Bought My First Car - Maruti 800 AC

[Varun560061]

OH God..

Hmmm, i20's dash combination on 800 ! Super.

Post some more pic's of the wiring kit.

I can see the paint on the fire wall has become dull, even I can find rusting too.
Before you could put the wiring why not paint it ?

For the screws just cut them off, we can remove them easily later.

 

[ss80]

Some more pictures of DIY - rewiring car

The above picture is for a simple mod I have planned for near future not sure what exactly it will be.




Brake pedals removed to do the wiring, these are the four nuts I was mentioning that have to removed.


Me at work for hours together




Dirt behind tail lamps


Bumpers removed


Mess at work




One big mess to clean at the end of the day




Rear photos


I missed to upload this picture about the fuses that come with the fuse box

 

[karthiksooji]

Hi ss80,

doing loads of work,

Varun: I am unable to remove those screws holding the front mud flaps to the fenders. They are rusted to the core, tried everything, spoilt a couple of screw drivers, finally gave up.

Have you tried a light hammering to the bolts holding a screwdriver to it.
it might work.

 

[Rao66]

Hi,
Impressive job indeed.

 

[Rao66]

Hi,
Hats off to you.! I just cant believe that you are doing the repair work alone. Varun confirmed it also. I should appreciate your hard work, and more over the confidence you are having. I am sure that the satisfaction you will get is unparalleled. All the bet.
Regards.

 

[ss80]

+1 to that. Your efforts are seriously commendable. Do you plan to completely refurbish the car from inside out?

Drive Safe,
350Z

Thanks a lot. Yes I am planning for complete refurbishing the car from inside.
The exterior part I cant touch it as I have Vitamin M deficiency

OH God..

Hmmm, i20's dash combination on 800 ! Super.

Post some more pic's of the wiring kit.

I can see the paint on the fire wall has become dull, even I can find rusting too.
Before you could put the wiring why not paint it ?

For the screws just cut them off, we can remove them easily later.

I think the colour I have purchased might be slightly darker than the i20 dashboard brown colour. Yes the firewall paint is dull, will have to sand & remove it & then usual painting process. I cant paint it now as I am yet to complete wiring. The compressors available for rent near my home do not work on single phase wiring it seems, so will have to make the car mobile first then take it to some safe, open place where I can use that compressor or just hand it over to a good painter.

I will surely pull out the tail wiring, blower unit, steering wheel, brake pedals etc before painting it. I will cut the screw may be by tomorrow.

Hi ss80,

doing loads of work,
Have you tried a light hammering to the bolts holding a screwdriver to it.
it might work.

Thanks Karthik,
Yeah I tried hammering but it is of no use, it is the worst of rusted screws I have ever seen and the hammering sound makes me somewhat worried about the car so will prefer cutting the screws.

Hi,
Hats off to you.! I just cant believe that you are doing the repair work alone. Varun confirmed it also. I should appreciate your hard work, and more over the confidence you are having. I am sure that the satisfaction you will get is unparalleled. All the bet.
Regards.

Thanks again, the joy of working on my car is unlike anything else for me. Lack of tools & space is slowing me down a bit. But I am sure this will get completed soon.

Today the engine bay wiring is almost done, burnt up my finger once as I had wrongly connected the wiring to the ignition coil. Yesterday the car was just cranking & switching off. Today it cranks, starts, idles but I guess I have very little fuel so it is switching off. All lights on the meter console work.

Somehow everytime I switch on the headlight the right indicator arrow on the meter starts to glow (not flashing just glowing). May be if I connect all wiring it should solve the issue. The exhaust pipe is completely rusted at the end (starting from end can output to the rear bumper) a replacement part is coming soon for the same. I have to purchase some more smaller components like the Coolant tank pipe, 55/60 Philips headlamp bulbs, Fender indicator cover glass, tail lamps etc.

Sunday I spent over 7 hours & could not hear the crank at the end of the day. Fully frustrated could not sleep. Yesterday I heard the crank in just 2hours so I am really happy now not just from the crank but also from the immense support & response from TAI.

 

[ss80]

M800 Wiring Harness renewed - YouTube

Here is a small Video of my car rewiring in progress along with the close up of carburetor. I will avoid taking Videos at night from now on

 

[Varun560061]

Nice video, thanks too.

But why is the butterfly valve always open, I guess its the issue which is causing the car not to breath properly !

 

[ss80]

Varun can you post a picture or Video of the actual position/ functioning of the butterfly valve.

 

[Varun560061]

I can post mine, but it would be completely different.

I would request jarpickle to post a pic. And also other members who have a carb 800.

 

[ss80]

Some more parts for my car

Thanks Sree hari,

Here we go a couple of more parts purchased. Here are the pictures









Bought a new high tension chord, but it doesnot fit on the distributor. Will have to exchange it tomorrow.

 

[Rao66]

Great thread...!I really excited.

 

[adil3996]

Re: Some more parts for my car

hi ss80 i am amazed to see ur interest towards your vehicle... one thing i want to ask you that from where did U bought that LUMAX Original Headlights?? is it available in company?? and one more thing do you have the Original Service Manuel or a copy of this model M-800

 

[jarpickle]

If it sounds like a two stroke bike when you use the choke cable or accelerator to increase the rpm its normal.Put the airfilter on and check.

If it still misfires check your distributor cables.Check the engine timing.Check the output from the cables are they all supplying enough voltage to the spark plugs.

The secondary butterfly is controlled by the depression chamber, this chamber will have a pipe(rubber pipe)Check to see if there are any debris stuck there.While keeping the primary open halfway,suck air from the boost pipe that connects to the depression chamber(pull out the pipe from carb side and suck air out of it) this will cause the secondary to open.If it does not or it struggles you may need to change the diaphragm in the depression chamber.Have attached a pic of the depression chamber.

The secondary opens only when the primary opens appx 80% you need to be doing in the range on 80-90kmph for the secondary to open.

For the coolant issue, check you radiator cap and waterpump.Is it functioning properly?Remove your radiator cap start the engine and let it idle.See if the coolant is circulating or just flowing out.If there are lots of bubbles shut the engine down and check the engine oil color.If its black-ok,same color as new oil-ok.If its white you have a problem with your head gasket.It must not have been installed properly.Change the head gasket and the problem will be solved.

 

[ss80]

Source of Lumax lights & thanks

Great thread...!I really excited.

Thank you so much

hi ss80 i am amazed to see ur interest towards your vehicle... one thing i want to ask you that from where did U bought that LUMAX Original Headlights?? ......

I bought the LUMAX Headlamps from J.K.Automobiles, Bangalore
This is his contact details, you can speak to the owner Mr.Satish - he can help you out even in couriering the item to your city if you make advance payment.


This is the shop where I usually purchase all spare parts for my car, the owner is well versed to most of the cars & their spares. He still has a Rx-100 stock condition with the OEM 6V Battery!

I have a service manual (pdf) file of M800 MPFi. Although it has a lot of information, usually i dont refer to it. A

If it sounds like a two stroke bike when you use the choke cable or accelerator to increase the rpm its normal.Put the airfilter on and check.

If it still misfires check your distributor cables.Check the engine timing.Check the output from t.............

Thanks Jarpickle, will do those steps by tomorrow and will update here. What is the average life of a carburetor? because mine is pretty old.


This is the place that Varun suggested me & I bought the paint & primer for the floor & dashboard from here. It is Mysore Road, easily to locate.