Power Steering Rack Overhauled

Hi all.

Another regular service was done last week. Plus, the power steering rack overhauled. It has been leaking for months. Started off with minor leaks where fluid decreases over weeks. Leaks are obvious on the under-engine anti splash pan. And the ATF level from power steering fluid reservoir dropped. As the car seldomly being used nowadays, we just topped-up the fluid before making any trip. However, it has come to the time to get it fixed; leakage rate was high. Went and see the same mechanic for last 'Major Service' in Sea Park, PJ. Oh, I think he is the one, the mechanic that I am looking for for years; a replica of our late mechanic. He really know his subject.

Sorry for not having any repair pictures here. The mechanic detached the two hoses from power steering pump, detached both RHS & LHS tie-rod end, and took down the whole steering rack. The rack were dismantled into parts; and being washed (using sort of turpentine/degreaser) thouroughly and dried off (very important to really dry it off!). Ordered a power steering overhaul kit which consists off oil seals, o-rings, and copper washers, all of them changed. The job was done very thoroughly to avoid any water or air seepage into the hydraulic system. It must be well airtightened to avoid air bubbles contained in the system.
After replacing all seals and o-rings, the rack then be re-assembled and re-attached to the car. Good mechanic will practice this; clean up everything before re-assemble; clean up the oily anti-splash pan, bolts & nuts, the steering rack holder, as well as its' oily surrounding. Why cleaning up is very important? This is because, within a clean and clear area, even a slow leaks could be immediately detected! This is why engine bay cleanliness is very important!

Got the engine oil changed as well. The car had travelled less than even 3000km since the last engine oil change somewhere on June. However, I stick to the maintenance chart; using semi-synthetic oil, engine oil must be changed every 10,000km or 6 months whichever comes first. I continue using the Petronas Synthium 800 Semi-Synthetic engine oil.


This mechanic really applies what he did before in Federal Auto I guess (FA is Volvo Appointed Sales & Service company in Malaysia); he raised-up the car, using a torch light, looking at all brake lines, brake pads, bushings, and overall undercarriage inspection. He also did air filter cleaning, check battery water level, coolant level, windshield washer level. He did used an 'original Volvo oil filter', changed the drain plug washer, as well as engine oil cap rubber. Complete!

Overall, now the car is in 'good running condition' again! Good day all :)

A Drive To Remember, 240GLT!

Hi guys. It has been a while since I last 'seriously' blogging about 240. Let me share something on my recent driving experience of another 240. I was on a trip for 3 days last week where I got a privileged to drive a 240GLT with B230E engine for the whole 3 days. Thanks to the owner, En Zahrin who kindly lend me the car during my stay there.


For the benefit of all, 240GLT in Malaysia is a non-turbo model. This models was named with GLT to be 'sport' model of 240. This model equipped with full accessories such as electric side mirror, all sort of gauges (engine oil pressure, fuel consumption, voltmeter), and I beleive some differences on the interior color (offered for Malaysia market that time). This has been always a misconception that GLT stands for Turbo, while that is not the case for Malaysian market. The engine remain the same, the B230E for either 240GL, GLT, SE, or even SE Classic.

the engine oil gauge is not working, wire detached from sensor...

Generally the car is well-kept. The body looks nice even with minor rust here and there (which is reasonable of its' age & location near sea shore). A body repainting or touch-up will do. However, on the first start and drive, I notice some lacking. The idling rpm was too low that the engine trumbles quite hard (the steering & dashboard also vibrates). I do not noticed this on my 240. After a day drive, I noticed this low rpm symptom occurs even when the engine had been warmed up and operating under hot sun! I also noticed some misfiring and pick-up was quite lagging.

nice interior huh...

With tight schedule, I only got the time to look into it on my last day! Before my afternoon drive, I did a very simple tweaks for the low idling rpm. I did this based on my readings and other Volvo club member's experience as I do not own/drive one with injection engine. I switched off the air-cond, and start to play around with the idling speed screw (see image). A little bit of adjustment only! This screw is meant to adjust idling speed/rpm. It is not a 'tuning' screw; meaning that it won't change the air/fuel mixture ratio at all. I successfully got the right rpm (see image) and got the engine to run smoothly. Even crank-up is faster, idling speed is more stable, and the best thing is no more steering & dashboard vibrating during traffic light stops. I suggest this link for more reading on this problem.

