[samaspire]

Originally Posted by Leoshashi

Sludgefest

(ran out of emojis)

How is that engine still running??
Any chance of fixing it? Or should he just give up on it?

[Captain Slow]

Originally Posted by samaspire

(ran out of emojis)

How is that engine still running??
Any chance of fixing it? Or should he just give up on it?

Its being fixed as we speak, Sashi is helping a lot and guiding on what to do and how to do.

[Leoshashi]

Originally Posted by samaspire

How is that engine still running??

Given the condition of the suction strainer, that's a million dollar question you have asked.

Surprisingly and luckily, the engine is still okay. Just needs a headgasket change, some serious cleaning and all oil seals are being replaced. MASS has given an estimate of around 12k, which should take care of everything. This is on the higher side, but he had no other choice.

These old Maruti engines are not so sensitive to abuse and neglect, and don't give up so easily.

Some more pics of the vehicle in question:













Regards,
Shashi

[R2D2]

Originally Posted by Leoshashi

Update regarding BHPian Madmanscam's Maruti 800: So the MASS has dismantled the engine, and here are some

My reaction is OMG. This car hasn't been neglected but abused. As @samaspire asked how the heck did that engine keep running?! Kudos to Suzuki/MSIL for designing an engine that can endure such punishment.

[tacho9000]

Originally Posted by R2D2

My reaction is OMG. This car hasn't been neglected but abused. As @samaspire asked how the heck did that engine keep running?! Kudos to Suzuki/MSIL for designing an engine that can endure such punishment.

Ask Me sir, during Goldie's restoration the head was opened and a craptonne of sludge and god knows what was in the head. Thankfully, due to the block being still in good shape only a head job and some miscellaneous were done to get the engine back to top shape. And now Goldie is running fit as ever. Really kudos to MSIL for designing and producing an engine which can literally run like a champion forever. I'm really proud to own such a brilliant piece of Machine.

Regards,
Subhra

[longhorn]

The older generation F and G engines are not only a hoot to drive but can also handle abuse much better. New gen engines are built to tighter tolerances and hence are no match for the old generation ones. The 5 speed was a perfect combination of the F8D motor and a 5 speed gearbox. Absolute hoot to drive in the city compared to the current K10 motor which has a pathetic low end.

[Sutripta]

With that amount of sludge, high chances the oil intake was also choked. Would be a good idea to check out the crank bearing areas and cam lobes for wear.

Regards
Sutripta

[chiranjitp]

Originally Posted by Leoshashi

These old Maruti engines are not so sensitive to abuse and neglect, and don't give up so easily.

First of all it's nice to see Bhpian Madmanscam's M800 getting fixed, that too without needing any major work. I too believe that the older Maruti engines (F & G series) are very abuse friendly, they are virtually indestructible.

A good friend of mine owns a 03 Zen Lx (first owner & 150k km on the odometer). Recently he took his car to a MASS for overhauling the engine, as there was a coolant leak, some oil seal was also leaking, the engine had lots of sludge formation, and of course the odometer reading was nearing the 150k km mark. Strangely, all the Zen needed was a new head gasket, few oil seals and the car was back to normal. Even the compression test result came out positive.

Here are some photos of work in progress:









Even my (now sold) 01 Zen Vxi had huge sludge formation, still it never caused me any trouble. Performance & Mileage were still good. Only problem was a bit of white smoke at startup & slight oil consumption (though it never needed any top-up). I have no idea about the longevity of the modern Maruti engines, still I am willing to bet they won't be as abuse friendly as these old Maruti engines.

Here are some photos of the sludge, almost as bad as Bhpian Madmanscam's M800:

[Leoshashi]

Originally Posted by Sutripta

With that amount of sludge, high chances the oil intake was also choked. Would be a good idea to check out the crank bearing areas and cam lobes for wear.

Point noted!

The MASS is being very difficult. Ask them to do anything, and they are giving a standard reply, "We do this only with overhaul, will cost you 40k"

Imagine the professionalism of the mechanic, he is doing an engine head gasket replacement but wasn't ready to clean the head unless we opted for the entire rebuild. Upon convincing them for sump cleaning, they quoted 3000 rupees as labour. The goddamn brand new sump and strainer costs less than 400 rupees.

