Lion's Den

Peugeot 807 Radiator Cooling Fan Removal

2009-05-28T18:49:00.000-07:00

My People Mover Peugeot 807 has clocked 94K km. Recently the temperature gauge has been showing 100C while at standstill condition. The symptoms includes warm air in the cabin even with the Aircon system turn "ON".

Observe the Radiator Cooling Fan Speed and guess what ? The fan moved in a very slow / weak rotation/Speed. Guess the fan is dying. Knocking it will "rejuvenate" it for awhile but will display same symptom later.

Removing the Radiator Cooling Fan for this people mover is a 2 spanner job /very easy ( 5 spanner job is very difficult ). Here are the few simple steps.

You need to remove the plastic cover. It has 6 Plastic Studs.

Flat face screw driver and a Long nose plier should do the job

Please use a long Nose Plier to pull this plastic pins as they might break if use excessive pulling force.

Here are the Plastic Pins

Please remove the Bonnet cable lever unit. Using a flat face screw driver and prise under the lever.

Once all the 6 plastic studs and the bonnet cable lever assy are removed, Just pull it out horizontally.

Please take note that there are 3 plastic hook below this plastic cover. So please draw this cover out horizontally so that you do not break these 3 locking hooks.

Don't pull this cover too out. You might snap the bonnet cable. !!!

Once you have done that, you can see the 3 speed Cooling Fan.

There are just 4 mounting screws ( 10 mm ). You will need a 10mm Spanner - preferably a ring spanner.

You have a wide working space. So no issue with removing these screws.

This is the back of the fan. The Aircon Condensor unit. Will clean it when I install back the fan. Recommended detergent to use will be AMWAY LOC ( I am not affiliated in any way to this company ) I use this cleaning solution as it has Anti Rust + Biodegradeble properties.. Using a spray bottle and rinse down with running water should do the job.

Once all the 4 screws are removed, take the fan out. You will need to pull the wire connector at the bottom as you draw the fan out.

A new fan is quite costly. 3 times the price of a Japanese model car. But this fan being a 3 speeds fan and have already worked near to 100K km ( considering the idling/waiting time while the engine runs. But the best part of this all, it actually cost me very little as I only change the carbon brushes for this unit. Quite a simple procedure.

Tested with the new carbon brush .. WoWWWW... it's powerful - the speed .. Now the Engine temperature + the Aircond is working as it should.

For installation, just work the other way around.

Hope you find this article helpful ..............................

Peugeot 406 Power Window repair

2009-03-11T06:31:00.001-07:00

Well .. It's been awhile since I update this blog. Imagine how time flies. Have not been able to indulge in DIY activity lately. Anyway, my front passenger Power Window has come of aged. You can hear the motor turning but the Glass window doesn't move. Good thing it is stuck at the top position. Otherwise with the rain, the cabin would be soaking wet and despite the problem, it can wait till I get it fix.

Since I couldn't live with the idea that the front passenger window is not working and it would be very embarrasing if you are in a situation that requires you to wind down/up your window electronically and finds out that it doesn't work and I have to give all kind of excuses and I hate excuses...

So, on a saturday morning, decided to take the window motor apart and here is the results.

1.Remove the Door screws / 4 screws and another 4 at the front speaker mountings / Then the Door card / Door Rubber sheet.

2. Wind down the glass window to the bottom most pos

ition. If the motor doesn't work

( like my case here ), Just assist by pushing the Glass down while pressing the down window switch.

3. Remove the rub

ber lining surroundings the window frame.

4. Pull the Window glass out from the door and place it at a secure place.

5. Start remove the W

indow motor cable assembly. There are altogether 5 screws.Once all the screws are removed, pull the motor assy out.

6. Now look at the cable motor assy here :- Observe the points that I have marked. They are important later.

There are just 2 screws for the motor cable assy.

click to enlarge photo

Once I open up the assy, all the 3 studs are BROKEN.

click to enlarge photo

Plastics being plastics .. they break after sometime....

Here are the broken pieces. Clean the grease out from the plastics gear.

Click to enlarge photo

I use Super Glue. That is what it needs. I cleaned the area from grease and I glued the stud in. Wait for it to cure. Then I glued the black rubber ring to the plastic gear to re-enforce and protect the studs. Hope with this step, the studs would be able to take the stress of the glass window and will last forever.

Once the glued parts are cured, just fix up everything.

Please ensure that the cable windings are wind correctly. Once the motor assy is fix in place, make sure the motor are wind down and load the glass window into the door assy and then, the rubber linings, etc..

I couldn't take more detailed photos as my hands are greased and I was so engrossed with the job that I missed taking photo shots of important moments. Hope this will do and if you have questions, please drop a line in my comment section and I will try to provide an answer your predicament.

Destination Chiangmai Thailand - Miscellaneous chiangmai

2009-01-13T06:26:00.001-08:00

They say a picture paints a thousand words ... so here it is ...

They Sell turtle, frogs , eel , insect , delicacies etc at the market. If you have the appetitie for it you can get it here.

This is the Twin Peaks Apartment that we have rented. Quite reasonably priced. We have friends who are living in this "Farang" colony.