i gained 800rpm idling speed without air-cond and close to 900rpm when air-cond switched on


the idling speed adjustment screw

As for the misfiring, I notices some water collected at the spark plug cable boots. I really have no idea of where the waters came from, but beleived that is the culprit. Later on the day I did sent it for a car wash where I borrowed their high pressure air-gun and dry off the plug cable's boot. It also solved the misfiring! However I do beleive that the cables may need to be changed :)

we called it 'Snow Car Wash' in Malaysia :)

How do I solve the pickup problem? Very simple! I dropped by a petrol station, inflate the tyre according to the pressure specification written on the petroll refill cap cover. Straight away after that, I felt the pickup is back! And I cannot deny that the car was fast!

The owner complaint that his family did not want to drive the car because of high fuel consumption. Driving for the first three days, I have to admit that the car fuel consumption was indeed really high! Of course as per compared to my caburated 240. Good that the car equipped with fuel consumption meter. After the simple tweak done (on the idling rpm), I can noticably see from the meter that the fuel consumption started to dropped from previous as I drive around. The below pictures indicated the fuel consumption while at idling rpm which is around 800rpm. I am not sure if that is the idle fuel consumption of an idling engine because I don't have that gauge in my machine; but I thought that is good enough.

gauges at idling

After all, it is really a pleasure for a chance of driving a 240 back, after months of not driving it! Good day all :)

History of Volvo

Its good to know the root of the machine we are driving now :)

Eid Mubarak

Dear Muslim readers,

I would like to wish all Muslim readers Happy Eidulfitri (Eid Mubarak). May Allah bless us and accept all our ibadah for the last one month of Ramadhan and bring happiness in this Syawal. Drive safely during this festival season :)

KAMI The Movie!

Finally, in Malaysia film industry, a VOLVO 240 being featured as a star! Last night I went to a friend's house where his friend did some nostalgic talks on their 'teenange' days; how he and his friends rode-on a VOLVO 240! Then I started to remember about this newly born film.

I haven't got any chance yet to watch this film, but the scenery of youths driving a VOLVO 240 really attract me to watch it, sooner or later. Nowadays, it is a common scene in Malaysia to see youngsters and college students driving a 240; most probably inherited from our parents. The resale value is damn low, the car is damn reliable that it still continue running after decades, our parents get damn bored already with the car and getting new cars, so the best option is to givi it to the children! The most cost effective & safest method to help the children to travel :)

Square Type Headlamp

A friend send this photo off. What a nice square type headlamp fixed onto this car. For Malaysian market, there is no such headlamp. We just have a big full square headlamp for all 200 series. I was told that the lamp was imported from USA. A friend who used to live in USA brought it back to Malaysia, and damn! Very nice!

This car still be driven by the original 2.1 244GL engine. However it used the latest 240 autobox, and got all 4 windows powered.

p/s - thanks Kay for the picture.

New Clutch Pumps :)

Both clutch pump failed last month. Please find below details;

Symptoms;

• While changing gears, I could feel that the clutch/gear engaged quickly with even a slight release of the clutch pedal.
• Up to my horror, when I was at a parking bay, I depressed the clutch pedal but the car continue to move! Slam on the brake and got the car stopped (of course the engine dead). Only after shutting off the engine, that the gear could be freed & changed! However, I managed to travel home safely.
• The clutch DOT4 fluid keep depleting. I was having a difficult time to really see where is the leaks. It was very minor that the slave pump got the fluids leaked.

Got a Volvo mechanic to do on-site job at my house compound area. Unfortunately I was not there when he changed both the pumps. He found that both pumps were 'seized' and suggested to change it. The quoted price was pretty high for us, but we have no much choice since the car cannot move already. After all he did a pretty good job, very tidy installation I could say.

Just Another Regular Service :)

Another regular service. Since I moved to Labuan, the car rarely moves. My dad use it for night groceries time, going to & back from the mosque, and other short distance journey. Believe it or not, after last service around November 2007, the odometer just clocked 3000km. Thanks to me who drove it all around the country when I went back home. Good thing about the car, it still operates smoothly. It was just getting dirty as it was parked under a tree!


Just let it have some fresh shower & shine again before got it serviced.



Thus, just another regular service. Got the same engine oil Petronas Synthium 800 Semi-Synthetic, oil filter, and all plugs changed.


Gimmick! Owh the car burnt!

