[bblost]

A 5 STAR thread.
Simply amazing.

[eternalck]

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.

[Jaggu]

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.

[silver_shadow]

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

[SirAlec]

Originally Posted by Jaggu

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.

Originally Posted by silver_shadow

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

[MalluDude]

WOW..great reading, SirAlec.

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

[silver_shadow]

did i miss it but i can't see the pistons/con rods in your bill? how much did that cost?

[SirAlec]

Originally Posted by silver_shadow

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.

[Mpower]

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?

[SirAlec]

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.

[deepclutch]

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!

[km120]

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.

[SirAlec]

Originally Posted by km120

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.

[Mpower]

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.

[SirAlec]

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.