View of ChiangMai hotels from Twin Peaks ....

Destination Chiangmai Thailand - ChiangMai Oh Chiangmai

2009-01-05T06:08:00.000-08:00

ChiangMai has a lot to offer. If you are up early, why not head to Bake and Bite for Breakfast. They serve good english Breakfast. Muesli, Blue Berry, Banana Pan Cake ,Egg Florentine, Spinach on English Muffins with Cheese Hollandaise sauce etc...

After walking around town, there is this nice cozy Tea Shop that serves all kind of tea. Complement with all kinds of cakes/cookies/ice creams

Look at the ice cream served .. yummm

At the backyard, they have gardens, in this cool weather, it would be nice to be out there having tea and chit chat.

If you want a good western dinner, the GoldenTrumpet offers a good varieties of good food.

Le Spice is a place that is very ironical. Why I say that is because the Cook that use to cook in Penang that serve good Tandori Chicken at the popular Kasmiri house ( Penang road ) is now cooking here!!. The tandori served tasted EXACTLY the way it is in Penang. Yummy..

There is this elephant show that one could go to. Watch them play football,draw,move logs and much much more. Their paintingd cost more than my own art work !!. This place is about an hour drive from Chiangmai.

Their aim are not very accurate but nevertheless they are OK

Or Visit an Orchid farm. The colours are very intriguing an they are very lovely.

Visit the flower market. Exotic and good value for money. 10 bucks for a bouquet of roses !.

Now this is an interesting signboard ... Wonder what it means...

Guess.. there are lots of things to do here.

More to come ...

Destination Chiangmai Thailand - ChiangMai

2008-12-30T21:42:00.000-08:00

After the Floating Market, our destination now is Chiangmai. It's going to be a long drive for this stretch. Around 9 hrs drive and it's about 760 km away.

If all goes well, 1 more refill of " Gasohol" ( Ron 95) should take me right up to chaingmai.

The condition of the freeway is better for the northern part of thailand. There are 4 lanes freeway and in bangkok, there are even 5 each way so total 0f 10 lanes without taking into account the Frontage lane on both sides of the freeways.

Some of the strecth are really straight as you can see here and I guess I am fortunate there wasn't much traffic to delay my trip. Smooth sailing all the way.

We were about 43km away from Chiangmai and it was around 6:00 pm. We decided to take a breather/freshen up at Doi Khuatan Rest area. I needed nicotine top up. You can feel the temperature is cooling. Doi Khuatan is a hilly area and we had to do the climb. With the 807 fully loaded, there was no lost of power. So far quite satisfied with it.

As planned, at about 7 pm, we arrived Chiangmai town. Some traffic jam due to the rush hour. The rental apartment is at Twin Peaks on Chungklan Road ( Beside Shangrila Hotel ). At least now I can look forward to some good times... heard the thai traditional massage is good.

Destination Chiangmai Thailand - The Floating Market

2008-12-29T19:21:00.000-08:00

After a good night rest, woke up early ready to take on the next challenge. Good thing nowadays we have wifi at most of the hotels in thailand. I think we need to catch up eventhough WERE AHEAD at one point of time. But that is another story for some other time.Check on emails and keeping abreast on the happenings in Thailand and Malaysia. My navigator studied the internet and the floating market is only 7 km away from where we are staying.

So, early in the morning, we loaded the 807 again. Interestingly, we are only half way to Chaingmai and 807 is already fully loaded. My Navigator cum Load Master cum Co Pilot is already complaining that we have too much stuff.

Now I have to give credit to Thailand for making it very tourist friendly with CLEAR sign board, Correctly PLACE and in ENGLISH. I believed that more people will be travelling into thailand using their own vehicle in the future. This brings to a question was my Navigator really good or it's the Thai authorities that provided user friendly clear sign board that even a "blind" driver can't miss.

Took the drive from the hotel, followed the road sign and guess we are there in no time. We arrived there quite early as there were ample parking space for cars. Not sure if I was early or is that the recent political development that causes tourist to stay away from thailand. According to the Star, Penang Hotels were fully booked due to the political situation in Bangkok. Asked the businessmen in thailand and they admitted there is indeed a "slow down". Even their new Tourist Minister is inviting Tourists to come back !!!

You can take a sampan ride and enjoy the ride. Shop/buy/eat on the boat. It's a good experience that you should not let it pass.

There are shops along the river and they sell anything from handicrafts to coffee
Just a note here, if you are the first customer of the day, the money that you have paid, they will use it to bless their merchandise/goods. They believed this is good luck to them. But also on the same note, once you have bargained /asked for specific price, he/she may choose to sell you at a lost, make sure you take it, you cannot walk away from the deal, if you do .. then he would give you his mind !!!! @#$!!***((!!!!)

Destination Chiangmai Thailand - The 1st Trouble

2008-12-28T06:33:00.000-08:00

It was around 7 pm local time and we are about close to our planned stop over at Phetchaburi. Saw a Shell Petrol station and make a pit stop for petrol + coffee+ refreshments + easing ourselves. Fuel gauge showing I still have around 35 litres of fuel. Told the station attendant to load in V POWER !!( I was told to load the best fuel ) . He obliged accordingly and after 9 litres went into the tank, he pointed out to me that he is loading in DIESEL !!!!. OOOH SHIT!!!!. Immediately told him to stop and without getting angry or panic I found out that in Thailand, V POWER IS only available for Diesel. Guess it was my mistake for being so uninformed!!!.

