My Maruti 800 Carb (1991): Now Restored!

[ramankanythia]

Re: Restoration of Maruti 800 1991 (Tonnes of Pics Uploaded)

i dont think that rectifier circuit is damaged by thinner(cleaning electronic circuit with thinner is a practice followed by many experts) may be some rubber part is damaged or there may be alignment problem while fixing pully just check is winding insulation is melted by thinner if not i think that can be repaired

 

[ss80]

New issue - Fuel line/Electrical problem?

Rayal:
Thanks, I feel one of the important things to have in mind while doing any restoration (small/big) is to quickly get out of situations that depress us. The more I think about a problem, the bigger it becomes.

Ramankanythia:
The other dynamo will slowly make its way to the engine bay till then its the TVS lucas one which has to hold the fort. I am really not sure what's wrong with it, once its opened we'll get to know.



New Problem:
Fixed the new dynamo & tightened it so that the belt does not flex.

CAR DOES NOT START NOW!

It looks like as if there is no fuel. The car cranks, all the belts pulleys work, but it does not start. If I keep the key in "ON" position & press the throttle cable, there is no fuel pouring in the carb (through that small pipe in the Carb) which usually does. I have checked all wires, still no idea.

Recently one of my friend's car (M800) had a break down & I checked everything still could not start it. Assumed it is a Carb issue. Later I came to know it was spark plugs that went kaput. Not sure if that is the case even here too.

Please check the pictures below & let me know if the pink pipe is connected correctly. & what is this part that has two pipes connected to it? Is it the fuel pump?







Car is stuck in this state right now, I want to fix back the grill, bumper, headlights but cant till it starts.

 

[ramankanythia]

Re: Restoration of Maruti 800 1991 (Tonnes of Pics Uploaded)

Try to put some petrol in carb if issue related to fuel pump it will start
if it could be distributor issue only wiring check for electric spark by taking out one wire from spark plug like we do for scooter see if any spark?

 

[ramankanythia]

Re: Restoration of Maruti 800 1991 (Tonnes of Pics Uploaded)

Just take out the pipe move the key in ON position (dont crank) see if fuel coming form pipe
if no then check pump wire below rear seat for crack(may be lose while removing seat etc)
you removed kit did to connected pump wire to the pump from switch?

 

[ss80]

Re: Restoration of Maruti 800 1991 (Tonnes of Pics Uploaded)

Thanks a lot Ramankanythia,
Yes you were right, while removing the back seat the power line to the fuel tank (yellow wire) had come out. I just fixed it (its still lose) & the pipe rounded in the below picture started pouring fuel. I poured about 30ml of fuel in the carb opening & the engine fired. Also this pipe is a bit lose & needs a metal clip I guess.


Old engines have a problem with them called as "Blow By"

"Article from Wikipedia"
Air ventilation[edit]
Main article: crankcase ventilation system
During normal operation, a small amount of unburned fuel and exhaust gases escape around the piston rings and enter the crankcase, referred to as "blow-by".[7] If these gases had no controlled escape mechanism, the gasketed joints would leak (as they "found their own way out"); also, if the gases remained in the crankcase and condensed, the oil would become diluted and chemically degraded over time, decreasing its ability to lubricate. Condensed water would also cause parts of the engine to rust.[8] To counter this, a crankcase ventilation system exists. In all modern vehicles, this consists of a channel to expel the gases out of the crankcase, through an oil-separating baffle, to the PCV valve, into the intake manifold. In a non-turbo engine, the intake manifold is at a lower pressure than the crankcase, providing the suction to keep the ventilation system going. A turbo engine usually has a check valve somewhere in the tubing to avoid pressurizing the crankcase when the turbo produces boost.
If an engine is damaged or enters old age, gaps can form between the cylinder walls and pistons, resulting in larger amounts of blow-by than the crankcase ventilation system can handle. The gaps cause power loss, and ultimately mean that the engine needs to be rebuilt or replaced.[7] Symptoms of excessive blow-by include oil being pushed up into the air filter, out the dipstick,[9] or out the PCV valve. In rare cases of serious piston or ring damage, the oil filter housing's sheet metal can even burst at its seam.

I guess the next big issue is on its way


Also please post a pic of the M800 engine (backside area below intake manifold & closer to the firewall) as I need to connect two coolant hoses, no idea where to fix them.

