(Sorry about the delay guys, I am very busy these days. Internet acting up at home too. And Jeep kept me busy today too.)
The highway was completely dark, my Jeep was practically invisible until the headlights of oncoming vehicles fell on it.
I hear couple of villagers walking by. I quickly asked them about the availability of mechanic. They tell me to check in the near by bar owner, who has the number of a local mechanic by name Rajesh. I could see some faint light 200ft away behind me. So I went there to inquire, at first the bar owner said no mechanic will come now, then he started reading out the number since I insisted upon talking to the mechanic.
Then he stopped in the middle saying the mechanic is here. I turned around and see a young fellow parking his bike. So I caught hold of him and told my problem.
He: Is there oil in the engine?
Me: I haven't checked yet, but the oil pressure is zero and oil lamp is on. So I stopped.
He: (checks oil with dipstick) Yes, the oil is very much there.
He: Do you have enough diesel?
Me: Yes, must be at least half tank.
He: (Starts checking the fuel line and finally ends up at the fuel injection pump.) Crank the engine.
Me: Ok, here I go.
He: Ah! the current comes to the pump, but the switch is not working. The fuel injection pump solenoid switch has gone bad.
Me: Can something be done?
He: Not without the part, can't get the part at this time. It is available only in Udupi. You will have to leave the vehicle here and we can look at it tomorrow, once we get the part from Udupi.
Now, I was not about to leave the newly rebuilt Jeep in the middle of nowhere on the highway. So I decide to get it towed till the office. Meanwhile I get a call from the Coorg Mechanic Xavier asking about my status. I tell him my sorry situation. Then I call my father-in-law asking him to arrange a tow vehicle and start waiting for it.
Then I get a call from Sibi who heard the story from Xevier, and Sibi has a solution. He asks me to remove the solenoid switch using a 27 number spanner and connect it directly. I didn't understand the exact procedure, but got the gist of it. After that the Jeep won't be able to shut off, I have to stall it in 4th gear when I am done driving. But I can get home without the business of towing. Cool!
By this time the mechanic had returned back to the bar. So I went looking for him again. Didn't find him, so this time I got his number fully from the bar owner. As I called him and introduced myself, he disconnects and says I am right here. Darn, he was just 10ft away in the darkness talking to somebody.
So I explain Sibi's plan to him. Fortunately he understands and says that the Jeep can't be shut off after that, you have to jerk it in top gear to stop it. That convinced me that he understood Sibi's solution. But he had no tools and not enough petrol in his bike to do the run around. He says he has enough petrol to go to Byloor tomorrow for some work, can't waste it today going to Hiriyadka towards his garage to pick up tools. It is already 9:30PM and the petrol bunks must be closed in Hiriyadka. My tools were in Manipal, so that was no help.
I finally prevail upon him that I can't afford to leave my vehicle in the road and practically give him a Carte Blanche regarding the charges. Finally he called the petrol bunk in Hiriyadka to see whether they were open, and they were open until 10PM. Then he sent his teenage assistant on bike to get a few tools and fill some petrol in the bike.
The assistant got back by 10PM with the tools. But there was hardly much space to put the 27 number spanner next to the fuel injection pump. The mechanic tried some strange techniques to turn the spanner and it didn't budge. Then he decided to remove the whole fuel pump out, for which he needed Allen keys. Again he sent his assistant to bring some more tools, while we sat inside the Jeep to escape the increasing rain. The only consolation is my Jeep has work-light under the hood, which kept the working area illuminated. None of us had a torch.
Meanwhile I was getting calls from my wife, parents, in-laws, to check on my status. They all knew I was stuck somewhere in the darkness, but they knew I'll manage something, so everybody was calm.
The assistant was back again by 10:45PM, and we continued working. But one screw refused to come out. The #4 Allen key was too loose and #5 Allen key was not getting in. Is there a #4.5 Allen key, I don't know. Finally by 11:15PM, the rain became too hard and we got back on the Jeep. Mechanic says there is no other way, we have to wait until tomorrow. I very reluctantly agree, and I drop the towing option since it can be very treacherous operation to try in this kind of weather.
But I didn't want to leave it on the street. So I asked the mechanic to hop on the driver seat and steer it while I push it all the way back to the bar. There was a spot in front of the bar which is a little hidden from the main road. I wanted to leave the Jeep there, next to a building, so that it doesn't look abandoned and unprotected. Then I pushed the Jeep single-handedly all the way (200ft), the turn towards the bar was a little uphill, so I had to stop and take a breath before the final push into the parking spot.
Then the mechanic left without asking for any money. I told him I'll visit him next morning, we had each other's number anyway. I called my father-in-law to pick me up, and I also asked him to get couple of locks. Once he came, I took the locks, and locked the spare wheel, gearshift and the hood. Somebody was asking why I need so many locking systems, now you know the reason. I finally reached home at 12AM.
Next day morning I called the Mahindra Workshop in Udupi and told my problem. My regular SA had only one question:
He: You are sure that is the problem? You just need FIP solenoid switch?
Me: Yes.
He: Is that Bosch or TVS fuel pump?
Me: Oops! I don't know...
He: Never mind, I'll send both with the mechanic. Where exactly is the Jeep?
Me: He can't open the hood without me, send him to my office, I'll take him in the taxi.
He: Ok, he will be there in an hour.
The Mahindra mechanic who usually works my Jeep showed up at 10AM and then we took off. I took my toolbox too since I thought we might need the allen keys.
The Jeep was still there, untouched, unmolested. The mechanic looked the FIP and decided there is no reason to remove it. So allen keys are not needed. He disconnected the injector pipes from the cylinder head, he removed the oil filter too. That made enough space to put the 27 number spanner. It was very tight, but with the extra space to work, he managed to remove it. He quickly replaced it with the Bosch solenoid switch and tightened it. He also tightened all the screws that were loosened in the process of removing the FIP last night.
Then he pumped the fuel filter, asked me to crank the engine to see fuel coming to the injector pipes. Then he tightened everything and the Jeep started like nothing had gone wrong.
As we drove back, I stopped at Hiriyadka to pay the mechanic from yesterday. He was away in Byloor, so I had to call him. When I asked his fee, he asked me to pay 200 bucks, which I happily paid his assistant. By then some other mechanics and some locals were circling the Jeep with interest. The CFL as usual drew their interest, not to forget hood lock, the high stance, etc. After I answered all the questions, one guy says "There is a lot to learn from this Jeep..."
With that happy note, we left back from Manipal. On the way, the Mahindra mechanic says this doesn't feel like a Jeep. No rattling, the suspension is like a car, I can barely feel all the potholes. I asked is it like riding a Scorpio and he says YES.
Thus, the Jeep finally came back home after nearly 5 months of rehab.
For those of you need a closer look at the paint job. This one is in really high resolution.