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Old 3rd September 2014, 17:14   #391
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Default Re: Zen and the art of maintaining it

There is an MGP part number 95999M70R00 (R134A, retrofitment kit, zen old) which costs Rs.5632. This kit includes reciever drier bottle and some pipes. After installation, you can run your existing system with r134a gas. There is no need to change compressor, condensor or evaporator. My zen has this kit for more than 8 years now, and it runs just fine. Cooling is not compromised.
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Old 3rd September 2014, 18:23   #392
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Originally Posted by chaudh2s View Post
There is an MGP part number 95999M70R00 (R134A, retrofitment kit, zen old) which costs Rs.5632. This kit includes reciever drier bottle and some pipes. After installation, you can run your existing system with r134a gas. There is no need to change compressor, condensor or evaporator. My zen has this kit for more than 8 years now, and it runs just fine. Cooling is not compromised.
Good to know. In my case the compressor is seized, so it needs replacement. So, if I factor in the cost of a second hand one and the labour plus other smaller bits, I would be spending close to Rs. 10000. I am trying to see what I can get for Rs. 5000 (including labour).
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Old 16th September 2014, 15:52   #393
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Two potential problems after getting the car restored.

1. In the morning (or after cold start), when I turn the key, the initial noise that comes up, continues till I start the engine. Earlier, I used to hear the humming noise and then there was a 'click' of the relay.
So, what does the absence of the 'click' mean?

2. The fans in the engine bay do not start, even after driving for a few kilo-meters.
The mechanic raced the engine gently for a few seconds and the left fan came up on its own.
Note: I am not using the AC.
I am observing the temperature needle inside and everything seems normal. But is this really a problem (fan not coming up even after 3 km of driving?)

Last edited by S_U_N : 16th September 2014 at 15:53.
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Old 28th October 2014, 16:25   #394
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Default Re: Zen and the art of maintaining it

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Originally Posted by S_U_N View Post
Good to know. In my case the compressor is seized, so it needs replacement. So, if I factor in the cost of a second hand one and the labour plus other smaller bits, I would be spending close to Rs. 10000. I am trying to see what I can get for Rs. 5000 (including labour).
My Zen's compressor [Subros made, running on R12] also "seized" last week - as was told to me by the A/C servicing-repairing centre. I was told that a second hand/refurbished Subros compatible for R134A [sourced by them] could be available and the cost of this replacement, along with Receiver dryer and expansion valve would come up to 9 - 10K. A new compressor replacement would run up a bill of 18-19K. My questions are -
1. How can one "test" the reliability of a second hand compressor procured from an unknown car?
2. Is it possible to procure a second hand R12 compatible Subros compressor in Pune at a lower price?
3. Are the prices for R134A compatible Subros quoted above competitive? Or will I be better off looking elsewhere? If so, what would be the best place in Pune to find one quickly?
Thanks in advance!
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Old 28th October 2014, 23:35   #395
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My Zen's compressor [Subros made, running on R12] also "seized" last week - as was told to me by the A/C servicing-repairing centre. I was told that a second hand/refurbished Subros compatible for R134A [sourced by them] could be available and the cost of this replacement, along with Receiver dryer and expansion valve would come up to 9 - 10K. A new compressor replacement would run up a bill of 18-19K. My questions are -
1. How can one "test" the reliability of a second hand compressor procured from an unknown car?
2. Is it possible to procure a second hand R12 compatible Subros compressor in Pune at a lower price?
3. Are the prices for R134A compatible Subros quoted above competitive? Or will I be better off looking elsewhere? If so, what would be the best place in Pune to find one quickly?
Thanks in advance!
Compressors are sourced from Kurla CST Road market. The cost there is starting from Rs. 1500 (is what I was informed).

The guys here charge you Rs. 3000-3500 for the compressor.

One way to check is to manually see if the front part turns by hand. But that does not tell how much of life is remaining.

I sent you details via PM as well.
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Old 28th October 2014, 23:42   #396
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Default Re: Zen and the art of maintaining it

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Originally Posted by S_U_N View Post
2. The fans in the engine bay do not start, even after driving for a few kilo-meters.
The mechanic raced the engine gently for a few seconds and the left fan came up on its own.
Note: I am not using the AC.
I am observing the temperature needle inside and everything seems normal. But is this really a problem (fan not coming up even after 3 km of driving?)
There is a temperature sensor that triggers the fan to start stop over a fixed threshold range. This should be normal. You would not notice the temperature needle in the gauges in the dashboard indicating anything, as the fan start/stop takes care that temperatures to go too low or high. If there is a problem with the fan starting up , then the temperature gauge will surely go into red and engine will loose pickup gradually as it heats up
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Old 29th October 2014, 18:58   #397
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Default Re: Zen and the art of maintaining it

The 'fan not starting' is not a problem as I can see. So, I will close that topic. The fan does start when the sensor tells it to do so.

Now, the main problem for me is that the engine races (and keeps racing) due to one small wire which does not seem to go back to normal position. The wire that I am referring to is the one below the mushroom type of part. I will try to post a picture.
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Old 30th October 2014, 01:31   #398
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Default Re: Zen and the art of maintaining it

Quote:
Originally Posted by S_U_N View Post
Compressors are sourced from Kurla CST Road market. The cost there is starting from Rs. 1500 (is what I was informed).