Being Thai, the station owner is a nice guy. I explained to him what had happened and after crossed check with his guy, he understood the problem. He immediately asked his people to push the 807. Make sign language to me to take the steering. Without starting the engine. The steering feels damn heavy to maneuver. We parked the 807 at a ramp ( similar to the one which is like tyre alignment shop - access from below ).

First the owner tried using compressed air pumping into the fuel tank and using another hose to channel the fuel out into a container.

This method could not hose out all the contaminated fuel. Check at the gauge I still have 20 + litres in the tank. Make a call to my Penang Mech ( Ah Hwa - OEM Engineering ). Told him my situation and he told me to drain the fuel out from the tank. Also he said if there is some leftovers, the engine should be able to cope . I thank him and we proceeded to remove the fuel from the fuel tank. It was quite easy. 1 X screw ( input hose and 1 x noose clip that holds the input hose and the tank is all it takes to drain all the fuel out.
We use a jack to tilt the 807 to oneside to drain all fuel out. Then just fix the hose clip and mounting.

In the mist of draining, I could not help to take this photo of an Elephant that is being transported on a truck.

Once the fuel is drained out, same thing in reverse, the 807 is pushed to the pump and loaded with Ron 95 ( that is what is available ).

Time to go and I thank the station owner ( no extra charge - though it was my mistake - Thai people are actually nice and friendly ).

Heads to our planned stop and check into a hotel. I need to take a good bath - my t-shirt and pant is semi-wet with diesel. One thing about diesel is that it will remain wet and oily and leaves a long lasting stain and toxicating scent.

Meantime, my navigator is looking at tomorrow's route - Floating market.

Destination Chiangmai Thailand - The Journey begins ..

2008-12-24T15:56:00.000-08:00

22nd Dec 08. After having several consultation and considerations, the family decided to head for Samut Songkhran which is about 700 Km. Reason being is that this place has the Floating market. I guess the 700km+ push was ok to them.

The journey started Ok and the open highway is not bad. You can't really speed as you have to watch out for traffics merging out from left, making U turn at the right lane and cutting into the highway from the right. Bottom line is, be careful. Drive safely. Speed is not the issue here but watch out for the vehicles merging from left/right etc.

Look at the Freeway .. ain't it good ? Certain stretch are really smooth as silk and some are just horrible. But generally they are OK ( free ma ).

Once you are familiarised with the driving style in Thailand, things begin to happen. There is a phrase " Familiarity Breeds Contempt". How true. Just a bout 2 hours away from Hatyai, I was doing >120+km constant and stays at the right lane most of the time.

The result was, I was stop by the traffic police for Speeding + Hogging at the right lane.

This is a tough situation. I do not speak thai, the cop does not speak english and I did what the laws says is wrong.

I tried explaining to the cop that this is my first time driving in thailand and I really do not have any clue as to the speed limit. I am not sure what happen but he say, ok.. and explain that the RIGHT LANE ONLY FOR OVER TAKING. Stay on the left after over taking. So Guys take note of this. The default travelling lane is left. Right is for Overtaking only. The cop relented and let me go. I felt good... and say thank you to him...

Not long after that .... "Famila.......breeds ...Cont.."" I was doing 140-150 km again ...

to be continue ...

Destination - ChiangMai Thailand

2008-12-23T15:36:00.000-08:00

I have been planning to drive to Chiangmai thailand since 2007. The trip was not possible then as I was advised against it due to thai election campaign ( Dec 07 ) - that was just after the military take over ( Thaksin Fled to UK ) and looking for a replacement Govt.

Anyway, year 2008 wasn't as promising either. Have bee reading Bangkokpost on a daily basis just to keep abreast on what is happening there. After throwing out a Prime Minister that cooks on TV, kickout Thaksin's brother in law, seizes Airports and elects a new PM, I could not wait till all the dust are settled before taking the trip. It has to be Now !!

The politics in Thailand is like Stock Market ( I maybe wrong here - my apologies ). Very Unpredictable and Volatile but Life has to go on.

Politics aside .. I could not let this volatility situation to derail my plan. This is also why I did not organize a group trip. It would be a nightmare making decision as to "When to go ?".

There are lots of preparatory works to be done. Here are just a few of them.

1. Prime up your Vehicle
- Beltings ( Timing belt/Aircon belt/Crankshaft pully)
- Oils ( Engine / AFT / ATX / Brake Fluid )
- Brakes ( front / Rear brake pads / Disc )
- Fans ( Radiator fans working fine / Aircon blower )
- Tyres ( all 4 + spare ) - Perfect balancing + alignment )
- All the bushings .. tie rod end/ multi links / etc
- Others ( ICE ? etc )

2. Paperwork
- Car registration
- Car Insurance cover to thailand ( I extended my coverage to Kingdom of Thailand with an additional payment for 1 month that cost me RM85 - get it thru your local insurance agent )
- Buy Thailand 3rd party insurance coverage at the border town in Changloon
- Valid Passport & driving license

3. Others
- Drinking Water
- Medications ( Just in case )
- Thai Currency

So on the 21st Dec 08, I set out to Thailand.......... now here we go ...

