Auto Rickshaw Overhaul Process Revealed

A comparison between the old and new shock absorbers revealed a height difference of about 1 inch, clearly indicating performance degradation due to wear and tear.

After installing new shock absorbers, the vehicle's height was restored, and shaking during driving significantly improved.

The mechanic pointed out the loss of function, citing the lower height of the shock absorbers and the unsealed capping.

A significant amount of carbon deposits was found in the engine oil, indicating the need for replacement.

While the engine oil condition is good, the high amount of carbon deposits suggests that timely oil replacement can prevent future problems.

The replacement was carried out using Piaggio PX engine oil to help maintain engine performance.

An engine oil level check revealed significantly low levels, indicating serious oil consumption.

Extensive oil contamination and leakage traces were found around the engine, necessitating overall maintenance.

The severe engine oil consumption and leakage require further precise inspection.

This excessive oil consumption was recognized as a serious problem directly linked to reduced engine performance.

During cylinder head disassembly, a cam follower was found detached from its normal position and fallen downwards.

Md Zakir, the mechanic, stated, "The cam follower has fallen down. To check this, we need to lower the engine," deciding to remove the entire engine from the vehicle body.

Such detachment can critically affect engine operation, so the entire engine interior, including the cam and cam followers, will be inspected.

The cam follower was found separated inside the oil chamber, along with severe damage to the locking component.

Md Zakir, the mechanic, confirmed the broken cam follower, checked the oil condition in the chamber, and decided to replace the part.

Despite repeated clutch adjustments, play continuously reoccurred and loosened.

Unstable jerking (Uchalna) symptoms were observed during driving, identified as a problem directly impacting driving safety.

To resolve the issue of clutch loosening and sudden lurching despite adjustments, the lower engine's clutch system is planned for disassembly.

It was identified that engine oil and gear oil not mixing properly led to the clutch becoming excessively dry, causing noise and clutch operation issues.

Md Zakir, the mechanic, prescribed soaking the clutch plates in oil for 15 minutes to fully saturate them before reassembling to resolve the problem.

Additionally, the wear status of the clutch pusher was checked, and bolts were replaced if necessary to enhance maintenance efficiency.

These measures improve clutch lubrication, reduce noise, and ensure normal operation.

Common rail nozzle cleaning and pressure testing were performed.

The current maximum nozzle pressure was measured at 160 bar, and Md Zakir, the mechanic, announced, "The current maximum nozzle pressure is 160 bar. Now I will open the nozzle to check its condition in detail," indicating a precise inspection of the nozzle's internal condition.

The process of seating the engine timing pin in the correct position was carried out.

Tiny, visually hard-to-see markings were made with a pen to enable precise timing adjustment.

Md Zakir Auto, the mechanic, placed two mother-of-pearl markers at designated positions for accurate timing alignment.

Such precise timing adjustment directly affects the engine's normal output and efficient combustion.

Immediately after the engine overhaul, once the air was bled from the fuel line, the engine started instantly with one step, unlike the previous 4-5 attempts, confirming stable sound and normal operation.

Unlike before, when 4-5 attempts were needed to start, it now exhibited improved performance, starting immediately in one try.

Md Zakir Auto, the mechanic, confirmed the stable start and sound of the repaired engine, stating, "ये देख सकते है पूरा बढ़िया व्हीकल से गाड़ी स्टार्ट हो चुका है" (You can see the vehicle has started perfectly).

This signifies the result of a successful engine overhaul, meaning the vehicle's overall performance has significantly improved.

It was pointed out that improper application of gasket sealant risks blocking engine oil or gas passages.

Care must be taken not to apply sealant into screw holes.

This is essential for maintaining smooth oil circulation and efficient gas expulsion within the engine, preventing overheating, and ensuring long-term performance.

The work involved manually rotating the pulley to check if the tappet clearance was appropriate.

If the tappet clearance is too tight, problems will occur, so the pulley must be rotated to ensure proper clearance.

After service, the engine is started to listen to the sound, making a final judgment on the tappet's normal operation.

Such precise adjustment contributes to efficient engine operation and extended lifespan.

To inspect the fuel and oil supply lines, the No. 10 nut was loosened to check the internal condition.

The No. 10 nut was carefully loosened to avoid damaging the threads, and the air pump was operated to check the oil supply status.

Upon checking the air filter's contamination status, it was found to be severely dirty, necessitating replacement.

If the air filter is faulty and air flow is blocked, vehicle output will decrease, so the filter's condition is checked first.

After installing a new air filter, changes in vehicle performance will be tested to confirm improvement.

Vehicle shaking occurred during driving, leading to an inspection of the front wheel's play.

Excessive grease was leaking from the front wheel hub, indicating a need to check the internal lubrication status.

Md Zakir, the mechanic, diagnosed, "We need to check the wheel's play. A lot of grease is leaking out of the hub. All the grease inside the bearing has dried up," indicating poor lubrication due to depleted bearing grease.

Such bearing problems are directly related to driving stability, so prompt maintenance is required.

After cleaning the contaminated bearings, new oil seals were installed to prevent leakage.

Md Zakir, the mechanic, stated, "I will install new oil seals and refill the bearings with grease to complete the maintenance," and then injected new grease for lubrication and tightened the hub lock nut to finalize the repair.