Monday, 25 May 2015

Almost overheat - yet again

So I thought the danger of overheating was over, until last Saturday afternoon returning from work, passing by bukit jalil stadium. There was a big football match, and lots of cars were out carrying flags, so it wasn't surprising there was a massive jam. I noticed my air cond wasn't cold anymore, so I adjusted the temp to be colder. However, there was no improvement at all after a few minutes, that's when I look at the temp gauge and saw that it has touched the middle horizontal mark. I noticed many times before if the temp reaches the halfway mark, the air con will not work. Its like the engine bay is too hot causing the air con unable to expel its own heat.
Having had a problem with the fan relay before, I listened closely and I knew the radiator fan was working, as well as the air con fan, I could feel both of them loading the electrical system. I turned off the air con and the temp did not rise beyond that halfway mark
 Luckily the jam did not last that long after that.
 So I turned back the air con on and it was cool this time, and the engine temp dropped too to above the quarter mark, where its supposed to be, thanks to the cooling air through the engine bay. I dropped by my mechanic and asked him to check if everything is ok, sure enough, both fans were turning on que, so this had to be a problem with the radiator itself. It is after all the radiator that came with the car, so its 24 years old. I remembered changing the hose last year and I felt how corroded the lower inlet stub was. After thinking throughout the night I decided to buy a new radiator and install it on Sunday.
Finding a radiator on Sunday was a challenge by itself, and after a few phone numbers gathered from mudah I found this guy who sold SARD double layer aluminium radiator for RM370. I was kind of desperate so I bought it. about 4 hours later I finished installing the radiator, with some grinding and drilling on one of the mounting brackets as it did not fit a 100%.
The radiator is very lightweight and very shiny.
After I mounted the SARD radiator, before connecting the hoses.
 
So I poured in 3 bottles of battery water, and 1 bottle of Toyota red coolant, of course I flushed the engine block really well and reinstalled the thermostat. So I start the engine, and got it to warm up so that the radiator fan will kick in, so I turned on the air con after the temp reach quarter, to my horror, the air con condenser fan wasn't turning ! I though perhaps I may have disturbed the wires, but couldn't find any problems with the wiring. So I booked an appointment with my mechanic the next day to check out the air con fan. The car ran great with the new radiator and it expels the heat very quickly. I was worried about overcooling but it was unfounded, as the thermostat held the temperature right above quarter, where it should be. In heavy hot jams, when the fan kicks in, the temperature drops back rather quickly and the fan stops again. Definitely an amazing radiator.
 
This is how my old radiator looked like..horrible indeed.



Well, its confirmed that my  condenser fan went kaput, so I bought a new ND fan for RM250 including installation. The pitfalls of owning an old car. However, the last air con fan I replaced was 15 years ago..and I just replaced my old radiator fan 4 months back after it jammed up, so these things do last very long after all.
 

Wednesday, 20 May 2015

Latest updates - a big change

So ,my welded roof was rusting yet again, and there is rust bubbles on my left rear door again, so I must repaint the car. I decided to change the roof to a sunroof since I have to change the roof anyway.
So I booked an appointment with MR Lee in banting, and he welded this 1st gen cefiro sunroof.

at shell near nouvelle hotel

Parked at the office

Top view from the office

side view

top side view

roof after cementing, sanding and painting

Right in front of YAC auto after I bought and installed their 2BS plastic wheel covers.
These are the best looking local wheel covers on the market, all the others and the wira 5 spoke ones are especially ugly.
Still waiting for the Pontiac grand am wheel covers which will look even better.

Still near YAC auto

You still can see the steel rim inside when near. The Pontiac Grand Am ones will cover all.

The cefiro sunroof controls and cabin lights. Its even brighter than the saga cabin lights.

Saturday, 20 December 2014

Are all oils the same ?

In a nutshell no. Here is my story so far.
This 12V saga left the showroom on 31st December 1991. It was the Iswara Meter Sagas, the last of its type.
This car was running 20W-50 mineral with the API standards of those times, from new till 2004. By 1997, clocking 270,000kms, the engine was already burning oil mildly. The plugs were also fouling mildly, cold starts were usually difficult, and would take about 5-7 seconds of cranking..every day !Oils were changed religiously at 5000km, and they were always duckhams Hypergrade, or Castrol GTX, as everyone said this was just a low end car and will require only low end oil. When starting up, the valves and cams would make some grinding noises and would eventually quiet down once warmed up. White smoke would come out of the exhaust only on revs higher than 3000. At those times, everyone believed engine wear was unavoidable, especially after 200,000kms, and is to be expected. By 1999, white smoke was coming out of the exhaust even at idle ! Starting was always a chore as usual, and I would always add oil additives to counter the burning. In late 99, something rather bad happened to this car. After an oil change, and it was with Duckhams Hypergrade 20W-50. The car ran fine and I took it to work. After work, I started the car. I cant remember the specifics, but a colleague of mine called out to me and said engine oil was pouring out from the bottom.

