Hell's Angel - Suzuki Zen Estilo LXi - Midnight Black


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I enjoyed reading your initial posts in this one. Also amazing how well you've maintained the car over 11 year period, considering all the hits taken earlier. Really appreciated your narration of the accidents, with philosophical humour.
 
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Thread Starter #172
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May 2019:

Finally ordered something from Boodmo. All these years was using their parts manuals to search for part number. Was skeptical about ordering due to some unknown reason. On casual search, there were some parts, which not even the MGP guys were negative about. Ordered them right away since they were low-cost parts. Total was only around ₹ 131.00. Parts were not readily available, so there was no ETA. Date of shipment kept bouncing. Customer care was prompt and transparent. I just took the hit-miss chance. There was option to cancel anytime, but I kept waiting. Finally after 4-5 weeks, one part arrived as a surprise. There was tracking details in their app, but I completely forgot about it. 5-rupee part arrived in Fedex courier, without any shipping charge. After 2 more weeks, the other part arrived, which I never expected. Two separate couriers from two separate location, and free shipping. I was pretty impressed.

Later on, I ordered a pair of Honda Brio tail lamps, which was received in 3-4 days and shipping was around 200 rupees. (Package was pretty large, and bigger than what would fit in an average hatchback).



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Breather Hose - 24825-M-67K00 - ₹ 5.00

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Fusebox Cover - 36738-76G00 - ₹ 125.50

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Another surprise. Made in Japan.

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Never knew fuse box had cover, until pointed out by Aditya when I posted a pic of engine bay. It was missing before delivery.

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And got covered after 12 years.

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Breather hose. It was cracking over years and I cut and fitted back and now there is no more length to cut.

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New one.

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New vs left over of the cracked one.

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With dust cap removed from older one.

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Installed.

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Thread Starter #173
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Sometimes **** happens....

...when you are too much pampered by reverse sensor...

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... and sometimes when parts disintegrate on its own.

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Now I understood why exhaust of most Marutis looks brand new.
 
Thread Starter #174
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June 2019:

Shopping spree:

Felt it's time for a midlife refresh, started acquiring parts for fixing niggling issues for once and all.

First thing is list was the silencer. It is available as 3 pieces. Exhaust manifold, exhaust pipe (with catcon) and the muffler. Our damaged part was the muffler. Surprisingly, it was readily available at MGP and recent stock too, indicating a frequently sold part. Same for both generation Estilos and Alto 1.1.

Muffler - 14300M76G31 - ₹ 3,602.00

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Muffler Mounting weren't damaged, but considering their age and since the muffler itself being new, bought them as well. Needs three of them.

Muffler Mounting - 14209M79020 - ₹ 35.00 x 3

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As equal important was replacing the broken tail light. It was an eyesore. It was available as well. Minda make.
Tail Lamp LH - 35671M59K00 - ₹ 1,037.00

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The repaired power window switch was malfunctioning as well. For the fear of burning the new window motor, decided to change it as well.

Power Window Main Switch Assembly - 37990M59K20 - ₹ 1,156.99

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Coolant change was pending, so bought a liter as well. No mention of ratio, but from the vague chart got an idea of 30% coolant and 70% water for up to -15 degrees.
ECSTAR Coolant - 99000M24120-551AA - ₹ 263.00


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All the above items were purchased from MGP, Pongummoodu. The guy over the counter was very helpful. Even searched through parts manual and checked warehouse to get necessary parts and he was fast too and happy faced. But only thing was he verbally promised to arrange rear bumper and call me in 2 days, which never happened. May be the part wasn't available.

Installed power window switch and tail lamp the first reaching home.

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My custom red backlit is gone. Gotta redo that soon.

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Later found side indicator cover fell somewhere. The base becomes brittle in 2-3 years and the lens falls off pretty easily. I was bored with amber cover, so switched back to clear. This is the fourth set. Stock amber>clear>amber>clear. These were from the last generation bug-eyed Zen. Got it from recently opened Mahindra Auto Mart showroom. Minda make.
Side Indicator - Minda 7067A-615 - ₹ 60.00 x 2
(Maruti Part #36410M74F00 - ₹ 82.00)

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LED fetish. Made a set for side turn indicator. Yet to finish.

