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Right, dismantled the damn thing again, took out the plug, the flame sensor and then the fuel inlet pipe. The gauze (filter?) as I said preveiously was completely manky! Replaced it with a nice new one, and cleaned out whatever I could in the process will it was apart (stopped short of de-coking it as didn't have the asbestos (!) gaskets). Cleaned the flame sensor, got it all back together....and......hey presto - the thing now fires - but produces masses of smoke :-( - white I believe. ...so the next problem isn't the plug (as its new) - am I looking at the metering pump? Few other observations, the exhaust packing looked saturated with diesel, and there has been a smell of diesel around the car for a little bit now, could this be another indication of the pump? What operations can I perform on the pump? Graham

I'm gonna work on the assumption that the gauze is nackered - have ordered a new one - and the screw for the end cover I had to drill out. I'll check the connections for the flame sensor to see if I've disconnected it somehow. I reckon VW would be able to get me a new flame sensor - they're getting me that gauze ! Graham

it looks like the glow plug is 2 (on the left hand picture) - is it worth replacing the gauze? Graham

Read fault codes last night, am getting "Repeated Flame out" ....any ideas based on previous message? cheers Graham

Read fault codes last night, am getting "Repeated Flame out" ....any ideas based on previous message? cheers Graham

Hi, anyone got the fault code for this? Cheers Graham

HI, I've been through the Aux heater issues before - back in Nov 2005, and with this excellent forum I managed to replace the glow plug and all was well.......until now. The smoke started to appear again, so I went and bought another glow plug from VW to fix it. Fitting was more of a pain - as all those bolts that were rusty last time were worse this time! - to the extent I had to drill one of them out. Anyway, got the plug replaced and put it all back together - but heater didn't appear to work. I bought one of those interface cables and free vag-com software and it reported a number of error codes (not visible without paying the extra for vag-com) but it did say "lock-out" - so I cleared the codes - unfortunately at that time it was too warm for the heater to have come on. This morning it was cold (!) and the heater started to fire - there was some white smoke (which I assumed was just a burn off of residual crap), the jet engine noise started and then some loud ticking (which is always a good sign) - then it all stopped :-( I heard it fire up again, more jet noise, more ticking - then off, and then nothing - so I'm assuming its locked out again. One thing that was different this time when I replaced the glow plug was that when I pulled out the old one, a tubular gauze looking object came out with it - pretty much stuck on the plug - I don't remember this during the first replacement. I managed to get it off, scrape some crud off it and then I pushed it back into the whole the plug came out of as far as it would seem to go, I then put the plug in but it was a tighter fit than before. Is the plug meant to sit directly in this gauze? anyone come across this? I'm confident I can reset the vag-com fault codes again but I assume it will just go to lock-out again at the moment Any help would be appreciated Graham PS. I've started a new thread for visibility - but please update the main thread.

HI, I've been through the Aux heater issues before - back in Nov 2005, and with this excellent forum I managed to replace the glow plug and all was well.......until now. The smoke started to appear again, so I went and bought another glow plug from VW to fix it. Fitting was more of a pain - as all those bolts that were rusty last time were worse this time! - to the extent I had to drill one of them out. Anyway, got the plug replaced and put it all back together - but heater didn't appear to work. I bought one of those interface cables and free vag-com software and it reported a number of error codes (not visible without paying the extra for vag-com) but it did say "lock-out" - so I cleared the codes - unfortunately at that time it was too warm for the heater to have come on. This morning it was cold (!) and the heater started to fire - there was some white smoke (which I assumed was just a burn off of residual crap), the jet engine noise started and then some loud ticking (which is always a good sign) - then it all stopped :-( I heard it fire up again, more jet noise, more ticking - then off, and then nothing - so I'm assuming its locked out again. One thing that was different this time when I replaced the glow plug was that when I pulled out the old one, a tubular gauze looking object came out with it - pretty much stuck on the plug - I don't remember this during the first replacement. I managed to get it off, scrape some crud off it and then I pushed it back into the whole the plug came out of as far as it would seem to go, I then put the plug in but it was a tighter fit than before. Is the plug meant to sit directly in this gauze? anyone come across this? I'm confident I can reset the vag-com fault codes again but I assume it will just go to lock-out again at the moment Any help would be appreciated Graham PS. I've started a new thread for visibility - but please update the main thread.

Hi, anyone got those torque wrench settings - or know where I can get them - I don't have TIS and I believe the haynes doesn't cover my year (02) cheers Graham

Hi, this threads been great! I can't believe fraud won't sell you a part that wears out after 90k km, but will happily sell you a new alternator at vast expense!! I have now sourced all the parts from VW for my 02 plate 1.9 TDi Galaxy, and have ordered the tool to lock the pully. Has anyone got the torque wrench settings for the pulley, and tensioner mounting bolts? cheers Graham

Hi, I posted a message on another thread about the aux heater - about it producing clouds of smoke - and Ford saying it needed a new one "the seals had gone" - that'll be

Hi, we have a dead compressor on our 2002 1.9 TDi galaxy. cheapestr I've got so far is

ah - ok - looked more closely - its "re- manufactured" On the www.fordpartsuk.com website - a new ford compressor is

anyone used these guys? http://www.bba-reman.com/content.aspx?cont...rcon_compressor ...turns out the compressor our aircon guy was offering was a Hella one, and according to their website - they're all refurbished - not new! - something which the bloke neglected to mention funny, I was just thinking of making sure I ask for the old one after it had been replaced - so I could take it apart and see what had broken - but of course - I bet the bloke would have wanted to keep it - so he could exchange it and get a wedge of money back - while charging us

I'm in Hertfordshire. Graham