My warm greetings to all on Team-BHP. After taking regular help and inputs from all of you, I like to share few of my experiences, that I have encountered past few months with my M800 carb model (clocked 1,45,700km till now), in anticipation that it would help to understand any technical issues faced by the owners of the same vehicle. I wanted to share this since a long time but due to time constraints, i couldn't able to present it till now.The issues stated are encountered during a one and half period tenure and request not to misinterpret for iterating problems every now and then. Initially i had limited knowledge about automobiles. It is Team-BHP which helped to understand the vehicle in a better way.
The car is often driven in city and interstate (bi-weekly) of Bangalore-Mysore stretch. Since last couple of years I had issues, like while driving the car used to jerk (cough) in top gears. I took the vehicle to a local garage at first(ali & sons @ Koramangala ) and they changed the distributor cable (1k). Initially it looked fine, but the problem came back. This time I drove to MASS (mandovi) and got it checked, as the vehicle is regularly serviced there. They first inspected the car and performed engine analyzer test and then recommended me to change the point condenser. Done it. Car was running fine.
Meantime when i was returing from Mysore at 7pm night, car suddenly started not responding to throttle, engine going down and came to hault.I tried several times cranking and by adjusting the delco of the distributor (as told by local mechanic on phone) but of no use. I asked him to come and check as I was 28km away from Mysore. He came, inspected and pointed timing belt went off and towed the the vehicle back to Mysore. It was next day i got the timing belt from MGA and fixed it. Total cost came around 2k( belt rs700+ mechanic charges rs500 + miscllaneous and towing rs800). There was still some minor job left which includes replacing the bearing of the timing belt as the mechanic said it was due replace and i didn't get the spare in Mysore. Came back to Bangalore, gave to MASS to change the bearing, check the belt tension and any adjustments involved + general servicing + spark plugs replce ( Regularly replace parts/spares that wear and tear). Car now felt ok.
Due to the breaking inefficiency in m800, I took advice of my friend and guide Pavan Kadam (You guys know him well for his brilliant works in Team-BHP) and changed them to Power breaks (KBX Break booster, total cost came around 3K). Got the break installed by a mechanic recommended by Pavan. But deep within I can still feel the car to be incomplete. Couple of months passed, still had jerks regularly, so again i got the car checked at MASS( some how feel they are better equipped than local mechanics for technical challenges). Now they say the distributor is weak and needs a overhaul ( as adjusted several times by that local Mysore mechanic and me disturbing the delco and point condenser) and gave estimate for 1.8k-2.5k. Instead I thought of replacing it with a new one (TVS Lucas@ JC road around 3.5k with labour) since the car was literally 11 years old and we are in no mood to sell (for centi reasons, got well attached to it).I thought atleast replacing it, should work. Other than this i had problem of mileage, which was returning 10kmpl. When servicing due date approached, i stepped into MASS again and its then I complained about mileage and pick up issues. The supervisor advised me to go for a carburetor overhaul this time. I felt it was reasonable as could feel the car needs it.Got it done and the bill goes to around 3k (including all other minor spares, servicing and labour).
Later after few months, another problem, the coolant started coming out and engine heats and car stops. At MASS the service guy said the radiator fan thermostat switch failed and needs replacement and also advised to go with radiator overhaul which costs around 2.2k (1k for switch + 1.2k for OH including labour and parts)
. I just opted for radiator overhaul and dropped the idea of fan switch ( was in financial crisis then) and made fan direct( it runs all the time as soon as you turn on the ignition key). Looked fine then, but again after couple of months, the coolant is flooding out and car stops.
I got fed up and searched Team-BHP for possible solution. That's how i got to know about blown engine head gasket. This time I directly pointed out the problem and they did a very good job by doing everything in perfect. Also checked for any possible leaks in the hose from the radiator. Total bill was around 3k. For a moment i felt i can't maintain it anymore as the bills are piling up, but still our love for the car never fades. So moved on. No major issues for a period of 6 months since then. Now A/C started giving trouble. When i switch on, it either fails to respond or the engine goes off. Got it checked at same place and they asked me to replace the A/C relay, top up gas and adjust engine idling. Got it done ( bill over 1k). Meantime had stater problem, got it replaced. Now hoped everything is in order.