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Hello @deville_56 Sir, I have been a follower of your thread since 2011. Coincidentally, we own a 2007 Maruti Zen Estilo Lxi in white colour. Your thread has been an inspiration to me for many DIY projects. I have installed a cabin a/c filter recently. [:)]
I want to know how you wired up the 'foglamps' in your Estilo. Yesterday while cleaning the engine bay, I found a white connector beside the passenger side headlamp which I'm curious to know about. Kindly let me know what is that white connector for. Could not upload any pictures because of the incessant rain in Hyderabad, will upload asap if needed.
Thanking You,
the9464guy.
 
Thread Starter #176
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Hello @deville_56 Sir, I have been a follower of your thread since 2011. Coincidentally, we own a 2007 Maruti Zen Estilo Lxi in white colour. Your thread has been an inspiration to me for many DIY projects. I have installed a cabin a/c filter recently. [:)]
I want to know how you wired up the 'foglamps' in your Estilo. Yesterday while cleaning the engine bay, I found a white connector beside the passenger side headlamp which I'm curious to know about. Kindly let me know what is that white connector for. Could not upload any pictures because of the incessant rain in Hyderabad, will upload asap if needed.
Thanking You,
the9464guy.
Thanks for the sweet words [angel]

Details of the cabin filter and the DIY job would be highly appreciated.

That white connector is still a mystery for me. My assumption is it was OEM connector for foglamps.

My foglamp is connected to it from the very beginning. First set was installed by Maruti dealer itself and of course a shoddy job. They chopped the other end of the white connector and an keyed wire from the steering column and connected it via an "Anupam" switch and voila it worked. That dealer pair was some cheap fake stuff and when I changed to better ones with better bulb, the switch melted and then only checked and found the crap job.

Rewired at Bosch and they did a better job, but not a good job. Same yellow wire from column and the wire to white connector with only addition of a 3 wire relay.

Finally my version. Yellow wire from column via switch to bonnet. A 4-pin relay and power directly from battery via fuse. Another relay (PCB type) powered by park light and it blocks the signal from switch when park light is off. Fog will turn on only when ignition and park lights are ON.

For making things simple, you can draw from Head unit connector, which has an accessory (keyed) connection and a dimmer connector. Think I am complicating things too much.
 
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Thanks for the sweet words [angel]

Details of the cabin filter and the DIY job would be highly appreciated.

That white connector is still a mystery for me. My assumption is it was OEM connector for foglamps.

My foglamp is connected to it from the very beginning. First set was installed by Maruti dealer itself and of course a shoddy job. They chopped the other end of the white connector and an keyed wire from the steering column and connected it via an "Anupam" switch and voila it worked. That dealer pair was some cheap fake stuff and when I changed to better ones with better bulb, the switch melted and then only checked and found the crap job.

Rewired at Bosch and they did a better job, but not a good job. Same yellow wire from column and the wire to white connector with only addition of a 3 wire relay.

Finally my version. Yellow wire from column via switch to bonnet. A 4-pin relay and power directly from battery via fuse. Another relay (PCB type) powered by park light and it blocks the signal from switch when park light is off. Fog will turn on only when ignition and park lights are ON.

For making things simple, you can draw from Head unit connector, which has an accessory (keyed) connection and a dimmer connector. Think I am complicating things too much.
I used Alto's cabin filter which is a tad bit small for Estilo. In my case, Maruti ASS was hopeless as they would not do counter sales and I was left with MGP and automotive spare parts shops. This alto's filter leaves a small gap on a side but fulfills the job of filtering the A/C air and reducing dust ingress to some extent.
IMG_20190613_113945264.jpg

This is the part number for the cabin filter with cap for alto. I guess you can source out a Estilo's cabin filter through MGP if you have any contacts with them.
 
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A 2010 thread (started then)and somehow I missed it completely. I started reading it today. I am on the first page the day your sister brought the car home with you following up in the Zen.
You have a flair for writing. I am getting totally entertained by your writing skills. It's like actually sitting with you and watching your sister struggling with the car controls.
Nice, very nice write up. Thanks for starting my Sunday on a smile.
 
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Thread Starter #179
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A 2010 thread (started then)and somehow I missed it completely. I started reading it today. I am on the first page the day your sister brought the car home with you following up in the Zen.
You have a flair for writing. I am getting totally entertained by your writing skills. It's like actually sitting with you and watching your sister struggling with the car controls.
Nice, very nice write up. Thanks for starting my Sunday on a smile.
Thanks [cheers] This is indeed my first thread in TAI. Most find my style of writing very immature [lol]
 
Thread Starter #180
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July 2019:

More shopping.
Got rear bumper from Swaraj Motors. Didn't get from MGP. Wanted type 2 bumper with fog lamp, but no stock.
Part number: 71811M59K005PK
Price: ₹ 1,600.00

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Gave it for service with purchased parts to Travancore Motors. Their paintshop was at a different location, so took some time for service + painting.