First day ..

Penang -- The traffic is already heavy going into Penang bridge

Oh what a day .. the timing is impeccable. But what else is new about Penang Bridge ?

Border Town - Danuk ( Bukit kayu Hitam )

At the border....

Once you have crossed the border, for those who are driving, take note of this.

Take a left turn and park your car at the car park. Walk to the immigration booth. Collect disembarkation form at the office.Fill up the disembarkation form and present it together with your valid passport to the thai immigration officer at the many booths available. Please also enclose RM1/xx. The officer that we met did not ask for it.

Once you have cleared immigration, present your Vehicle ownership claim form ( grant ) together with your passport at another booth ( specific for vehicle registration into thai ). The officer will key the Vehicle data into a computer and will pass the whole set ( 4 copies ) to you together with your passport. Take that set of forms and pass it to the next booth. This when the last officer will ask you to "Bring Car". Get into the car with all the passengers and drive into the lane and stop right at the same officer. He will give you 1 copy of the approved form and will signal for you to proceed into thailand ...

First Town

We started our Journey and the traffic was smooth. As we move towards Hatyai, we decided to take a break before undertaking this Long Haul, do some shopping, get familiarised and to start early. Saw lots of Malaysian and Singapore Cars there. Guess it was a weekend and everyone was looking for a bargain.

The Christmas Mood is already in the air.

View of Hatyai Town from the hotel

Driving in the Rain

2008-12-13T03:18:00.001-08:00

This is a short take on one of my drive in the rain. It has been sometime since then and I guess it's good to share experiences.

I have always keep my front windshield speck&clean. I use windshield wax - Japanese brand.

This short movie take is in a heavy downpour and I know it's dangerous driving at 120km/hr - 140km/hr. I would not encourage you doing that.

But this clip is to show the effectiveness of this product ( not gonna name it here ) and how important it is to always keep your windshield clean all the time.

Don't try this ... this short clip is to show you why you should keep your windshield clean all the time. You never know how the weather gonna be like. So be prepared.

Picnic at Teluk Bahang - Penang - Dec 08

2008-12-07T18:48:00.000-08:00

Just had a Picnic on a beach at Teluk Bahang Penang recently.

Will post pictures later. The Picnic starts at 10:30 am and we packed up at 10:30 pm. Decided to take the "Round Island Route" back to civilization. It was a cool drive in darkness with it's snaky twists and turns.

Here is a short brief take on the drive video I took using my handheld digital camera. ( not a very good one -apparently ).

Pollen Filter replacement

2008-10-14T06:37:00.000-07:00

When you buy a used car or mpv, there are several things that needs to be fix. Depending on the previous owner, the amount of work needed to be done is inversely proportional to his/her passion. Here I've got a used MPV Peugeot 807 with 80K km on the clock. Everything else works but there are minor work to do to make it close to perfect. This is the first of the series of things that I have done.

In the coming days, I will try and add more helpful simple tips on my Peugeot 807.

This is the Pollen Filter ( Filter located at the engine bay to allow dust free external fresh air into the cabin ) will filter out all dust and small particles from entering into the cabin. All Peugeots I have owned 405/406/807 has this filter.

You can see the Pollen Filter housing once you open the bonnet. It is located just below where the rain wiper sits.

There are 2 mouting screws ( half turn and 1 on each side). Turn anti-clockwise to release the front end of the housing. There are also 2 quick release securing clips at the front end ( 2 clips on each side ). You will have to slide your hand and you can feel it. Just lift the clip and it will be unsecure. The next picture will show how the quick release clip looks like.

As you can see, the Pollen filter is already disintegrating. It has done it's fair share of service and is now "dead".!!

You can also see the quick release clips.

This is the underneath of the housing. There is a drain hose that is connected to it. When you pull the housing out, please also remove this hose first.It's just a simple twist and turn at the hose end to unsecure it. The challenging part is when you are installing it back the housing. You will have to twist and turn to secure it back. I wish you all the best. As a tip, put some water at the hose end to make it slippery and slide the hose back into this hole.

The new Pollen Filter is ready to go to work. Installation of the housing is pretty straight forward. Slide the housing into the bay, Twist and slide the hose ( wet the hose ends to make it slippery ) into the hole ( underneath). Secure the 2 screws ( clockwise half turn ) and then the quick secure clips.

Hope you guys have a good day ...

My People Mover Peugeot 807

2008-09-16T07:56:00.000-07:00

Well ... this is my new people mover. It's a Petrol 2.0 GLX model. Kind of a basic model. It comes with D9 engine as with Peugeot 406/407 with 4 speed auto/Triptronic gear and comes with AL4 gearbox. Curtain airbags with auto sliding doors. One need to change the way this baby is driven. Not like a normal car. I need to learn to slow down. This is especially true if you are driving a 405 and a 406. I need to "adapt". But generally the handling for this 807 is not bad actually. Have not really had a chance to really stretch this baby yet. Anyway here is how it looks. ain't it gorgeous ?