A SPEED TRAP!!

My mom just called asking for money to bank-in; i started to wonder why?? I just got traffic ticket sent to my house; A SPEED TRAP!!

I was caught cruising at 130km/h while the highway speed limit is 110km/h during recent trip to Penang with the new Yokohama tyre. Is it the tyre to be blamed?? The tyre was damn silent even I cruise up to 130km/h, bless the old Silverstone with speed warning noise... eheheheh...

A big loss for my pocket this month! Aiseyh :(

p/s - not my picture;

New Yokohama Tyres!

Last week, the car got 2 pieces of new tyres. The old Silverstone Kruizer had badly worn out. The initial intention was to replace it with Goodyear tyres. However the dealer said that Goodyear tyres were out of stock.

As I am going for a long trip the next day, I really need to get the tyre changed on the day. So the only stock left is the Yokohama A Drive tyres. Got it changed, and some alignment works were done. It was badly out of alignment.

The next day is the review day! I cruised up on the highway heading north of Peninsular Malaysia at average speed of 120km/h. I went up to the maximum speed of 150km/h at times. Overall, I am satisfied with the tyre performance.

• the tyres grip very well, I can feel as if the tyre is sticking on the road even while raining and with wet road surface
• noise and vibration was really eliminated as per compared with the old Silverstone Kruizer
• handling is good, lighter steering feel

Please bear in mind, usually new tyres will always feel good. Because of the soft new rubber and the fresh thread. It is not fair to directly compare new tyres with the old ones.

Good day all :)

Why 240 So Special ??

As time passes, this model had 'classic' in the modern people's eyes and hearts. But driving one, you will always defend the car that with quotes that others will definitely deny. Examples of quotes; "i had never drove a car with such good handling like this 240, even the new generation of Volvos"; "this car is a computerized, even its ignition is regulated electronically"; "the car saves fuel"; "to maintain the car is very easy & cheap" & etc.

In this post, I would like to highlight the facts & figures of why this Volvo 240 is so special; in terms of its' technology advancement and technical specifications, of which among the items, there are still things that cannot be found on modern vehicles. Please do bear in mind that all these technologies had been used since 1970s!

1 - Braking power varies with speed.

This is one of the safety features of this car. Your 240 should react like this; the faster you drive, the more braking power you have. For instance, when you are driving slowly around town area, you need to apply brake a bit harder to have the braking effect. However, when you are driving on a highway with speed excess of 100km/h, you will find that you need to apply less to get more braking power (apply less on the pedal, but the braking is more).

2 - Collapsible steering column.

The steering column of this car is not though! It can collapse into parts! Why? In the event of accident, the U-joints on the steering column is designed to break away, and even some area inside the column and the steering itself designed to collapse. This to ensure that the steering will not hit the driver; given that he fasten his seat belt!

3 - Day running lights (DRLs).

Yes, this feature applies to certain model in certain country. I feel very lucky to drive one with DRL. It is very important to be able to see & to be able to be seen clearly as well. This feature provides 6 times more visibility of your vehicle to the other road users.

4 - Triangle-shape brake circuit.

Generally, cars will have 2 circuit brakes. And generally, one circuit will be connected to 2 tyres each. Volvo invented that this model use triangle-shape brake circuit where each circuit holds 3 tyres (in triangle shape circuit, 2 front tyres & 1 RHS rear tyre + 2 front tyres & 1 LHS rear tyre). The main purpose of having this setup is if either one of the circuit fails, the car still have 80% of the braking power.

5 - Less flank angle windshield.

You may have noticed that 240 have rather 'straight' windshield. The advantage; the vision is less affected during rainy days due to the less angle & surface area. Less drops have a chance to even drop on the surface of the windshield itself. However, this setup is beleived to decrease fuel efficiency because it is not aero-dynamic and creates wind drag.

I guess this is all for now. There's a lot more to be written here, but let it be saved for later posts. See you soon guys. Good day :)

FINALLY: New Bumper & Tail Lamps!

Guys, finally I got the broken bumper and tail lamps changed last week due to the accident happened in August. Was too busy to send in the car until last weekend. As the car exceeds 5 years old, we have to pay 40% of the total cost for the new parts. The rest is taken care by the insurance company. Thumbs-up for AIG for its' assistance.



I sent the car early morning and pick it back around 4pm. I then brought it for a complete car wash, including engine wash. Awesome, the gloom is back, especially for the rear end which was very ugly for the past few months.