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Checked with their parts shop. Wanted better spark plugs. They had Denso TT (twin tip) spark plugs. Model XU22TT. It had nickel electrode. Second tip was center electrode like bump in the ground electrode. It was made in Japan and they were listed Denso parts dealer for Trivandrum. Price was ₹ 167.00 per plug and fits most of the Maruti models. Pricing was in par with the OEM plugs. They even offered to arrange Denso Iridium plugs. Being an NGK fan, inquired about G-Power. After a couple of calls, promised to arrange them. Denso was kept as plan B, in case.


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And got NGK as promised.
Model number - DCPR7EGP
Costs ₹ 275.00 per piece. Needs four of them. Total damage ₹ 1,100.00

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Only sore part of the service. I hate these stickers. Removed as soon as home.

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Jobs Done:

Coming to that part, the main reason for getting it serviced was LH drive shaft was making annoying noise when accelerating without load, kata-kata-kata noise. Gave it to the previous FNG for replacement, instead he made it worse and didn't replace. Next thing was the denting job and bumper replacement. Brake was also making noise despite multiple visits to previous guy. Coolant level was dropping and turning rusty pretty fast. He didn't even looked into it. He was all money, no proper work nowadays. Expanded the garage, bought new gold chain. Hopeless.
Work done now included oil change plus full service, drive shaft replacement, steering and suspension overhaul, brake overhaul, silencer installation, coolant system overhaul, rotor polishing, and spark plug replacement. Specifically asked to replace gear oil as well. Told the other guy many times, he was like no need. New bumper install plus denting the boot lid and quarter panel and painting them. This was done at their painting facility, which is a couple of kilometers away. Painting quality was good, OEM finish, no dripping or orange peel, but he polishing guy ruined it. Full swirl marks. Workshop job was neat except some foul smell inside from the damp cloth used to clean the car. Only after final test drive, the found a clinging noise from the front half of the silencer near the cat-con. Asked for one more day for repairing it. Had order placed for seat belt. Took the car anyway with the plan for getting it done at time of seat belt installation. Now the Angel drives well with no rattle or noises.

Now the bill.

Parts:
Engine Oil - Shell Mineral - ₹ 350.00/liter x 3.1 liter
Oil Filter - ₹ 82.00
Axle LH - ₹ 4,615.00
Wheel Cylinder LH - ₹ 265.00
Lower Arm - ₹ 501.00
Spark Plug - NGK DCPR7EGP - ₹ 275.00 x 4
Steering Rack - ₹ 489.00
Steering Pinion - ₹ 460.00
Damper Kit - ₹ 235.00
Lock Washer - ₹ 10.00 x 2
Rack Bush - ₹ 102.00
Gear Oil - ₹ 350.00/liter x 2.2 liter
Silencer O-Ring - ₹ 35.00
Water Inlet Cap - ₹ 60.00
Water Inlet Gasket - ₹ 56.00
10 mm Bolt - ₹ 6.00 x 4
Water Inlet Hose - ₹ 75.00
AC Belt - ₹ 153.00
10 mm Washer - ₹ 4.00 x 2
Taper Screw - ₹ 5.00 x 2
Screen Wash - ₹ 15.00
Steering Boot - ₹ 80.00
Wire Tag - ₹ 8.00 x 2
Shim Washer - ₹ 5.00 x 6
Brake Fluid - 100 ml - ₹ 53.00
End Pin - ₹ 5.00 x 4
Brake Light Bulb - ₹ 40.00
Consumables - ₹ 100.00

Total - ₹ 10,499.00

Labor:
Periodic Service - ₹ 650.00
Steering Overhaul - ₹ 600.00
LH Axle Replacement - ₹ 300.00
Brake Overhaul - ₹ 600.00
Suspension Overhaul - ₹ 450.00
Silencer Installation - ₹ 200.00
Coolant System Overhaul - ₹ 750.00
Rotor Polishing - ₹ 600.00
Wheel Alignment - ₹ 350.00
Service Tax - ₹ 279.00
Wash - ₹ 500.00

Denting and Painting - ₹ 6,000.00

Total - ₹ 11,279.00

Total hole in the pocket - ₹ 21,778.00

This excludes the parts provided by me. That included will make it close to ₹ 30,000.00.
 
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