Solex Carburettor Pdf files

2008-06-23T07:35:00.000-07:00

Hi Guys,
I thought it would benefit those who are looking for information on Solex Carburettor that is used in Citroen & Peugeot cars.

I have this .pdf file on Solex carb. If you are interested please click

DOWNLOAD LINK below FOR ANYBODY WHO WANTS A COPY OF THE PDF FILE:

I am still getting requests for this file and I think if you have read all the comments , it was posted by Boris ( thanks buddy ) that he has made a DOWNLOAD LINK FOR ANYBODY WHO WANTS A COPY OF THE PDF FILE:

http://download711.mediafire.com/zcevxq3tdxtg/mzymoizwtnl/solex+z1.pdf

I think this would help you to get it faster.

Last I checked it stills works.

thanks and regards

Oil Cooler for Peugeot 406

2008-04-29T06:04:00.000-07:00

It's been awhile since I have update this blog. Hope this new entry will cheer some of you up.

I happen to come across 1 Peugeot 406 ( D8 ) fixed with an additional ATF oil Cooler. The way my friend installed it by using Oil Cooler from Hayden Auto. The web link is here :-

http://www.haydenauto.com/products/transmission-and-engine-oil-coolers.htm

As we all know the No# 1 killer for any auto transmission is HEAT. The Oil cooler that comes with the Peugeot 406 ( D8 ) is kinda small. But from my experience, it is apparently quite efficient and reliable as it is. However, if you still feel there is a need to add another one, please do so as this will definitely provides more cooling effect.

Here are the pics I took on my friends installation.

This is how it is installed. Kinda neat place to be. There are ample room to place this oil cooler. I believed if this is installed at the front air intake, the cooling effect will be much more efficient. This installation is in series with the original 406 cooler. So now he has 2 oil cooler. One is water cooled and the other is air cooled.

This is the Original installed oil Cooler that comes with the car. It is actually sealed. Noticed the coolant intake and outlet ? This is water cooled oil cooler.

If you intend to use the original Oil cooler in series to the new one, you will need to do some modification to the unit. You will need to drill open this unit to allow the ATF to flow out to the Hayden Oil Cooler and return. How this is done is to drill 2 holes. One for the outflow and one for the inflow. You will need to weld it with pipelike fabrication so as to allow the hose to secure the outlet and the inlet.

So here you have it.

Peugeot fuel gage indicator Phenomenon

2007-10-03T21:42:00.002-07:00

This is how a fuel pump looks like. There are several types for different models of make but all performing the same purpose. They are immersed in the fuel tank which is right under the rear passenger seat.

The thin film resistor with the float assy will provide fuel level signal to the meter at the dashboard. This carbon film resistor wears out over time and will give you the "swing" effect thus inaccuracies.

I have not found a replacement part for this as I believed ( I could be wrong ) it comes together with the fuel pump unit.

Peugeot 406 Rear 3rd Brake light

2007-07-20T06:00:00.000-07:00

There are many questions as to the versions of the Rear 3rd Brake light. Is it LEDs or using the old filament bulbs. Well, there are 2 types actually.

For the benefit of all I have the pics of both. They both have their advantages and disadvantages. I personally like the LEDs ones as they consume less power and doesn't generate that much heat. The filament bulbs produces brighter light causing more heat that could warp the red plastic casing.

To replace the LEDs needs a little "spanner" know how. One will need to de-solder the burnt out LEDs and replace them using super bright ones which can be bought from electrical spare parts shops inexpensively.

As for the filament bulds replacement, it's easier by just pulling them off the housing and inserting them.

Both of the above requires careful removal of the whole light unit that are mounted on the roof. If you are not careful, you could break the whole casing. So do it with "passion"

Sunday Fun Drive

2007-07-09T05:34:00.000-07:00

It starter out early at 9 am on the 8th Jul 07 at Seberang Jaya Mosque. A short briefing and the route map were given out.

The Road is wet. Probably just after a downpour. But the view of the surrounding green hills with low hanging clouds gives you a relaxing feel coupled with cabin temperature set at 23 degrees, IT IS COMFORTABLE !!!

I was going a bit too fast and did not get a better view of the bridge. But anyway, here it is. Maybe will do better next time.

I was following a Honda Stream that was going fast too. Here again the view gives you a sense of WoW feeling.

As we convoy into Lenggong. Notice the straight road infront ? Just too bad it's a double white line all the way .