Sadly, I am moving out from my hometown. I have been posted to work in Labuan, Sabah. The gloom, and nice car, I left it to the original owner; my dad! This blog will always remind me of the car; even I don't know how it is now in KL. :)

Major Service!

Hi, it's been a while since I last post in here about the 240's maintenance or repair. So yesterday, I got the car for MAJOR SERVICE which nearly cost me thousand bucks;



PROBLEM

First, I got splashes of oil around the air-cond compressor, it dripped down to the anti splash pan, and further down to anti-sway bar and brake lines. I am very suspicious at the moment I found the splash as my power steering fluid did not decrease, nor the brake and clutch; and my aircond works well too.

Second, I got 'tok-tok' knocking sound when starting the engine. Thought it came from loose rubber mounting on exhaust; but it was actually the engine mounting.

Third, I got some vibration and vibration noise when turning right; also due to engine mounting and cracked timing belt inner cover plastic which made contact with the pulley.


SO WHAT HAVE BEEN DONE

First, upon troubleshooting, it was confirmed that the leak came from the air-cond compressor. So, have to take out the air-cond compressor and change the worn seals and gaskets.

Next is major service. The work done includes changing timing belt, the timing oil seal, change drive belts as well, change engine mounting, as well as engine oil change.


PICTURES

Taking the compressor down.


The picture above shows that the oil seal have started to leak. Thus, I decided to change all of the oil seals as well.


Upon opening up timing belt and its' cover. Wow, so dirty. The mechanic did clean them thoroughly using a brush and water since they are just cumulated dusts.


New oil seals in. See how clean it is after the cleaning done.

New inner cover plastic.

How bad the engine mounting were.


RESULTS

No more 'tok-tok' knocking sound, no more vibration when turning right, and no more humming noise at 80km/h. Next will be the transmission system and suspension system.

Good Day :)

GPS In 240!!

This is a story of an old car having a new car features. I am very sure that most of you have heard about Global Positioning System (GPS). Using satellite, this GPS technology enable a real time tracking to be done. In countries such as France, GPS had been used in cars. And even some new cars have this GPS features built-in in them. So now, how do I have GPS in Malaysia; in this old brick (which definitely have no such thing as LCD stuffs).

First of all, credit to my dad who gave me chance to know and get to use GPS. He went to France about a year ago when he started to appreciate how feasible to have a GPS system inside a car. To have GPS, simple and basic things that you must have is a device that is able to transmit and receive data to and from the satellite (which can be called as navigator or transceiver), and an interface device that have software and maps to indicate your location such as a hand phone, laptop, or PDA.

In my case, I am using a HP iPAQ PDA which runs with Windows Mobile 5.0 and a GARMIN GPS 10 navigator (transceiver). The GARMIN GPS 10 navigator is connected to the PDA using Bluetooth. Note that you can also used PalmOS based PDA.



How about the software?? The software comes along with the GARMIN navigator. Maps?? The software given by GARMIN is a navigation software and of course it needs database or maps. Let say you stay in Malaysia, you definitely need to put in Malaysia's map into your handheld so that the software can use it. Maps for countries such as US and UK are expected to be available anywhere on the net. I am focusing on Malaysia's scenario. Maps for Malaysia & Singapore is available at Malsing (http://www.malsingmaps.com/portal/). Just download and follow the instructions or details on the portal. There's a lot of mappers and GPSers there.

Then, just turn on the Bluetooth on my PDA, turn on GARMIN GPS 10, and let the software track my location first before i start searching for places. I can enter name of roads, city, or even places of interests such as mosques, names of buildings, nearest petrol station. The software also provides route preference features; you might want to skip U-turn and want to choose the least distance route. It also have voice direction which is really handful because you cannot take a look at the map all the time while driving. Yes, definitely it will take about few days before you can really understand and handle the software properly; practices make perfect.



For me, I need to use this device as my current job need me to get all over customer's place on time, so that I can complete my job for the day. Believe it or not, all was done by GPS. I have to go to Bangsar area, Damansara Heights which I don't really familiar with. Sometimes GPS will asked me to go through housing estates and small roads, and before you know it,the building that you want to find is in front of you :)

Where to get this GARMIN device?? There is a GPS shop in Low Yat Plaza, I forgot which floor but this shop sells GPS related products only. I believe he can assist you as he assisted us; from hardware selection, software, and maps.

