Engineering Fail: Critical Component Damage (Finless Condenser)
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”Intro Music by Karl Casey @ White Bat Audio”
Thanks to Jesse for making the intro and graphic for us to enjoy!!
Ray, as an Engineer who collaborates with Production and other departments, I can give at least some answer to the question you posed at the beginning of the video about the plastic fasteners. Production, at least where I work, hates the one piece plastic fasteners. This is because (in our assembly line setup) the greater force needed to install them all shift long has led to worker soreness and occasionally repetitive motion injuries. Our Service department also doesn’t like them because the ribs can get mangled during removal and then they need to be replaced. I don’t care for the two piece fasteners with the screw-type center piece for exactly the reasons you stated. The styles with the center part that pushes straight in to lock the fastener and pulls most of the way straight out to unlock are easier to remove and (as you know) just as easy to install as the ones with the screw center. Thank you for pointing out the “bean counter problem” that we have to so often deal with. I’ve experienced frustration numerous times because I was told that I “had to take cost out” of a design that I thought was going to be great, and things like reliability and serviceability suffered as a result.
Systems to keep the EPA & safety features have run the price of vechiles up. Cost cuts are made else where😂
Imagine poor Rosie the Riveter at Willow Run fatigue level.
I thought worker complaints would just go in the paper shredder
Service should be high on the list, The harder it is to change a part The more its going to cost if the part fails during its warranty time So the best bean counters aside Is make it simple to change cost effective and durable enough to last longer then the cars factory warranty. The dealerships will always find stuff that needs repair work. As far as bean counters cost They need to look at all aspects. Seriously 100k for a new truck Maybe if it will last 30 years Ford came out with the ranger a second time it gained 17k in new truck cost over what the older models cost, truly they are not worth 37k.
Know of anyone looking for a designer/drafter?
This was phase II of de-northerning my Kia. Ray came in way under budget for this part, and I'm very thankful for that. Part 3 will be sometime this summer when the front suspension gets replaced. Cost of repairs is lower than new car payments.
Ve spent over $10K on my four vehicles in the last year. Way cheaper than a new car. Did the work myself and saved a bundle. One clown wanted $1,259 to change the timing belt on my 2001 Honda Accord! I do all my own work now. The level of incompetent expense has changed me for the worse, or better.
At only 56K on it, it may worth it for you to do a mod. Maybe find some old or buy some new aluminum window screen mesh (ten bucks at the Depot of Homes), take off the lower front bumper, single or double cover the air gaps. Fasten in with screws and washers.
@@trillian23xwhat i thought when Ray showed the huge openings in the bottom of the bumper.
7:33 I tell my wife all the time: "I'm watching my stories on youtube."
That's awesome
I tell my gf I do the same.
Watched Eric's video on the engine rebuild you and him working on for the family in need. This is so awesome what you're doing.
That you! We’re excited to get it back to the family!
Yeh! Way to give back! Salute! 🫡
@@RainmanRaysRepairs I visited their channel, posted to it and received a very nice reply. Good people. Glad to see you, and Eric, taking care of them.
Saw that clip as well. Dorman has a line of aluminum/metal parts for those Pentastar engines ( thermostat housing) . Hopefully. Eric or Ray can use some of those upgrades parts in this engine replacement.
Ray? If your content is addictive? Just call me an addict. Because my day isn’t complete without a hit
I like watching the grass dry and the paint grow. It's very mesmerizing
Like Rocket Surgery.
My dear old Dad used to mix up words, allusions and metaphors too. My favorite one was "Dickonian" - a mix of Draconian and Dickensian like in mean and sternly policed Victorian times 🙂
Im with ya... it's back asswards...
@@chrishengeveld6117 Hmm. Did you mean bass ackwards?
@@MonkeyJedi99Assy McGee
This might raise a smile, my “critical component” incident today. Decided to change the oil and filter on my wife’s MX5. Simple job, do it on the driveway today. Finishing up, bent down to pick up the drain pan full of old oil. The ignition key, which I’d put in the top pocket of my overalls, fell out. Into the drain pan.
Noooooo!!
Ooof
The paaaiiin
oh fuuuuuuuudge 😂
Gravity!!