Sunday Fun Drive

2007-07-07T04:08:00.000-07:00

A group of us decided take drive along the scenic Kulim - Grik highway. Will update the photos soon. But here is the Planned scheduled. I have also pasted the rough Map of the route we will be taking.( courtesy of Ooifa )

9.00 am: Start off from Seberang Jaya Mosque , use the BW Kulim Expressway Distance abt 20km toll RM 2.60

9.15 - 10.15am : Kulim to Grik . Distance 115Km , time estimate 1 hr, toll free

10.15 - 10.45am : Teh Tarik at Grik Batu 2 R&R 10.45am -2pm : Grik to Kuala Kangsar ( abt 94Km ) Along the way,suggest to visit the "Perak Man"(who should be 10,000 years old if still alive) at Muzium Arkeologi Lenggong. estimate to spend 1 hr there.Brief stopover at the Tasik Raban Resort before the Raja Muda Nazrin Bridge.Then have lunch at Sauk/Sauk New Village. Halal: Ikan Bakar. Non Syriah compliance: Steam fresh water fish at seafood restaurant.air liur meleleh woh!Eat durian as dessert. Buy Ikan Perkasam (local delicacy)

2pm - 3pm : Kuala Kangsar - JURU by Plus Highway . Distance abt 100km, toll RM13.60

3pm : High tea at Juru Autocity

406 Cabin temperature Sensor Unit

2006-09-10T07:39:00.000-07:00

If your cabin temperature goes haywire, this guy could be the culprit. The temp sensor is located above the head where the reading lights is located. The IR open/close door tx/rx is also housed there.

Took out the temp sensor unit and cleaned. Dirt was wrapping the sensor thus the feedback wasn't that responsive. It has a small dc fan that will suck in cabin air while the thermister will sense the temp which provide feedback signals to control the hot/cold air flap to mix the set/desired temperature. After cleaning the thermister and the fan fins, the unit now is more responsive.

Damp/moist Cotton bud will do the trick. This is quite an easy task.

The Motor spins better and the thermister senses better now.

Happy Motoring..........

2 Flush or not 2 Flush ?

2006-08-27T07:17:00.000-07:00

There is this hot debate regarding the 406 Gearbox - ZF 4HP20.

One school of though felt that flushing will improve gearbox functionalities as all the smug, slug and "impurities" will be flushed out and thus will keep the GB in optimum state.

Another school of thought think otherwise. Flushing will actually cause more harm than good. This is due to the Gearbox ATF filter also known as "Main Pick Up" is made of materials that filters very fine debris. It's so fine that flushing would not help as it will actually clog the filter faster.

here is the picture of the ATF Filter.

Another angle.

The Filter material.

Now, the questions is 2 Flush or not 2 Flush ..??

The choice is yours .....

Rejuvenating 405 - Cooling coil replacement

2006-07-28T07:18:00.000-07:00

My 405 is already 12yrs old. Mileage passed 200K km. Engine still in excellent condition. Recently did a "dashboard down" due to Aircond cooling coil sprung a leak. With the dashboard down, replaced new heater matrix. Now, despite being a dozen yr old, she is still able to set comfortable cabin temperature. It's climatic controls function still works !!!

Here are some of the pics I capture for references as to what is behind the dashboard.

This is how the firewall looks like.

The cooling coil are practically blocked and the airflow are "weak"
It was actually worst than this as some of the "biscuit of mud" actually dropped-off before this pic is taken.

This is part of the cooling coil assy. This shows how the airflow from the blower motor to the cooiling coil. So sometimes when we have foul smells, weak airflow, not cold enough, it's most probably the cooling coil is blocked !!. I am still trying to figure out a way to clean the cooling coil without having to remove the dashboard.. it's possible .... maybe some of you out there can come up with a better toolings/gadgets to make it easier.

This is where the flap motor that controls the hot/cold air mixing for the "desired" temperature.

adious amigo for now

External Air Ventilation Motor for 405/406

2006-05-23T20:11:00.000-07:00

Hi Guys,
This is how a Ventilation Motor unit looks like. It is use for opening and closing the Vent for 405 and 406. Probably also use for others models and makes. It is basically a DC drive motor and the plastic gear will wear out after sometime. For those who are into DIY, then getting the unit out is a bit of a challenge. Servicing the motor should be simple enough.

Repalcement parts can be obtain from discarded toys especially the gears. Use silicon grease to lubricate and this motor should be good for at least another 5 years.

Observe the arrow indicating it's position when reinstalling it back.

Inside view of the gear set up.

This damn plastic gear that wears off easily.

Replacement gear from my children's discard toys.

This unit is located just above the glovebox. Removing the glovebox for 406 is easier. Just pull the 2 plastic pin at the hinges at the glove box. For the 405, would be very tedious.

The Vent motor has one brown connector plug & 2 x screws holding it on.Watch and observe the small plastic gear that attaches the motor to the flap, Have a look at how it goes together before taking the 2 x screws out.

Happy Motoring....

Most sought after logo in Malaysia

2006-05-21T07:46:00.000-07:00

This will be the most sought after logo in Malaysia with the launching of the new beAstari. Take a look .. isn't this look nice ?

Mono Point Injection

2006-04-07T08:04:00.000-07:00

Hi Guys,
My 405SR was converted from Carburetor setup to Monopoint injection system. This conversion is nice in a way as I get to use back my Xu9 engine which is still in good condition despite it had aready clocked 200000km. My Carb was leaky and looks like the way to rejuvenate it, conversion was the way to go. What is evident after the conversion was the fact that the idling is consistent while I save on fuel with more predictable power.

What I have "lost" was the Carby and the manifold, fuel pump, dizzy+ignition amp, flywheel,SR rpm meter, wire harness and ++.

What I have gained was ECU,Flywheel with speed sensor, Manifold + injector unit,fuel pump in the fuel tank,RPM meter,wire harness,O2 sensor,Map sensor ++

Here is the picture that might say it all.

