply With Quote
Old 8th November 2008, 03:14   #25
Senior - BHPian
 
Join Date: Sep 2006
Location: zxc
Posts: 3,394
Thanked: 658 Times
Default

i didn't, i felt it opening it up after 2lac kms.

i don't have a pulley. So disassembled it inside. here is the sequence.
battery> air chamber> radiator and hoses> tappet cover>head >drive shaft>starter> gearbox>an finally the block.

no i used standard piston.

i did the block job. it was not necessary but did it anyway, same goes for various parts that i changed.
SirAlec is offline   Reply With Quote
Old 8th November 2008, 15:10   #26
Senior - BHPian
 
deepclutch's Avatar
 
Join Date: Oct 2008
Location: Muvattupuzha
Posts: 1,120
Thanked: 109 Times
Default

Quote:
Originally Posted by SirAlec
i did the block job. it was not necessary but did it anyway, same goes for various parts that i changed.
you mean reboring?or a new block? If rebored,horned etc ,Did you use a Lathe for exact measurement for the first oversize?are all the 3 cylinders worn out evenly?and in which part does the engine number is etched?suppose if we get a brand new barrel -block set ,where we wanted to etch the old engine number ?(RTO lafda otherwise?)
Sorry ,if this a newbish questions!
and yes ,this thread deserves 5 star!
deepclutch is offline   Reply With Quote
Old 8th November 2008, 20:44   #27
BHPian
 
km120's Avatar
 
Join Date: Nov 2007
Location: Bangalore
Posts: 30
Thanked: 0 Times
Default

Excellent Sir Alec ! Lot of patience, and good work. Good Job. By the way can You kindly post the M800 service manual. Thank you in advance.
km120 is offline   Reply With Quote
Old 8th November 2008, 22:41   #28
Senior - BHPian
 
Join Date: Sep 2006
Location: zxc
Posts: 3,394
Thanked: 658 Times
Default

Quote:
Originally Posted by km120 View Post
Excellent Sir Alec ! Lot of patience, and good work. Good Job. By the way can You kindly post the M800 service manual. Thank you in advance.
actually its not a maruti manual in particular. Its a suzuki hatch manual. If you follow book to book you will be in a fix.

Its already posted in manual section somewhere else. please use the search function.

@ deepclutch.
Please go through the thread thoroughly. I rebored the block. bore size is 68.505 to 68.520mm (+or- 0.05oversize.mm). You can make out its for a standard piston. not oversize.

Engine number is etched at the backside below the carb. where Big F8B is written. The skit plate can be removed and etched in new block if you go for half engine assembly.

Last edited by SirAlec : 8th November 2008 at 22:53.
SirAlec is offline   Reply With Quote
Old 8th November 2008, 22:53   #29
Distinguished - BHPian
 
Mpower's Avatar
 
Join Date: Mar 2005
Location: Bangalore
Posts: 10,432
Thanked: 1,682 Times
Default

Do you regularly work on your car or do you have any kind of formal training. This is a job that is a challenge for even a regular mechanic.

Any concerns with dust getting into the engine. Usually engine build areas in car plants are clean like hospitals.
Mpower is offline   Reply With Quote
Old 8th November 2008, 23:13   #30
Senior - BHPian
 
Join Date: Sep 2006
Location: zxc
Posts: 3,394
Thanked: 658 Times
Default

no formal training, not even related to automobile, I am a computer guy! i have been fiddling cars for nearly a decade now. family tradition. have you checked fully restored 72 land rover. Check the garage section. unfortunatly i lost lot of images when i dropped my iomega long back. i had some really precious images of other work on frens cars etc. when i was single, when we had lot of spare time. . For landrover we take help from a vetern land rover specialist call Karma kaka. Our family fren and mechanic. He had a permanent job at our old factory when we had fleet of ex army Mercedes/tata 312 4x4s.

I like to work under the sun, not that sun you people use to have in delhi or so, Abu is a hillstation remember. Dust is a problem, but care is what we can do, its cheaper than to invest in an environmentally controlled work area. Its just a hobby yaar.
Biggest problem is painting in that condition, engine rebuild is no problem at all.

Last edited by SirAlec : 8th November 2008 at 23:22.
SirAlec is offline   Reply With Quote
Reply


Thread Tools Search this Thread
Search this Thread:

Advanced Search


Similar Threads
Thread Thread Starter Forum Replies Last Post
My Gypsy Rebuild Project krishnathanthri 4x4 Vehicles 326 26th June 2014 23:59
Project M800 with F10A swap noidaboy Modifications & Accessories 115 11th March 2013 12:25
Creaking noise in Cedia : 15K kilometers on the odo ranjithc Long-Term Ownership Reviews 1 25th November 2008 10:21
1000 kilometers, 781cc, 12 hours, 1 rider. The beginning of something special. Rtech Travelogues 124 30th October 2008 18:42
m800 vs ikon (what comp can a M800 be?) manaa45 Street Experiences 13 31st March 2005 12:06


All times are GMT +5.5. The time now is 23:00.

Copyright ©2000 - 2017, Team-BHP.com
Proudly powered by E2E Networks