20:51 screwdriver sticks the landing, awesome 😎
Hey Ray, I don't know if you know this but when you said "Watching the paint on the grass dry" at 6:45 that actually has a name, it is called a malaphor. There are some hilarious malaphors like: You hit the nail right on the nose. Let's burn that bridge when we come to it. One man's goose is another man's gander. The list goes on.
"Let's burn that bridge when we come to it." I really like that >:D
@@awesomecronk7183 💖
Similar to Ray's malapropisms.
Make like a tree and buzz off!
Back when I worked at Denso (radiator plant) we had an issue that the Fins wouldn't stick to the tube's after they were brazed. Their solution you ask? Glue said fins to the tube's.
South Main Auto’s Eric doesn’t worry about making it easy for the next mechanic, because he says that the car is probably going to the crusher by then.
That's the difference between NYS rust and Florida.
especially for KIA
Depends upon the car.... otherwise he wouldn't use fluid film
@@garbonzobean1Go Bills.
As soon as you began putting in the condenser you said, "Should be pretty easy." and I'm sure I wasn't the only one that said, "NOOOOO Ray, never say something like that."
Definitely part of "Murphy's Law" Same thing can be said of putting your tools away before checking to make sure the repair is successful, been there done that many times😆😆
@@REDBIRD-95 Ehem... This night's third-shift at the ER sure is QUIET.
I'm addicted to Cars and Coffee with Rainman Ray's Repairs
My bet is this was more a manufacturing cost decision. If the car got built, those often overrode engineering decisions if there was arguable area. A mentor told me "You never know how cheap yo can make something unless you make it a little too cheap."
Those AC condenser extension lines cost a lot more than plastic fasteners. They could have installed a low grill to protect the bottom of the condenser 😂
Hey ray. I’m an HVAC guy and we get the same issues with condensers. The actual issue is there is likely a dog or cat is marking the front of that car. And the ammonia eats the aluminum. That’s why those fins crumble. Then you add road debris hitting it and you get what you seen there.
Male dog's urine will rot an a/c condenser quickly. They act like they're putting out a fire. I had to take in my sister's two male dogs this winter and had to fence our condenser off.
If it's a northern vehicle, the road salt laden spray will do it too.
I can’t count how many condensers I’ve replaced because of it. We tell homeowners to put a small fence about 2 ft around the unit to prevent killing the new condenser
@GARDENER42, yup. My thoughts, precisely.
Interesting 🤔
Ray has the uncanny ability to condense the nonsense and get the job done. Especially in today's era of rampant bean-counter engineering on the part of the automotive industry.
The 2 piece push pins are used because they are "usally" easier to reuse. The push pins tend to have their fins deform when being removed and don't typically hold as well when reused.
I remember when cars were held together with screws & bolts they held together. They're not as pretty 😂
We appreciate how u teach others on how to repair there cars and show how repair shops do the work and we respect how your honest on your work not pull wool over people eyes
It is like watching a train wreck you are unable to look away even when you know you should🤣
I am always impressed that Ray can do work in one hand and hold a camera in the other hand. Makes you wonder where he gets this experience from.
Underrated comment
The "illegal right turn"...you're response makes me laugh, and when you're sitting in front of the judge contesting the ticket, he's going to ask you "if that guy jumped off a cliff, will you do it, too?" 🤣🤣🤣
After subbing to this channel for the past severeral years .., my wife says I no longer speak Normular... Observation: Much respect for you, wife unit and Eric for helping a family in need.( Thanks to you Ray, I now sub to his channel). It was refreshing to see you talk directly into the camera for a change. Question: What kind of salad did you turn down? Salad is actually food that food eats so I agree with you there...say no to salad.. Synopsis: Good job on the condenser , this is the perfect type of video to raise awareness to other KIA owners to look at their own condensers and condition. It also points out what they're up against to have it repaired.