Here is the birdeye view of the new setup.

regards

406 Heater outlet hose Sprung a Leak

2006-03-13T05:54:00.000-08:00

It was on a Saturday ( 11 March 2006 ) 2:15 pm. Was crusing down towards Sungai Dua heading towards Bagan Ajam. Observing the temperature Gauge indicating ~ 90 degree C. This is not normal as my cooling system runs on Redline Water Wetter Coolant. On a normal day, the temperature should be just above 80 degrees C. Shelf that thought aside but keeps periodic glance at the gauge. Proceeded to the said rendezvous point to listen to a "Purist" hifi System.

The hifi "Sifu" was well prepared to feed me with "vegetarian" diet ( Purist ) first and then fed me the non-vege diet. I can tell that he is a person with a high degree of skill and knowledge in this " purist " hifi subject. The music played was enjoyable and guess now am confused, To be a Purist or a Non-Purist ? Well, will think about this.

At 4:15 pm, time for coffee and to Bagan. On the way there, the temp gauge was climbing and immediately I suspected something to do with the the cooling system. I was thinking it could be my heater core leaking again since I had it repaired sometime ago. But the cabin looks dry. Need to stop. I could tell that the high speed fan was kicking-in. As the distance was about few minutes more, I proceed to the Cafe and park at a spot that I could work on later.

Stops the engine and switch the ignition "ON" without cranking the start. let the fan spins to cool it. Yes.. you could see hot coolant flows out as indicated. Lock the car and went for coffee.
Called up Tai Hoong - Ah Ngan. Ask him about the hose and he said to come over to his shop. One thing he said was pleasing to the ear " I'll wait for you" unqoute.

About 5pm, the "Purist" drove me and my family to Tai Hoong. Talk to Ah Ngan and I was asked to follow him upstairs where he keeps his stocks of Peugeot and citreon parts. Could not find this heater outlet hose. Apparently not many people looks for it. Found a generic Japs hose that I could use. It was a little bit longer and well I could cut it. He charged me RM20 for it.

Went back to the car and open up the bonnet. Started working by removing the hoses. removing was easy. Using a plier, grip the 2 points of the clip and move it outward. Installing the new hose took me almost half an hour. The clip was too tight ( New hose ) and my old trusted pliers ( old John ) was having some "loose teeth". Hoses were in place but I couldn't hang on to the grip. It just keeps slipping in that tight working space. The clip just won't budge. My Purist friend was having "teh tarik" while I was struggling to insert the top clip into it's position.
My purist friends realised that my "old John" plier could not do the job, volunteered to go back to his home and get a better plier. I thank him for that and told him that I will keep on trying till he comes back. But if he don't see me, then I should be on my way. We bid farewell and had a laugh over it.

I guess "old John" wanted to proof that he still have some Juice left, he gave a good grip on the clip, slip it to it's position and Woaa laaah . It's in.. !!!. Poured bottles of water in and starts the engine. Keeps filling up the water and waits till it was 90 degrees C. called my Purist friend and told him it's OK. He was just about 5 mins away and waited for him. We met and bid farewell again. Drove to Alor Setar without any incident.

What I can say is that if I had not stop at the Purist house, I would be stuck on the highway. I believed the hose was already leaking and that was why the temperature was ~90 degrees on the highway. So it was a blessing in disguise and will buy another round of Ipoh White Coffee.

Blue Battery Terminal

2006-02-26T05:37:00.000-08:00

Today I had a few hours to kill. Did general check up on my wife's car. When I open the Bonnet, WoW, what did I see, Blue-greenish flakes surrounds the Battery +ve Terminal. Got a shock!!. This is actually a thin film of sulfuric acid. If left un-check will eventually lead to corrosion of metal parts around the battery. It can be cleaned away easily before it causes problems. If corrosion is ignored, it can damage battery cables and holddown parts and lead to operating problems, such as a no-start condition.

This blue-green flakes are corrosive !!!

Remove the terminals ( -ve) first, then remove the (+ve) side. Ensure no spill of the corrosive flakes. I then remove the +ve cable that connects to the start-motor. Did a good wash on it. Use lots of running water. Use eye-protective goggles. Then wash the battery mounting areas. You do not want any residue of the flakes to starts "eating" your paintworks and subsequently your car metal parts.

Washed thoroughly the cable connectors and the terminals. They look ok now. Then install back the cables and the battery.
This time I apply a layer of grease to protest both the +ve and -ve terminals.

This cleaned terminal and connector will give you a "one-Kick" start.

Give me a tinkle

Heaven & Earth Meets as 1

2006-02-12T04:14:00.000-08:00

Spent 2 days in Ipoh at clearwater Sanctuary Resort. Nice to have met some of Perak's Pug Owners and had some open bonnet session.
Had a good time there. Good place to "Let loose and Fancy Free"

At the reception, you are welcome with greeting from the 3 monkeys. This reminds me of the "missing 4th" monkey ..... created during the Clinton-Lewinsky scandal
( both hands clasping to cover the private area)

This is where the chalet are. Ample and shady parking area too. Was told that Jodie Foster stayed in one of these chalet when they film "Anna and the the King" with Chow Yuen Fatt.