 

[ramankanythia]

Re: Restoration of Maruti 800 1991 (Tonnes of Pics Uploaded)

i would have posted pics but i m not at home

 

[SankarNarayanan]

Re: Restoration of Maruti 800 1991 (Tonnes of Pics Uploaded)

Hi SS80,

The way you have taken care to restore the 800 simply amazes me. This vehicle known for being responsible for migrating Indians from 2 wheeler into 4 wheeler and i am a fan of M800. My dad owned one for 15 years and it never gave us a problem. Also had good value as we sold it off for 70k. Now i feel we should had kept the vehicle. Hunting for her in second hand market now

Regards,
Sankar

 

[ss80]

Coolant pipe fixed

After searching internet for hours I got tired & started searching for the engine picture of M800 (stock 800) in my hard disk & finally I got a pic which I had uploaded in my other engine rebuild thread. The task was pretty simple, but with no one to confirm if my understanding was right, here is the result. Coolant leak fixed.

Here's the pic that gave me some idea about the coolant pipes


The trouble makers


the plan


Rain playing spoil sport for about 15mins


Disconnect pipe from intake manifold first


Cut the coolant output pipe to the required size


Old & fairly ok pipes


The rerouting done


Fuel line empty


Cut the pipes one end to as flat as possible


Fuel lines in place now


Car dint start so checked & cleaned some electrical points in the engine bay






Cap inside






Cleaned the coil points


still no fuel


checked & cleaned fuel pump wires (a little sand paper helps)




Got new screws for headlamps


new screws in place & ready to take the headlamps


Headlamps fixed


more to come soon...

 

[ss80]

Re: Restoration of Maruti 800 1991 (Tonnes of Pics Uploaded)

SankarNarayanan:
Thank you Sir.

Pics continued:
Removed the chrome sticker lining on bumper & cleaned the dirty gum left behind


In most M800's I have seen a engine ground wire, which is missing in my car


Now water leakage has started in both corners of front windshield so had to put a temporary fix on it by using a transparent gasket maker (kind of glue).









Hoping the rains wont enter car for sometime, also the car is not starting (no furl supply in that pipe I fixed - guess too low on fuel, so I will get some fuel into the tank & then try cranking once again.

 

[Varun560061]

Re: Restoration of Maruti 800 1991 (Tonnes of Pics Uploaded)

I guess the carb 800's have mechanical fuel pumps, the wire which is shown on the above post would be of the fuel guage..

Sorry could not get you the pic's for the coolant pipes.

 

[ss80]

Re: Restoration of Maruti 800 1991 (Tonnes of Pics Uploaded)

Thats ok Varun, no problem. I never knew that the 800 came with mechanical fuel pump! I always assumed that it had electrical fuel pump & that the yellow wire shown was for that. I will try putting some fuel into the tank soon & then check again if the car starts.

Today removed all door pads, plastics cladding etc to see the floor condition & it is a bit disappointing indeed. Pics will explain everything here...

 

[Shantanu.lko]

Re: Restoration of Maruti 800 1991 (Tonnes of Pics Uploaded)

Anand Bhai, Extremely sorry in delay of posting the pic. I hope this is helpful in connecting the coolant pipes.

 

[ramankanythia]

Re: Restoration of Maruti 800 1991 (Tonnes of Pics Uploaded)

Hello anand bhai
rusting is not so bad that this could be disappointing .in fact it is good that a good tinkering work is already done
Suggestion from my side
-if you plan long term business buy welding equipment of your own and start DIY i bet it will cost you very less
-If you want to sell this car you can just do makeup and fill these things with filler and sand for perfect shape ,do paint will solve the purpose. you can get good margin from here for next car

This is my suggestion only
My friend do not invest so much in car (like last one) so that margin may not become too less

 

[ss80]

More pics...

Hello anand bhai
rusting is not so bad that this could be disappointing .in fact it is good that a good tinkering work is already done
Suggestion from my side
-if you plan long term business buy welding equipment of your own and start DIY i bet it will cost you very less
-If you want to sell this car you can just do makeup and fill these things with filler and sand for perfect shape ,do paint will solve the purpose. you can get good margin from here for next car

This is my suggestion only
My friend do not invest so much in car (like last one) so that margin may not become too less

the next pictures are my real concern about the floor & rusting. There is a hole which is kind of sad. Posting more pics of the rusting..

Anand Bhai, Extremely sorry in delay of posting the pic. I hope this is helpful in connecting the coolant pipes.

View attachment 100166

Thanks a lot Shantanu, can you just confirm from one of the pics I have posted above if what I have done is correct?

 

[Varun560061]

Re: Restoration of Maruti 800 1991 (Tonnes of Pics Uploaded)

These are the common rusting points in 800.. not to worry much.
Even bulging of the floor, this might be because it might have hit some hump on the road. My car has the same kind dent / bulge on the floor.

We can get a new piece welded, get the mud cleaned from the running board.

How about anti rust treatment ?