Some kind of lettuce and fruit mixture. I'll eat a salad on occasion but only before the steak
@@RainmanRaysRepairs without the steak.. I would not say no to.., a club salad, cubed chicken or turkey, cubed ham, lots of crisp bacon, grated old cheddar, tomato and iceberg lettuce, topped with ranch dressing and thick slice of garlic bread
I usually eat a salad after the cow eats it. Lol
It's not "road destroyed AC condenser" - this is just low quality condenser. We had the same issue on Focus MK3 - mechanic said that factory condenser lasts about 5 years and then recycles itself... Quality Ford parts... :D
I'm a Retired Mechanic, I've got big respect for the way you work. Sadly, Gov, & auto manufacturers are fighting to phase folks like you & I out. Making it a requirement all repairs be made by the dealer, offering limited lifetime warranties.
If the screwdriver had slipped at the start when Ray had the screwdriver aimed at him for those 4 screws in the grill, it would've been a great time for Sam to say "Oh boy" when he showed up.
Ray You Jinxed yourself, When you said 'IT SHOULD BE EASY 😮 I'M A RETIRED LEO AND WE NEVER SAID " IT'S GOING TO BE A QUIET NIGHT " BUT GOOD JOB, Like Your never Quit ATTITUDE. Love watching you first thing in the morning, with my coffee. 😅
Being a retired mechanic from the northern fringe of civilization in Canada I think if I worked in your shop at 90F I'd puke myself daily.
That’s some intense drama! Using a power cutting tool right next to a delicate radiator.
Yes Indeed!
It is true once you start watching these videos you can't stop
Nice to hear wife units speaking impediment has cleared up (for now) interaction was hilarious 😎 My wife and I had similar one. I showed her yours and we couldn’t breathe.
As an engineer who works in automotive assembly those "scrivets" as we call them are much easier to remove if a repair needs to be done. Especially at the plant where the vehicles are being made. Plus they are less likely to get damaged when taking out making reuse easier.
Could never engineer today, industry controlled by bean counters instead of "Quality Longevity Pride consultants." Makes me SICK !!!
Easier than plastic pop rivets?
Ray … Matco makes stud remover sockets that work really good and they don’t damage the threads on the stud …. Good work Ray 🇺🇸😘😘
About the "watching the paint dry and grass to grow" , we have a saying in Portugal: "to watch hair and beard grow". Different words but pretty much the same meaning.
Years ago I worked at a factory that made radiators and oil coolers. That condenser was not built correctly. After the unit is assembled it is immersed in a sequence of chemical baths for a specific time which chemically bonds the fins to the tubes. Evidently that unit was made just before quitting time and was short-timed in the chemical baths.
You can give it all the chemical baths you want the rocks don’t care
@@gimmeaford9454 That wasn't rock damage.
40 plus years of turning wrenches and my son is an engineer. Oh the irony… This is something I’ve preached to him since he was a little lad. Unfortunately, he is a computer/software engineer and will never have much influence on mechanical, human systems or other aspects that will prevent stuff like this. An engineer with common sense and a mechanical background is like a unicorn these days.
I enjoy watching Ray even if I learn nothing new. He’s very entertaining.
IKR I can't stop watching your channel. I wish I lived closer so I could get to know you. It keeps me smiling all day. Great job Thanks.
Great tip to help protect that condenser in the future is to run flywire from the skid panel up over the bumper. Very common for this to be used for rock and bug protection, also helps keep dust and dirt out as well. Easier to clean the flywire than get into the condenser and radiator and clean them.
Your hybrid comment version is on point. I understood it. Hopefully you and I don't end up in a suit with extra long sleeves
Im a beginner mechanic and i learn so much from your videos
Watching painted grass dry seems like a "normular sitcheeation" to me.
I also despise those plastic screws as they always strip with the least amount of force. Have a great weekend Ray👍
I agree with the "no salad" answer! I don't eat the food that my food eats!! 😂😂😂
Morning Ray...coffee andddd...Go😎👍
Uh but Ray I enjoy your content, it's one man's epic battle to fix the unending waves of Cars that badly need repair's and find a balance of doing it with out loosing his Sanity Guest staring Wife Unit! Along with other guest star's from other channels. Take care Ray! I've been enjoying your stuff since you where working at the Dealership before you moved to your current place.
As long as the turn signal is used, you are good to go! It’s ok to let people know what you are doing while driving
I use turn signals as a courtesy to other drivers 😂
It wasn't the road that destroyed the condenser. Poor materials and manufacturing are at fault here. Good video. Thank You...