What a view from the balcony. the serenity, tranquility and the chirping of the birds. Makes this a sanctuary for us to recuperate,rejuvenate and recharge.

Now with this kind of view from my balcony, what else can one ask for in life ? Well, what else ? With Old town white coffee, cigies and Newspapers to read ... No wonder it's tagline says
" it's heaven and earth meets as one"

Were "caught" in the middle of a Kavadi Procession. Very colourful sight !! Watch the red car in front.. that's a 605 !! a very RARE breed.

Ain't she a beauty ?

Well, here are the Pamelo girls !!. I guess this veiled view should suffice.

Give me a tinkle ..

Changing Coolant

2006-01-22T01:39:00.000-08:00

Bought Distilled water and also Redline Coolant
8 Litres cost RM7.50

Redline Coolant
Bought this yesterday.

Radiator drain Knob.
need to turn this to discharge the old coolant out.

Preventive Inspections - Pre-CNY holidays

2006-01-22T01:25:00.000-08:00

Did an Inspections on the 406 today to prepare for the CNY. All checked out A OK. However saw some cracks on the Drive belt ( the one that drives Aircond,Power Steering Pump and Alternator ). Will get it change tomorrow.

The belt starts to cracks. Hope you guys do your Preventive Inspections too. Especially CNy holidays, workshop could be closed for days.

Give me the Tinkle

Heater Core Updates

2006-01-16T21:33:00.000-08:00

So far the heater core is holding on. No leak. Hope this stays.

Running tempt. is hovering near 90 degrees during hot days and at traffic lights stops. Rest of the time >80's degrees <90 degrees.

Will be flushing out the older redline coolant this weekend and replace it with a new bottle. All the efforts was real worth it.

Lesson learnt, the 406 Heater matrix is repairable and one does not have to remove the whole dashboard to fix it.

On the 405, is also possible except one will need a revert tool as the dashboard is reverted. will embark on my 405 later this year.

Give me a Tinkle

2006 2nd TT - Auto Detailing session

2006-01-15T04:43:00.000-08:00

Hi Guys,
Oh what a night. It was fun,tiring and satisfying. The results speaks for themselves.
Here are some pics ....

I must be crazy to be here

Another Sifu at work

My shine will beat them all

Let me show you all the right footworks

Give me a tinkle ?

405-Dashboard down !!!

2006-01-12T05:16:00.000-08:00

Notice how dirty it is ?

dashboard - Rear view

The airflow from the top of the blower fan goes to the cooling coil

Behind the dashboard.

Hi Guys,
Had an opportunity to see 405 dashboard strip bare. This is normally required to replace the AC cooling coil that has sprung a leak. For those who have not seen how is it like behind the dashboard, here are the pics.... ( I am not good at taking fotos - guess you just have to live with the quality of pics taken )

Notice the condition of the cooling coil ( Dirty ). Despite the fact that this car was well taken care off. If your blower fan speed is slower, guess it's time to clean the cooling coil. Now have to figure out how to clean it without having to remove the dashboard.

Give me a Tinkle ?

How to Remove Peugeot 406 Heater Matrix / Core

2006-01-10T03:36:00.000-08:00

Hi Guys,
I have re-connected my hose today. All system checked out OK.
No leaks, at the inlet,heater matrix and oulet. Set to 30 degrees C. The Hot air makes me feels like like Winter again.

Hi Guys,
Took the heater core out and there was 2 holes in between. The first welder doesn't want to weld for me. The 2nd one did it for me for RM18/xx. Pressure tested OK.
Installed back the core and the Glovebox. Have not connected the inlet hose yet. Will wait till weekend to do it. Who Knows if there is going to a big "Flood". The pics shows the leaks.

1st TT - Sunway Tunas - 8th Jan 2006

2006-01-08T19:11:00.000-08:00

Hi Guys,
Our first TT of 2006. I was DIY on my Peugeot 406 Heater Matrix that was leaking. You do not need to remove the whole dashboard as required from the Peugeot 405. There is a short cut to this. Just need to remove the Glovebox. Remove the plastic hinges at the glove box. There are 2 if not I am not mistaken. Just pull them. Then remove the screws that is holding the glove box in place. There is however 1 screw that is located at an awkward position. YOu will need to use the torque wrench L shape and using wrist power to unscrew it. Thanks to Wlchin for removing the 1 screw that was so difficult to remove. Once that screw is removed, the rest is no issue. Will be taking out the heater matrix tomorrow for welding and hope that it works

Sorry I did not take photo of the screw locations as I was too engrossed with the Heater Matrix removal.

This Squad is mighty expensive.

Welcome to the Lion Den

2005-01-27T03:05:00.000-08:00

HI to U all.. I think this is a good way to stay in constant contact and also keep the latest gossip going. I 've just stumble upon this Blog stuff ( from my kids) and find that we can use this as a platform to develop something for ourselves. Especially when we want to share infomation globally. Well, just a thought that this might develop into some form of a "Northen Lion Forum".
Who knows ???. "every thousand steps begins with the first".

regards
Rodium_plated_pipe