 Upon inspection, I found that the oil filter failed. I had to get the car towed back home, the first time in 7 years of ownership. Thinking it was a bad filter, we claimed a new one from the parts shop, installed a new one, and re filled the oil. My brother went underneath just to check ,and I started the engine, I suddenly heard him screaming at me to stop. He said when I started the engine, the oil filter expanded and gave way at the o rings. We knew we had a serious problem, so we got it towed to a mechanic. He removed the sump, and he found a few short steel chips in the oil filter passage, causing the blockage. I now know that these were wear metals from probably the cylinder block. By this time it was already at 300,000kms. Accepting this as normal and unavoidable signs of engine wear and aging, I went on with this car, maintaining it with the recommended oil, and watching in horror as all the bad signs of an unhealthy engine show up, erratic idling, difficult cold starts, horrible noises, plug fouling, exhaust smoke and soot...I heard about synthetic oils but did not pay much heed to them as they were expensive, and as some one who just started working, I did not have much money.

In 2004, I was earning a better paycheck. I also met a racing gearhead who was also a mechanic, he was meticulous to the point of obsession, so I knew he was the right guy to over haul my engine. August 2004, I let him remove the engine . What he found was bad news all the way. The crankshaft,pistons, piston rings, camshaft, valves, cylinder bore,oil pump, water pump, all were basically in very bad shape. All those had to be replaced. So I gave him the go ahead, and he remachined the cylinder bores as they had ovalized. He put in new bearings,con rods, pistons, rings, oil pump, water pump, camshaft, crankshaft, valves etc..and told me to put only synthetic oils if I wanted it to last. So I boutght 2 bottles of 4L Duckhams QS 5W-40 Synthetic. Of course I ran mineral 20W-50 for 1000km then switched to the synthetic. Well since the engine was like new,everything worked great. No horrible sounds, no smoking, no burning oil, starts were easy(cranks only takes 1 second, even now in 2014), power was there. So OCI after OCI I kept with synthetics, just to see if this was true. I ran the car pretty hard some times , and still the engine sounded and worked really good. I drove up to genting highlands, which is a mountain resort, which has a windy steep road to climb for about 10kms. I drove my car up there 4 times,in the span of 9 years since 2004. Still the engine did not burn any oil, and sounded good. Even the plugs looked good everytime i checked them. They always have brownish deposits and they are dry, all 4 plugs. So far I have clocked 120,000kms.And I hope to clock up to 370,000km, and see if the engine will go as bad as it did on mineral.
 As comparison, my colleague who uses the same car (LMST) and same engine, his car left the factory in 2006, and clocked about 120,000kms also, but his is on a steady diet of Shell Helix HX-3 20W-50. He has varnish all over his cams and valve rockers, but look at my valve rockers !
This is how my valves look like in December 2013, I have never took it apart since overhaul in September 2004. Before overhaul my valves had sludge, and my plugs were fouled with oil









 

He changes oil every 5000km, which is 3000 miles, and yet, his engine does not look as clean as mine, nor sound even remotely as good as mine. Keep in mind the HX-3 is a SJ certified mineral, so it was better than whatever was available from 92-2000. Yet he has varnish in his engine, and may even have some slight sludging issues.
Remember, my car is carb operated and not with EFI, so in theory this should contribute to more deposits, yet I do not see any on my rockers and camshaft.
I am not against mineral oil, if it can keep my engine working as long as it possibly can, but if synthetics can help my engine to retain it peak operation 2 or 3 times longer than dino, then that is what I want.
5W-40 synthetics are not too thin as people always say, and I have proven it. Heck, Shell Helix Ultra 5W-40 performs better than magnatec 10W-40 semi syn. Just stay away from 0W oils , I tried Castrol Edge 0W-40 from Tesco and it made my valves noisy at operating temps. For the first time , I did an oil analysis that costs me 35 USD in april 2014. It confirmed that the Tesco sold Castrol oil was not fake.
The result was pretty good as it shows the oil still has  a lot of additives left, as shown by the TBN at 5.7. Also there were no water or fuel in the oil, which shows the engine sealing is very good.
 
As of 19th april 2014, I filled with AMSOIL fully synthetic 10W-40, which has high zinc and zddp, its been a little more than 9000km and the engine still sounds damn good. AMSOIL guarantee this oil up to 15000 miles, but I intend to change at 15000km or May 2015, and will send this sample to Blackstone for analysis. At 9000km, this amsoil seem to have lost 1/4 quart, and I topped up with whatever is left in the bottle. So far I find Castrol magnatec to be the worst, losing one quart every 3000km.
 
So this is the list of oils I used since overhaul
1. Shell Helix Ultra 5W-40 Syn (about 8 OCI)
2. Castrol magnatec 10W-40 semi syn (2 OCI)
4. Duckhams QS 5W-40 Syn (2 OCI)
3. BHP Syngard 8000 Syn (1 OCI)
4. Mobil 1 5W-50 Syn (1 OCI)
5. Castol Edge OW-40 Syn 6278kms
6. Amsoil AMO 10W-40
 

Why start this blog ?

I own a 12V saga , and I have been pretty anal retentive about taking care of it since I got it overhauled in late 2004. I owned this car back in 1997, when I my dad bought it used. He had a orion Saga 1.3 in 1986 that he sold in 89, because no one could drive it, and he was overseas.
I have been through hell and back with this car, it has stayed by me through the ups and downs in my life, over the years I have learnt a lot about this car. I see a lot of people asking questions on forums about problems and advise about this model, and it saddens me when I see misinformation spread by people who think they know best. I don't claim to know best, but I can say my observations and experiments works, as my car runs like new, at least engine wise, as of today, nearing the end of 2014.
I will be posting all my experiences on this blog. Stay tuned.
Here are pics of my car.