One hack I learned years ago is to magnetize all my screwdrivers. It is a simple process where you wrap a coil of #14 wire around the shaft of the screwdriver and then flash it on the battery, Works pretty well to hold Phillips screws
Hi Ray, Based in he UK and love your channel. I actually designed many of the plastic fasteners you come accross, (I am to blame). The two piece type are designed to be 'quick fit/ low force/ removable' and the single piece are designed for one time use but are higher installation force. In service, the two piece get brittle with age and often break. Of course, with your experience nothing is a challenge. Keep it up, the channel is brilliant! I'd let you service my car any day, but I'm based in the UK and don't want to get my feet wet!
Ray and fam, I’ve enjoyed every video that I’ve seen. Started back when you were at dealership. I enjoy these so much more. You are on your own! It’s fabulous!
Did anyone else see when Ray tossed the mini pry driver it landed at a 45 degree angle on the bench😂
I agree with Ray; since the Kia obviously spent some time in The Great Frozen North, I'm more inclined to think the condenser fins were the victim of road salt, rather than rocks. And Ray's description of watching paint grow makes the process interesting.
Tbh I'm impressed that condenser didn't have a leak in it flopping around like that
Having worked for an automotive North American distributor I can tell you what you said is absolutely correct. Engineers and designers do great work and making beautiful and functional designs. Than marketing comes in and the vehicle is dumbed down to something that falls apart and they all look the same. I'm not sure about Florida but in California unless it's posted that you can't make a turn than you can.
Love the malaphors and malaprops, keep those coming 😂🤣
Haha Ray, I've been watching the paint grow!
The two piece fasteners are actually slightly more expensive to manufacture. Two dies are required vs a single die. The reason they are used is that they hold the panels together with less rattle. The outside piece forms a wedge that cannot be compressed until the pin is removed. The push pins rely on compression alone and have more flex, allowing the plastic parts to rattle.
As someone who knows nothing about cars, though likes to watch your videos, i appreciate your explanations on why or how a part failed and / or how it works. Thanks Ray
Happy Saturday Ray. Have yourself a great day
Watching the paint on the grass dry. We actually had a neighbor when I was young who painted his grass. It was some kind of fancy golf course grass in his front yard that would turn brown in the winter. He was pretty anal about it and would actually paint it green with an air compressor and spray gun. I guess there must actually be 'grass paint'. Thanks for jogging that forgotten memory LOL.
I agree with a comment you made in this briliant offering. That these sort of videos will become addictive. What with your content and Eric at South Maine Auto. Loving watching what goes on when we drop our vehicles off at our local garages.
Came over from Eric's channel. Good on you guys! Has to be a tough go for the family.
Plastic connectors are also designed for assy time and ease of assembly...not necessarily service and or repair.
Ray should give an oscillating multi tool a shot at tasks like cutting that condenser out. Way less risk of cutting the wrong thing. More control overall, and no sparks.
It’s more like watching the clothes go around in the dryer 😎.
hey that's fun to do stuck in the laundromat 😂
Nicely done Ray!
Along time ago I had just gotten to work, parked my truck in the gravel parking lot and started to walk away. Along comes a tractor trailer pulling out of the parking lot with a load and as he turned to aproach the gate his front steer tire caught the edge of a stone and sent it flying right into my radiator. GUSHHHH
Hey NO beep on reversing out of shop,yea alright I am being fussy after an excellent tight squeeze repair,look forward to next job Happy Days
Bean Counters - Bob Lutz wrote about this - the Dodge/Phymouth Neon got its engine from BMW - designed initially for the 3-series. Lutz knew about it was he had just gotten to Chrysler after being the President of BMW. He said it was a very good motor, well engineered BUT Bob Eaton of Chrysler save millions (it was a huge volume seller) by "replacing parts with lower spec substitutes such as using a cork/tin head gasket instead of the multi-leaf metal one the engineers specification had. In any case every single change - heralded by his finance people and share holders - destroyed the cars reputation. I had 3 head gaskets replaced in my 1995 ($650, $200, then free) .. with the last one being the multi-leaf metal one ... finally! (I said to myself)
Looks like WINTER SALT CORROSION to me. Was that a northern car at some time? True, aluminum does not "rust" but it does "corrode" which is basically the same thing "oxidation". There are different grades of aluminum but auto makers use a very poor grade. You can spray aluminum with lacquer to prevent corrosion from salt spray.