After a lot of requesting and pulling some strings, they have finally agreed to clean all sludge for Rs. 4,000.

The issue was that the car wasn't drive-able. It would have been a risk to drive 20kms in that state. The head is an aluminium one and costs eye watering 22k rupees for this variant of M800. I don't know the reason behind its absurd pricing. A new Swift's head costs 1/3rd the amount of 5S 800's head.

Anyways, they are working on the car, and hope the issue gets resolved soon.

Regards,
Shashi

[Leoshashi]

Update on BHPian Madmanscam's 5S 800-

MASS has cleaned the head. But, I have a doubt: It looks like they have used paint at some points. It looks unnaturally shiny at some places. I'm not getting a good feeling. There is inconsistency at some places. Experts: Please comment















Clogged up coolant galleries











Brand new Sump-Do note that the sump is different for F8D Engine.







Regards,
Shashi

[Leoshashi]

Update on BHPian Madmanscam's 5S 800- He had asked the MASS to get the block cleaned as well. Some coolant galleries were chocked with deposits, and it didn't make sense to clean the head and leave block as it is.

They have also changed the piston rings and the oil pump.















































Regards,
Shashi

PS: I have halted updates on the Golden Goose till the time his car needs attention and suggestions.

[chiranjitp]

Originally Posted by Leoshashi

Update on BHPian Madmanscam's 5S 800- He had asked the MASS to get the block cleaned as well. Some coolant galleries were chocked with deposits, and it didn't make sense to clean the head and leave block as it is.

It's nice to see the car being brought back to its previous healthy state. To a non-technical guy like me, the Engine (both head & block) now look really clean & healthy. How long can one realistically expect a partially overhauled engine (like this one) to last? In 2013, there were some problems with our Omni's engine (mainly engine oil coming in contact with spark plugs). We ended up fitting a new half engine (F8B half engine only costs 12k), as we were told that an overhauled engine doesn't last very long.

[Leoshashi]

Originally Posted by chiranjitp

How long can one realistically expect a partially overhauled engine (like this one) to last? In 2013, there were some problems with our Omni's engine (mainly engine oil coming in contact with spark plugs). We ended up fitting a new half engine (F8B half engine only costs 12k), as we were told that an overhauled engine doesn't last very long.

Depends on quality of work done and the condition of old engine. Regarding the debate Overhaul vs Half engine, this is what I have to say: Overhauled engines can be better than factory engines IF the work done is good, and, Half engines can also fail and become a nightmare IF the workmanship is bad. That's a king sized IF in both the cases. However, the risk involved in half engine is certainly less.

Here the block was in a good shape, and all it got was some polishing on the cylinder walls and new rings. So I am expecting it to be as good as new. Workmanship of MASS looks good, albeit expensive.

The engine has been assembled and will be mounted tomorrow. Some pics of the WIP:









































Regards,
Shashi

[Leoshashi]

14th December, 1983-2018: The Iconic People's car of India, the Maruti 800 turns 35! Sharing some images to celebrate this occasion.

The first owner, Late Harpal Singh and his SS80:



The Original Maruti 800 aka SS80, courtesy Autocar



The successor to SS80, the SB308, courtesy: Autocar



Couple of images from my archives:

[Leoshashi]

Update on BHPian Madmanscam's 5S 800- He got the car back on Saturday. Except erratic idle which I suspect it to be from the IAC(Idle Air Control) valve, increased engine noise(suspect them to be from the tappet area) and a couple of leaking hoses, all the issues have been solved. The engine noise is subsiding and I expect everything to become normal by 1000 kms.

Some pics and videos shared by him:

https://www.youtube.com/watch?v=NDxaIYFQY2A

https://www.youtube.com/watch?v=6niI9i0LACI

https://www.youtube.com/watch?v=5VDUXqYIy9E

https://www.youtube.com/watch?v=D8LipwacmF8

https://www.youtube.com/watch?v=psfnY_HCvCg

Regards,
Shashi