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Originally Posted by Scarlet_Rider Please do post some pictures of the interiors, engine bay and dicky. Wishing you many happy (s)miles in the car! |
Dear Rahul and all - I get only one day in a week to work on my car, that is Sunday. So yesterday, I finished the following jobs on the car, working continuously between 9.30 AM to 7.30PM. I have not taken pictures, will take and upload shortly.
1. Electronic fuel pump moved from inside the engine compartment to inside the spare wheel well, same as in all my other cars. Flexible fuel lines in the engine compartment were routed completely haphazardly, they were actually touching the spark plug wires which carry 25000 volts, all removed and thrown out. Reverted to production layout with additional collar made and fitted on the fuel filter mounting to cylinder head to route the fuel delivery line to the carburettor.
2. Engine oil leaking from filter cartridge body top seal, engine oil found aged, oil and filter cartridge assembly replaced.
3. Oil bath air cleaner assembly was dirty and clogged, cleaned and refitted. Piece of cloth was used in place of rubber insulator, replaced with a new insulator.
4. Maruti Omni fuel filter added before the electronic fuel pump inside the spare wheel well, same as in all my other cars.
5. Wiring harness laid out from front to back to actuate the electronic fuel pump in its new location.
6. Petrol tank loosened and retightened, to be able to replace all the flexible fuel lines, tank to filter, filter to pump, pump to main line.
7. Checked engine valve clearances. All eight were completely tight, reset to production specification.
8. Intake manifold breather pipe completely choked, replaced with a new part. Engine breathing much better.
8. Engine valve cover packing was torn, replaced.
9. Engine breather flexible pipes were aged and torn, replaced.
10. Mechanical fuel pump was loose and its packing was torn, engine oil was leaking out at this location, replaced packing and tightened.
11. Fan belt was bottoming its pulley, replaced. S1 alternator bracket still to be fitted.
12. Spark intensity observed extremely poor, checked ignition coil output voltage, it was not even 25% of requirement, oid ignition coil was malfunctioning, new ignition coil fitted.
13. Centrifugal advance mechanism of the distributor was not working to specification, replaced distributor assembly complete with contact breaker, condenser, rotor and insulator assembly. Distributor was not fitted in correct shaft orientation, spark plug wires position was off by 90 degrees which was completely haphazard, removed the base and reoriented the assembly as per production.
14. Distributor cap was cracked, replaced. Push type terminals were used inside screw-on cap, it was a complete nonsense, removed and replaced.
15. High tension wires were not original, they were with carbon core, there were of four different makes of wire for four cylinders, replaced by assembly line original wires with stainless steel connectors with dimpled spring locks.
16. As a resultant of ignition coil malfunction, spark plugs had got overheated and were not functioning properly. All spark plugs replaced.
17. Wiring harness inside the engine compartment was completelly berserk (yes, berserk!). At least 10 dead wires were identified and removed. Harness temporarily reoriented and taped. Ignition coil and distributor low tension connections rectified with properly soldered eye connectors.
18. Battery was relatively new but was not fitted and connected properly. Battery connectors cleaned and refitted, needs to be done properly once again.
19. New battery hold down bracket to be fabricated and fitted.
20. Spare wheel hardboard cover was loose. Bolt threads were worn out, bolt replaced, tightened properly.
21. Cross brace wheel spanner found rusted and not of 19mm size as required. Replaced.
22. Jack fulcrums lubricated and fitted inside the dicky.
23. Air intake horn and big flexible hose on the LH side of the engine removed and kept safely to be used during restoration.
24. Car cleaned inside to out. All old and rusted parts lying inside discarded.
Car is running much better than before.
Next work:
1. Completely overhaul electrical system. It is still very bad.
2. Replace carburettor assembly. There is minor leakage.
3. Overhaul radiator assembly complete. Fit temperature guage adaptor in the radiator tank.
4. Overhaul front suspension complete. Original spiders and new shock absorbers to be fitted.
5. Overhaul steering gear. There is slight grabbing, seems to be due to inefficient lubrication.
6. Overhaul front suspension complete. Original spiders and new shock absorbers to be fitted.
7. Overhaul rear suspension complete. Spring bushes have perished, to be replaced. New shock absorbers to be fitted.
8. Overhaul brake system complete. Procure and fit all Brakes India parts.
9. New clutch assembly to be fitted with new original linkages.
9. Accelerator pedal and rod assembly to be replaced. Original parts are very difficult to procure.
10. Pressure wash, service and grease the car properly. Transmission and axle oils to be replaced.
Best regards,
Behram Dhabhar