Yep, that thing battled the brined up roads with the moon craters in New Jersey for about 10 years. It's enjoying its new home and care from an incredible mechanic.
I believe they use those type of screws to make it look like a better quality than what you actually have😮
There's no pride in work and quality in cars anymore
Well. It is a KIA.
@@BadBiden - If you read the rest of the comments you'll see that it's not only KIA.
@@module79l28 I have a personal friend right now that owns a 2019 Sorrento that he bought from a neighbor super cheap. It has 19,000 mi on it and the AC does not blow cold. I sent this video to him. 🤔
The AC did work perfectly fine when he bought the vehicle with 16,000 mi on it.
This car like everything else we buy today is a product of a throw away society. It's engineered to only last so long till the owner gets tired of paying for repairs and buys a new one.
"I heard the machine beep a minute ago"... erm, sounded more like the Tropicana train to me...!!
Welcome to my world Ray! This car is rough.
Paint dry, grass grow...addictive, but bearable when you change the play speed to 2x 😊
Excellent video Ray... Really liked the methodical replacement process.
Good job on being able to see these nuts
I had the exact thing with my opel astra h underside of my grill is designed with open stripes gotta love car engineers (not) love all vids ray keep em coming❤
Well done Mr. Ray.
Thank you for video Ray. Very enjoyable
Ray was that grass paint thing it’s all good. It’s all entertainment Ray
Love mixed metaphors
Ray I’m here for the long haul. Been watching your videos for a long time.
Engineers like to build stuff for proof of concept, not actual real life use
And so many people would say that Kia are disposable. My 2,000 Sportage says otherwise with just over 275,000 miles on the clock.
Better vehicles than most Ford, GM, and Stellantis products
More like watching the grass on the paint grow😂
On several autos I have installed expanded plastic 'gutter guard' (comes in a roll) behind/across the large openings in the lower grill in an attempt to offer a small amount of protection to the cooling system from road debris. Started doing this after a Honda Fit suffered damage that required replacement of a condenser.
Every single set of those plastic push type trim fasteners I have bought from Amazon have ended up becoming too brittle to remove without breaking within about a year. Very, very frustrating.
Even cheaper plastic 😂
I had to turn the sound down when you were angle grinding. I was having evil flashbacks to my last dental appt.
thanks Ray
❤😅 I found out years ago from a mechanic that did this for people he would go to a lumber yard and get a piece of chicken wire mesh that was firm strong but enough holes a letter through and he cut and fit a piece across the inside the grill and protected from chips and rocks and debris that's all. Mile marker Mikey Trenton Michigan. If you notice most cars made today that section where the condenser is is wide open to all kinds of crap on all cars even off-road vehicles.😮
Great video, 90 inside! .Ray you should really look 👀 into some central air conditioning for the shop. Happy employee is a productive employee.
I am addicted to the best channel on KZhead!!
Ray ! This was a very enjoyable video.
Can we talk about how long that screwdriver is?! Love the fun and games we get to be a part of! Screwdriver cam was awesome!
It reminded me of the game operation 😂
Mechanics world for decades, we called that A swivel socket, FYI. (Webbles wobble but they don’t fall down)😉
I have nothing except the DEEPEST RESPECT for Ray & Eric. I.M.H.O., both belong to an exclusive group of honest & educational (teachers) When I was young, seriously wanted to be a auto mechanic, however my life went in a different direction. Now retired from an HVAC career, that I enjoyed
Condensers don't usually deteriorate in this fashion from Road debris, usually chemical contamination, pressure washing or similar crumbles the material. Poor engineering or defective materials can also be a major factor. Push pins are changing all the time, I think we keep about 40 styles in stock. They are just messing with us.
Nice, the camera is actually useful for the job itself 🙂
Ray it has been reported that since they don't have gravel or rock roads in Korea, the origional Master Engineer for Kia did not see the need for protection of those item's. This engineer was the first employee for Kia, when they began in 1944, building bicycles.