M800 Engine Rebuild Project....Post 2 lakh kms

[Landrover]

Hey people! i wanted to share this here. Actually i have written this in 2008 in other forums. Its just a transcript from there the Ctrl+C Ctrl+V way due to lack of time. And also i am not much of a writer.

BTW PS to Mod: i hope you have enough server space. As in coming months I will be uploading many useful stuff, as and when time permits.

Thanks

This Diwali the good ol Green baby crossed 10 years of use and abuse and clocked 2lac+ on the oddo. Initial plan, was to install an alto motor, but couldnt find a suitable doner in time. Many crashed alto that came through had people killed in it. Am not paranoid but frens and family and especially wife insisted not to go for them types otherwise.
Hence thought of selling it but was not fetching more than 50k. Goosh! that alloy and tubeless alone had set me back by 21k. Add another 4.5k for those big spot light. 25 k for the body and engine.LOLZ!
I thought, what the hell, why not a rebuild project, luckily I had a spare four days after diwali.
Also Ahm Kabadi friends found two doner, a battered '04 Zen and '02 esteem heart. but lot of work on frame for four days, Had to scrap the idea. Maybe later sometime next year.

As time had come and magic two rotation of oddo took place, had to open her up. Still amazed with what Papa Suzuki's boys had done back in Japan. It easily reached three figure speeds without a hitch in such conditions of head.

enjoy the images.
Thanks

Resting for three more Days


Removing mounting bolts




Battered Head






Gasket


Block


Head Disassembling






Block Disassembling






Removing Crank, Pistons and Connecting rods






Hardest part for me is to secure the bolts that comes off.




Intake Manifold and Carb


Hope you will enjoy!


To be continued.........

 

[RSM]

You are true petrohead. Excellent.

How many KMs you covered now after re-building?

 

[Landrover]

Part Two

Welcome back after the break!!!

@ RSM, it has done little over 9000 kms.

Getting Hands in this state is a great joy.


Flywheel, always change the small bearing along with the flywheel.




Redone Block


Pistons ready to be installed with connecting rod and pins already installed.


Pistons Installed


Redone Crank


Redone Head, same 6 valver. Sigh!!


New Oil and Coolant pump, check the loctite 596 used neatly along with new Oil seal. Always change all the Oil seals and O rings (Oil strainer etc).


Timing Belt install, Well setting this need lot of practice and patience. and not to forget a special tool.


To be continued.....

 

[Landrover]

Part three

Welcome Back!!

Timming Cover Pad kit



Flywheel base and oil seal installed. You can never go wrong while installing flywheel. Check the small guide between two upper sockets.


This is what a oil seal looks like, As i said before never use any old ones even if it looks good to naked eye.


Gasket, Again, it cannot go other way round, check the small copper washer thingy.


My personal choice is Valeo, I swear by Valeo. I hate Ceekay.
Valeo has lesser springs, but the springs are much thicker and sturdier. If ever there is an insanely tuned 800 which does quarter mile in single digit, I bet this Valeo, it will never fail.


Yeah! the plane jane Micos. MGA supplies champion, avoid those at any cost.


Cleaned Gearbox, not purely clean, but what can you expect in 4 days project.


Clutch bearings, Change these also while changing Clutch+Pressure plate.


Comparison between the old and new


Assembled carb intake manifold and Head


BRB.....

 

[Landrover]

Part four

This is a mod that I had done long ago, added that extra piece and removed the thermostat valve completely.




That heater assembly is donated from an old zen. Look! though I have new pipes now. Lolz!



Battered steering Rake






New Sona rake


Tools of the trade, very handy eastman small and mid.


Loctite 596, gasket maker


Mr. Mannaram, a great helper


Very old, but very useful for a DIY guy like me.


The Kharcha List, add to that head & block job.




GOOD NIGHT PETROLHEADS! hope you will enjoy this as much as I did in compiling it

 

[cooldhaya]

Hey great work Landrover!

So the total cost involved is only 10k??

 

[ilango[speed thirst]]

That was good , makes me remember the day when i was with my mechanic on a indica rebuild. Excellent pictures
The new sleeves and block were rebuild at a lathe , which i was not able to witness .
Also i missed the part of fixing the piston at the workshop. It needed(mechy explained then) special tools and accurate placing plus dust free place. I misses this part as i went out on a work.
Could you elaborate the piston fixation method

 

[Akash]

Now thats a true carlover. Great work landrover.

 

[ss80]

AWESOME! AWESOME! AWESOME!

Thank you so much for this thread. It goes directly into my bookmarks at home, off & mobile. Loving it