[silverstreakcbe]

Now I understand, the sense of satisfaction, happiness and pride, of all the fellow Team-BHPians who have worked on their car themselves and were able to fix the issues. Whatever i did was a small fix but the happiness that i got after cranking my vehicle to start was extraordinary.

A little bit of history, i brought my Nano LX Sunshine yellow in 2011 January. During Dec-2011, i drove it from Coimbatore to Trichy to meet my parents. On the day of return, the car did not start. After trying everything, it did not budge and since it was relatively new car, the ASS promptly came to check. Since we brought it from VST, Trichy, they showed some accountability. After checking for a while, they said the Fuel Pump was faulty and will be replaced without any cost. Thankfully, the part was available and they replaced it the same day and i returned to Coimbatore for my journey aboard.

Back to 2020, I had asked my dad to crank the car at least once every 2 days to keep the battery alive and also engine running. For some reasons, he could not do it and he left it in his parking for many months. My dad informed me that our Tata Nano was not starting. When i came back to Coimbatore, I tried cranking but would not start. After charging the battery and some self inspection, we concluded that there was some issue with the fuel pump.

Called the Tata Mobile ASS and they were very prompt in arriving and assessing the issue. They did not even charge me saying they will collect it when they come for part replacement. They confirmed that the Fuel pump was faulty and had to be replaced and that they did not have in stock and on paying 50% amount as advance, they will order one. I paid the 50% and waited. after 3 weeks, they called back and said the part has arrived and will come and replace. I was happy that they called and came to replace. They replaced the part and the car successfully started back once again.

I decided not to keep the vehicle at my dad's house just in case if he failed again to start the engine. I took it to my home and since we had place only for one car in portico, i had to keep it inside my go-down in the basement. I used to follow diligently to start the car once every 2/3 days, run it for 5-10 minutes, check all the levels and instruments working and then switch off. Since my godown is elevated from ground, it was hard for me to take it for a spin every time. But I was happy to be able to keep the engine running.

Due to some official work, I had to leave for a week out of station. After returning back, I tried cranking and the vehicle started. But due to some reason, on the second try the next day, it did not. How much every I tried, it did not start and it was evident that there was no sound coming from Fuel pump. So, once again I went on to the same cycle of checking the battery. But only this time, the battery was bust. The battery mechanic said, the Battery is dead and cannot be charged. Thinking it might be the issue, I brought a new one and replaced it. To my utter disgust, the battery was not the issue, it was the fuel Pump once again.

Again called the Tata Mobile ASS, they arrived and checked everything once again. This time they even changed the fuse, starter motor relay. It did not budge. Once again, the same story of fuel pump had to be replaced. I told then I will call once i get a replacement and then can be replaced. That's all, I lost interest.

Now in 2022, I was very sad whenever I looked at my Nano in the shape it was in the godown. I badly wanted it to start running. There was already service due for other vehicles. I did it one by one and then came to my Nano. But only this time, I decided to do it myself. After some reading from fellow Team-BHPians experience and Youtube videos, decided I will fix my car's fuel pump rather replacing the entire assembly. I got to know that the Fuel Pump motor is the main source of problem. After some googling and check on boodmo, I came to know that the Motor comes along with filter as well. So, I decided to buy and replace and then try to revive my Nano.

Since I had a long weekend on 13,14 and 15 of August, I decided it would be the right time to do it. On 12th, I woke up, finished my morning tea and went straight to godown. First thing was to remove the Battery and give it for charging as I knew since it was replaced as a new unit. After some painful effort and some time, removed the battery and gave it for charging. The battery guy suggested that it will be ready only the next day. I agreed and planned to procure the parts required by the time and keep it ready.


Old fuel Motor


Old Fuel filter


Assembly unit


On 13th, i went and collected the Battery and with some curiosity, tried my luck in cranking, but no. Did not even budge. But the Good thing was, I knew all other instruments were working. Next, was to remove the Fuel pump assembly and take out the motor for buying a new one. This was very painful. The position of the fuel pump was very odd and I had to fight hard to get it out. After spending some 45 mins, I was able to take out the assembly. Now came the task of removing the motor. Since I also had the very first fuel pump replaced in 2011, was to play around and understand how to remove the motor from the assembly. After spending some 15-20 minutes, was able to remove it and understand the wiring to be put back.

Went and brought the Motor and filter combo. It costed me around 800rs. While returning, went to a electronic shop to get the wire soldered. Spent 25rs for the soldering. Also, brought petrol for 300rs in case if needed to replace. Now, all set for putting it back together. When i checked the fuel tank, it was horrible. The fuel was corroded and with some bad odour coming and also lots of dirt pieced inside. I decided to clean the fuel tank and used the old way of doing it using cloth. Put it in, soak petrol and squeeze it out onto a container. I spend some good one hour to clean all the fuel and also the tank to some extent. after convincing myself that it was ok to put it back, i assembled the fuel pump motor, with some effort the fuel filter on top and locked it in. Then placed the fuel pump back to place.