OK, may this post click up your mind to have a GPS system. Oh before I end-up, this GPS is FREE! Why FREE?? Because there is no service provider. GARMIN GPS 10 is only a transceiver device, and the rest is done by the software, so why pay??

More details?? Just drop me an email...Good Day :)

Brake Booster Failure :)

After all, today is the time for the brake booster / servo pump to fail. The first symptom I got early this morning is when I brake while driving down a slope, with just a little braking power, the tires jammed and skid for a short while before it stopped. From that point of time, I have suspected that something is not right somewhere, but then I just continue traveling to the office. Everything seems normal.

Then I have to go out to the customer's place. Driving just outside the office, while braking at a traffic light, I felt the brake became harder and engine tremble vigorously if the brake being applied hardly. I could also hear hissing vacuum leak sound. Luckily there's one VOLVO mechanic around that area and I just passed by to have him rectify that it is the servo problem.

Got it changed (BOSCH brand) this morning also :) Whew, I got back the feeling of driving a VOLVO with good braking power :) It's quite simple to DIY, but with time limitation, I just let the mechanic do.....

Stucked In Mud ??

If you got into mud, what to do?? First, don't panic and keep revving and rotating the tyre because it will just get things worse. Second, gather some friends, make sure enough member to push the car out of the mud slowly. Then only get into the car, and speed off from the area quickly.

GOOD LUCK!!

p/s - 240 is damn heavy to push to get out from mud, believe me.... we were really exhausted that day after pushing one 240, one Kia, and one MPV!



NICE MAN!!!



GET CAR WASH TO DO THE CLEANING... DON'T MESS UP YOUR OWN PORCH :)

Treasure Hunt 2007 :)

Yeah, this is the second treasure hunt I joined. Although with an ugly looking bumper, we still continue our treasure hunting program. At this moment, please do enjoy the pictures first. Details will be online later perhaps.

Good Day :))

Accident :(

Last Friday, in Kuala Lumpur, I met an accident. I was on Jalan Hang Tuah, stopped and waiting for the RED lights. Everybody were happy at that moment in their stationary cars. All of sudden, BANG!! I got myself pulled to the back, I realized my things on the dash compartment area gone! Ooooppsss... I looked back through the rear-view mirror, I saw an uncle in a Perodua Viva rubbing his head. I moved my car aside a little bit, then I switch off the engine, I came down from the car and the first thing I go and see is the 240's back. Bumper got tears, LHS rear tail-lamp get off from its bracket, and all chrome linings were down on the road. I really pissed-off!

But then, I saw the uncle in Perodua Viva got blood flowing from his forehead, he keeps wiping it with his tissue, then the mood changed into sympathy. The story did not end there when I discovered that the Viva was also being hit by a Proton Waja before it hits this brick. Again, I am really sorry for the poor uncle, whose brand new Viva got sandwiched. We then just proceed to the nearest police station and make reports.

So what happened to the brick?? Interior parts also affected because of the impact. First, the glove box got itself opened upon impact and RHS hinge broke. All cassette, papers, and pen inside the glove box thrown out to the front passenger seat. Exterior parts includes the bumper got tears, LHS tail-lamp bracket broke, cracks on both tail-lamp, and all rear chrome linings fall down on the road.

It is a very memorable experience, as this is my first time road accident after 5 years of driving. Take care guys :)

p/s - i think 240 may have the pre-whiplash system, because at the moment of impact, the seat support me well as if they were saying "relax zhafri, we are supporting you!"

Volvo 240 in Top Gear

VOLVO 240 FOR SALE.... a hard time huh??

Its time to let go the car. Selling reason?? Maybe to get a new car. Details of the car are as follows;

Specifications;
2316cc
Solex Cisac Carburetor
Manual M47 Transmission
Petrol

Problems;
-long shaft vibrating at 80kmh
-rear gearbox oil seal need to be changed
-ignition key spring sometimes just did not pull back by itself
-boot rubber seal might need replacement

Privileges;
-full service record available
-serviced only by Volvo authorised mechanics only
-odometer fixed
-new original tail lamps
-new taiwan made headlight reflectors
-new taiwan made sidelamps
-stock Day Running Lights
-new recond aircond compressor

Feel free to browse thorugh this blog for more info and pics on this car. Just drop me a message if you are interested. Thank you :)