While I was on the way back to Bangalore from Shimoga, with 210 kms left, my NE started developing some problems. There was a small hissing sound that was present right from the beginning of the trip. I had ignored it. Suddenly, between Tarikere and Kadur, the engine started to make a lot of noise and the power and speed considerably dropped (about 60% drop). I thought that the issue was of the hissing sound has now become big and causing trouble. Just when I thought I should visit a mechanic, magically, there was one just there.
The mechanics checked the spark plugs and thought one of them were bad. They replaced it, nothing changed. They then cleaned the points and checked. Still no luck. He then called the owner of the garage. Seemed expericed enough. He said that the sound we were hearing was some connecting sound and at a minimum, the head needs to be removed and checked. One of the cylinders was failing to function is what he said. I wasnt sure how to go about. Since I hadnt even tried to drive with this issue, I wasnt even sure if it will sustain 210 kms of driving/slow driving. The sound surely told, its not worth trying to drive it home. I thought of towing options, looked difficult (last 30 kms of the drive is too huge traffic coupled with very bad roads and diversions) and also would be expensive. Getting the car back to Bangalore was one option, again expensive as you need to pay to and fro charges. My only concern about getting it repaired was parts. In case there is a need for parts, except Bangalore, there is no other place for it.
I then told him that I will just drive for a couple of kms and see how the car does and I will then evaluate if I can drive her home. Just about time of leaving, he told they could check some wall head and wouldnt take much time. They then removed the head cover. They then removed the horizontal bar like thing at the top that holds the 8 tappets. As soon as one of the bolts were out, the mechanic told that the bolt was smudged at 2 sides and probably the last mechanic who worked on the head hammered them in (I was shocked in disbelief
). He removed the remaining 3 and were in the same state. 3 other bigger bolts too were in the same state. At this point, I was not really sure if that was the root cause of the problem. Only thing that came into my mind was how was it running all this while? I have never had any work done on the head (not even removed the head cover). I myself have driven it for 10000 kms with no issues till date. he said the solution was to over size all the 7 screws and put them back. I wasnt really beliveing in what he said, and thought he is taking me for a ride. I dint really have any option and just took the chance and asked him to start the repair immediately. He then used a driller to make the holes bigger on the horizontal bar like thing. He found appropriate bigger nuts. He washed the bar and the head area with petrol and put the bar back. He then adjusted the tappets. Boom! Everything started working like before.
Apart from oversizing the screws, he only set the tappets. I dont know if oversizing and putting the right bolts fixed it or just setting the tappets fixed it. Anyways, I drove back all the way to Bangalore just fine.
Please do comment with your views. Since, I wasnt really believeing that this mechanic would fix it, I did not take much pics (just 2 pics using my mobile). I hope the pics are clear enough.