Fuel tank emptied & cleaned


Old & New fuel pump motor & filter combo


After soldering the wires


Putting all together


Only problem was, i could not put the circular metal bracket that comes with the fuel pump. The screws on the fuel tank did not align to the bracket that was there. So, i had to skip the bracket installation and directly put the fuel pump to the screws as it was earlier done by the ASS. After fixing it and then pouring the new fuel to the tank, time for truth.

As soon as I turned the keys on, I could hear the fuel pump motor run as it used to do earlier. Convinced that it will work, I cranked it, with one go, the engine came back to life on my first crank. I was happiest man at the moment. Excited to see my Nano back to life, i was happy to hear the engine roar again but only to be short-lived. The engine stopped after 5 minutes of running. I tried again, it started but stopped after 2 minutes.

Thinking the Fuel might have run out, I went and brought another 500rs of fuel and poured in. This time also, it started and ran for 2 minutes and stopped. Then I thought to check if fluid levels, opened the engine lid, checked the oil level, Coolant level, and also the radiator level. All were fine. I had a doubt on the radiator, so poured enough water to bring it to the brim. After closing the lids, tried again and it started. This time, put it on gears and tried to move, it was struggling. I tried to keep the throttle raised so that at least I can bring it out from the godown. I put it on reverse and brought it out to some 3 feet, the engine went silent. This time, there was not indicator on ignition as well. Thinking something went really bad, I guessed it was due to battery loose fitting. I did not screw it all since just trying to revive. After putting the battery cables in place, tried, it started back to life.

This time, there was no struggling, the engine was running without any hitches. I was able to bring it out from godown and then put to forward gear and take it out for a spin. But since it was idle for more and a year, one of the tyre was flat. I had to replace with the spare, but that was also down. So, went and got it filled up and then again replaced it. This time, started, it happily started and I took it for a spin. I drove for some 5-7 kms, got all four tyre pressure checked. My Nano was running as smooth as ever, the gears shifted like butter. I enjoyed the feeling. Then came and parked it near my home. First thing I wanted to do was to give it a nice wash, then discuss with my mechanic and do a complete service.

Since my wife also had a connection with our first car, she was also very much joyful to see it back to life. We both washed it and cleaned it and the Sunshine was once again glowing (only from outside). Then we decided to go for a short ride for evening and visit temple. By the time i got refreshed and ready, it was already late, so we decided to go to temple the next day and for the evening just do a small ride. My daughter also was happy to join. I informed up front that there was no AC and only natural air. They all agreed happily and we set out. Visited some eateries and has some chat items and came back. All this time, Nano was running absolutely fine.

Sunshine Yellow, shining





I was very happy and satisfied person to see my Nano back on road. The next day, we got ready and took our Nano to nearby temple and did some customary rituals as it was once again back to road and this time we want it always to be. We drove for some 20-25 kms and came back to home. After checking with my mechanic, went and left the vehicle for service. Below are the fixes had asked to be done:

1. Tighten fuel pump screws along with the metal bracket
2. Tighten and place the battery in its holder and bracket.
3. Engine Oil/Filter
4. Coolant oil
5. Gear oil
6. Breaks
7. Replace wiper blade (completely torn)
8. Put all screws in place for the engine lid.
9. Few other minor fixes

This much happy story for now folks, once Nano is back, i am planning to do the below additions:

1. Replace new carpet
2. Steering wheel cover
3. New foot rest
4. New Seat covers
5. New Sun visor
6. New Rear parcel tray (broke off in 2011 due to those dumb people in service)
7. New speakers for the audio set

Now I understand the kind of happiness it is for some who fix their own cars and see it working. Thanks to all Team-BHPians experts who helped me with their knowledge and advice. I will share the update once i get my car from service. Till then, bye for now.

Regards,

Raaghav K S

[Aditya]

It is indeed very satisfying to mend something and bring it back in shape, no matter how small the fix is.

The Nano is a legend and glad to see you not giving up on it. Fuel pumps can be a real pain in the neck. Good that you had the long weekedn at your disposal.

Your thread will help many other who would like to perform such repairs. It's very detailed. Good to see you not getting too ambitious when it comes to future additions in the car.

[HappyWheels]

That is one beautiful yellow bug!

Yes, working on your own car, does give a lot of joy.

Also, good to see another Trichy T-BHPian.

Whilst changing the fluids, recommend you change the diff oil as well. Seems to be the only one missed out and something that many often do.

[SnS_12]

Do you think the condition of the fuel tank/fuel (rust/dirt) was contributing to the fuel pump going kaput on multiple occasions? Maybe you should consider replacing or getting it coated internally considering the age of the car.

[mark4nano]

It was a wonderful read and also a motivating one. Glad you decided to not lose hope and revived the car successfully.
It is certainly a heart warming moment when you see your first car full of life.
Even my first car is a Tata Nano and since I am not in the country and i have asked my parents to start the car at least 2 or 3 times a week. Planning to do couple of updates in the car when i will be visiting India next time.

[Revvman]

Excellent DIY update and icing was your perseverance in spite of the frequent stutters. It must would've felt extremely satisfying to see the car back in it's full glory

If not exactly for the same model, your update will definitely help a lot of us in making the effort with our vehicles.