Months passed but no sign of relief from that age old Cough problem. Through out an year I had a strange problem of the stereo going off when i increase sound level above 18 units. I thought it might be a wiring problem. When once checked with the local automobile electrician, he said the battery was not charging up fully. I had an idea of getting my alternator modifying to generate more amps for fast charging. When researched for the same topic in Team-BHP, i noted some valuable points. I soon forgot about it untill one day, I was stranded in the middle of the road(at marathalli), late night. Thank God, it was sunday and did not had heavy traffic then. All of a sudden head lights got dim and the engine was not cranking after it turned off automatically. I thought battery went dead and got help for a push start. But even that didn't help. As per the knowledge i acquired here (Team-BHP), i realised for an alternator failure and thought of a back up battery. I called the Maruthi Onroad Service, gave my location and asked them to bring a service battery with them. They arrived in 40 mins and had it checked. Initially they performed a jump start with their service battery. The car started but the engine wont run for long time ( just 10 mins and engine would go off). They determined alternator to be faulty. Replaced their battery with the dead one and assisted my car back home that night with all electrical components turned off.
Next morning i called up MASS and asked them to collect the vehicle. They inspected and suggested with alternator overhaul. I queried for inspection, estimate and parts to be replaced, since i already had idea about it. They came up with 1.8-2k including labour and parts needed are regulator, rectifier (I doubt if both are same , correct me if wrong) and bushes. Since the new one costs me 3k, spending 2k on old one didn't strike me reasonable and i asked them to replace it with new TVS one. They requested for couple of days as they are out of stock. I just headed to JC road and purchased Bosch alternator which costed 3.1k ( which is said to be a fast charger with 43A rating towards 35Ah of existing old Battery + 1 year warranty) + alternator fan belt rs.60 + radiator fan thermostat switch rs.160 (minda). Got everything fixed the same day.Between the power break was not working, when i asked them to check about the same. They did break bleeding and replaced a rear drum/cylinder. Still no use. I personally inspected and shocked to see that the air vaccum tube is in no point of contact to the power break intake. A small tube connecting both has a major cut in it. That's when the connecting tube must have come off.
Sorry for not being able to use technical words here due to less knowledge. Now the car is simply great, smooth and the jerk( engine cough) and stereo going off has vanished, which points to the weak alternator. I have not done the engine work till now ( may be that's the reason for low mileage) as only one cylinder has dropped the compression to 75% and rest are fine. I am still amused that the MASS besides conducting regular engine analyzer tests, that also includes the examination of proper functioning all electrical components, still was not able to detect my weak alternator and prevent my car from break down, and me from getting in to a helpless situation. May be the supervisor has overseen it the last time I got it checked. It is always better to know about the situation first before we can completely (or rather say blindly) rely on any mechanic and handing over our buddy to them.
I learnt few lessons during the entire process, and that would be, we have to understand the automobile first, so that it can respond in the manner which we expect it to. Finally after crossing every hurdle and to get my sweet back in to condition, it was an amazing experience. I love driving it again and again. I personally thank you all for your enormous support and time you are investing here(I am sure its not a dead investment).
Bill Summary of major work done ( Excluding regular service and wear and tear parts replacement):
1. Distributor Cable + labour---------------------------------- 1000.
2. Timining Belt + Bearing + other spares +labour -------------- 2500.
3. Distributor Replacement------------------------------------ 3500.
4. Carburetor overhaul --------------------------------------- 3000.
5. Radiator Overhaul + parts --------------------------------- 1200.
6. Engine Gasket + Tappet Adjustment + Spares -------------- 3000.
7. A/C Switch Replace --------------------------------------- 1000.
8. Alternator+ Belt + Radiator switch + Labour----------------- 3800.
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Total 19000.
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I wish everyone in here gets to know the better way to treat their beloved ones. Happy cruising !