The guys here charge you Rs. 3000-3500 for the compressor.

One way to check is to manually see if the front part turns by hand. But that does not tell how much of life is remaining.

I sent you details via PM as well.
Thanks a lot S_U_N! I scoured a few shops in Nana Peth and finally got hold of a "working" Subros compressor - from the ones who salvage parts like this probably from scrapped/accident/total loss vehicles. These shops have an unbelievable assortment of such stuff! Anyway, he demonstrated its "working" by rotating the pulley with and without the clutch and generation of "pressure" from the intake/outlet openings on doing so. The magnetic clutch was also checked by connecting to a battery. Only the top plate which had differently aligned openings was changed - the one from my existing compressor was used! All this quoted for Rs. 2000/-. Finally gave him Rs 1800/- and gave my old seized 196000km run compressor for him to salvage whatever he wanted from it or scrap it! True, there is no way of telling how much "life" this one has left.

Just to complete the episode, I took the second hand compressor to the AC mechanics, who fitted it back in [of course after telling me how its no good and it will not work!], replaced the old receiver dryer and expansion valve [reason given was that the old compressor would have given out debris when it burned and seized, which would choke these components and probably damage the replacement compressor too], flushed out the entire system under pressure, replaced all old 'O' rings and one leaking filler valve and finally refilled with R134A. The resultant effect was quite good, with the temp dropping to 6.5 in the central vent when the thermostat cut off the compressor. The compressor pulley is also more silent than my previous one although there is a very slight bearing noise, I suspect. The expenses here for the parts changed, labour and gas amounted to Rs 4600/-. Thus total expense was Rs 6400/-. True, that I had to spend 2 days just for this and make a couple of trips to Nana Peth and the AC mechanics, but it was quite an experience. I only hope its worth it - time will tell. I shall keep updating here as per the situation.
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Old 13th November 2014, 14:23   #399
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Just an update - AC's chilling fine, even in the afternoon periods. There's a bit of screech from the belt, I presume when started after a period of rest - will have to adjust the tension, maybe? The bearing noise [krrrrrrrr] seems to have reduced.
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Old 12th January 2015, 01:08   #400
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Default Re: Zen and the art of maintaining it

Can anyone tell me what is the ignition timing setting for the Zen MPFI? The engine seems to be knocking under load.
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Old 13th January 2015, 15:43   #401
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Default Re: Zen and the art of maintaining it

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Can anyone tell me what is the ignition timing setting for the Zen MPFI? The engine seems to be knocking under load.
1) You can follow the steps shown in the attached image.

2) Here is the link to the zen MPFI workshop manual
https://skydrive.live.com/redir.aspx...MqZh7rMuR6qABU

Hope this helps.
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Old 5th February 2015, 21:09   #402
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Default Re: Zen and the art of maintaining it

I got the A/C system of my 1998 Zen overhauled yesterday at Ram Cool Cars on Bannerghatta Road. The car has the original R12 compressor. Gave the car at about 10:30 AM and the SA promised the car would be delivered by 6 PM. He kept his promise and the job was done very well. The total cost was Rs 4,300.
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Old 6th February 2015, 12:53   #403
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So, I had been facing constant issue with the car - slowing down would just stop the engine. Tuning and idling over the last two months did not help.
The last resort was to change the carburetor. Now car starts in the first crank and does not die in the mornings.

So, I asked my friendly mechanic to get a good second hand carburetor and get the work done last week.
There is a remarkable difference in the engine noise - it has become very quiet. The low end pickup is smoother - though I find the high end pickup to be little slower - not an issue though.


It would be interesting to check the mileage sometime in the near future.

Lot of rattling from under the dashboard and the steering wheel sides continue.
I will keep updating when I observe more.

Last edited by S_U_N : 6th February 2015 at 12:54.
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Old 6th February 2015, 14:45   #404
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@S U N, I too faced carburetor problems in my zen (@ about 1.45 lac kilometers). For me the problem with the carburetor was that the idle screw would not stay in place as the threading inside the carburetor was worn out and the same was with the case of the fuel and air mixture screw. Hence at mornings the car would have to be cranked at least thrice and until the engine warmed up the car would jerk a lot. The engine idling would keep fluctuating and at times it would just stall at traffic signals and would start only after cranking twice. During the last few days before a new carburetor was installed the problem became too bad. The car started giving black smoke and the fuel efficiency in the city dropped to 9 km/l where as I would usually get 14 km/l. After the carburetor replacement the car has good pick up and gives good fuel efficiency. When I had asked the SA why the old carburetor's threading was worn out he said that the tuning was done by hand a lot of times. He told tuning should be done by some tuning machine. The MASS people keep the idling a bit on the higher side but it is fine as the car starts faster during cold starts (takes only 1 crank). I would suggest you to get the tuning done by MASS people itself. I got a new carburetor from Sagar Automobiles. They took a week to order and get the carburetor. It was replaced in September 2013 and after the replacement the car has run 18K. The car now is smooth, has good pick up and also gives good fuel efficiency (about 14 km/l in the city).
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Old 6th February 2015, 19:09   #405
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Default Re: Zen and the art of maintaining it

Swamyzen, Is your new carb, original MGP or some local brand? Last I enquired about a new carburetor, I was told maruti has long stopped procuring this item from vendors and it cannot be ordered as even the part id has been removed from the internal ordering system.
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