I think I'll take the covers off my 2002 Pulsar 180 for it's annual maintenance and get it whirring again now

[W16rocks]

This thread Really made my day man, I was having a really boring day, but seeing your Indian beetle come to life made my day.

Really happy to see people still have this kind of connection with their cars, a quality only visible on this forum.

Wishing you many more happy memories with the yellow bug…..

Cheers
W16rocks

[ASHUJNMC]

Your post made me nostalgic. I guess first car is a bit like first love. You will always remember it.
I had 2011 LX Nano in Champaign gold colour(My first car). Drove it for 5 years on broken Kerala, Bangalore, and Kolar roads.It was finally sold after I upgraded to Tata Zest. Parked for long after zest arrived, it developed issues like brake booster went bad, and some broken parts due to abuse in horrible Bangalore roads. Had to spend 12k to get it fixed. Other than that, no major issues. I guess Nano doesn't do well if parked for long.
Tata always honoured it's obligations on warranty and Gold/silver AMC.
Overall I was satisfied with the Nano. It was a small beautiful car (I know looks are subjective) with Surprising amount of space inside, and even crazier turning radius

P.S. Once thay had to down flash the ECU in 2013 because of a very specific issues after ECU update it used to hiccup at 30 kmph speed in 3rd gear. Basically engine used to shut down for 0.6 second at that perticular combination of speed and gear Only. I had to bug the RF motors Kochi for 1.5 months into finally the acknowledging the issue and someone from Pune plant had to come and down flash the ECU (apparently local guys are not allowed to down flash) and problem went away for good.

[roadrunner_nv]

Such a brilliant package sadly non-existent now due to public perception of a cheap car. I had a yellow bug myself and sold it since I wasn’t driving it anymore. I kick myself regularly for letting the bug go. In today’s mess of Pune traffic and roads, it is the right answer. It has the swag that none of the other four cars in my garage have..

[silverstreakcbe]

Originally Posted by roadrunner_nv

Such a brilliant package sadly non-existent now due to public perception of a cheap car. I had a yellow bug myself and sold it since I wasn’t driving it anymore. I kick myself regularly for letting the bug go. In today’s mess of Pune traffic and roads, it is the right answer. It has the swag that none of the other four cars in my garage have..

Yes, what you said is very true, excellent package. It has run 49K with Zero Breakdown and Zero Puncture. I have driven CBE-MAS (2 Times), CBE-TRY (N-times), CBE-BLR (2 Times) all non stop. Never I had a feeling that it will break down. Its only perception that let this car down, not the build or quality. Even today my parent feel its very comfortable to get into Nano than my i10

We are also planning in similar lines, to use our sunshine for Local rides and exchange my Grande i10 for a bigger one for long journeys.

Originally Posted by SnS_12

Do you think the condition of the fuel tank/fuel (rust/dirt) was contributing to the fuel pump going kaput on multiple occasions? Maybe you should consider replacing or getting it coated internally considering the age of the car.

Yes, I am planning that as well after some time. As of today (22-08-2022), All technical services completed, Interior change completed. I have just two remaining, Horn and Audio setup. Once done, I will plan in next service what you have suggested. Thanks for the suggestion.

Originally Posted by HappyWheels

That is one beautiful yellow bug!

Yes, working on your own car, does give a lot of joy.

Also, good to see another Trichy T-BHPian.

Whilst changing the fluids, recommend you change the diff oil as well. Seems to be the only one missed out and something that many often do.

Yes, I have changed Engine Oil, Gear Oil, Coolant oil. Rear brake pads replaced as it came off. Out of all the list that I had published, except Stereo setup, all others are completed. Will share once done. Thanks for your suggestion.


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[silverstreakcbe]

Hello Folks, Good to be back with updates. So here are the updates:

1. Task-1: All Engine services completed.
2. Task-2: AC Checked and Serviced.
3. Task-3: Floor Mat & Seat cover replaced.
4. Task-4: Stereo speaker connected (I did it myself for fear of floor mat and seats getting damaged)
5. Last but not least: A short trip with wifey to bring some old memories.

I will let the pictures speak

Fixing the AC - Since it was parked for long, we had to check for leakage and then get the AC serviced and Gas filled up. Now its back to its original cooling.

AC Service





Next was one of the time taking tasks. Removing existing floor mats, cleaning and then new floor mats. Finally new seat covers.

Floor Mat & Seat Covers






Since the stock rear parcel tray was broken log ago. I had to get one new which i did by ordering in boodmo and fixing it myself.

Rear parcel tray



Now, with the car back to its shiny stage, i was fearing what if stereo fix would damage the floor mats or the new seat covers. So, i decided to do it myself. But i did not have typical car speakers. I checked my garage room and found two 3-way stereo boxes that i had purchased very very long back. I decided to use it instead of buying new speakers which would add me costs of making the box, wooden frame and fitment which needed outside assistance.

Stereo speakers installation

Checking the connection and if speakers are working


Placing in its respective places


Wires neatly tucked in


Finally, the outcome









Just like old times, a short trip to Anaikatti and back. The Rain god showered our Nano with best wishes and lots of miles ahead.





Cheers!!