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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

drat - compressor pulley is going around, but either pipe out of the compressor after a few minutes shows no sign of being anything other than the same temp before the compressor was started. bloke who did the regass came back today and said basically the same thing, shearing compressor drive shafts are very common on galaxy compressors. He said the compressor was probably the weakest part of the galaxy - and then we told him about the auxilliary heater! :D he quoted

The inner disc seems to be spinning at about the same speed as the pulley. Does the fact that the disc is spinning mean the clutch has successfully engaged and the compressor is being driven? ...how do you tell? If the disc spinning is not a guarantee of the clutch being engaged - is it possible to clean the clutch (I think the car went back to ford before we bought it and they diagnosed a fault with clutch not engaging - they cleaned it (somehow) and reported it working again. when I press the auto button, the revs dip, the radiator fan comes on and theres sometimes a click from the engine bay - which I assumed was the compressor engaging. Graham

The aircon man said my 1.9 TDi had the dual system - how do you tell? I'm now worried that: a) he overfilled it - and thats why the compressor is not working, or :ph34r: he charged me for regassing a dual system - when it was only a single. also - with regards my compressor not engaging - should I try the brake cleaner around the compressor pully? (avoiding the belt and pulley itself) ....how do you clean the compressor clutch safely? Graham

Hi, our Aux heater (under passenger wheel arch) started belching grey smoke a while back so I pulled the fuse. Have read all the threads on the site - but the ford garage it went to for a service seemed to say something different. they said......."the seals have gone" - now, other than the obvious - what does that mean.? ....I thought reasons for grey smoke were things like the metering pump? Is it worth trying to replace just the pump - and can you? Is it worth replacing just the glow plug - has anyone had success with this? Are the ford garage just trying to blag me? ...they did suggest ringing ford customer helpline - as car was just out of warranty - I explained to them that the heater was bust - and it seemed like a very common problem - could they help at all (sometimes they help fund repairs for common faults on cars just out of warranty) - anyway, as we were the second owners of the car - they had no intention of helping! the spouted something about not having all service history blah blah, which, with regards to the Aux heater has got to be bollocks - as I don't imagine a service comes anywhere near this part - until it goes wrong! ...gee - thanks Ford Graham

Hi, I have a 02 1.9 TDi galaxy, and we've been having soem problems with the air-con not working recently - and we're about to go to France for 2 weeks - so I need to get this sorted! The garage thought the gas was low - so we've had it pressure tested and regassed - and the aircon man said all was ok. However, the car isn't getting cold inside - and I think its something to do with the compressor. I'm sure it used to clunk before when you switch the climate control to AUTO (along with a slight dip in revs) - but now you get the dip in revs and no noise. If I look in the engine bay, with the engine running and the CC set to ECON, I notice that theres a "disc" inside the pulley thats attached to the compressor (just under the altenator) thats stationary, when you hit the AUTO switch, theres a click and this disc starts spinning at the pulley speed. (and again - if you hit ECON it stops). Now I know generally these aircon compressors use some sort of elctro magnetic coupling to engage and drive them off the cambelt (or auxialliary belt) - but whats the significance of the "spinning disc"? - does that mean the electro coupling is working? can anyone tell me the mechanism by which the compressor on Galaxys is driven what should I try next ta Graham

thanks Jeff - that reply was useful! I guess I got the impression it was quite a simple fix for did - removal of gas etc seems a bit more complicated. Where is the compressor located - I might have a look see if I can't get at the plates some other way... Graham

Hi, we have three year old 1.9 TDi galaxy that we've had aircon problems with (like everyone else I hear you shout!) Difference here is it was fixed by a rather simple solution before by a Ford garage, but its gone wrong again - and I want to know if this is something I can do myself? The air-con doesn't engage at all, if you switch it between Econ or Auto - the air never gets any cooler. Apparently, what Ford said last time was that the two metal plates (electro-magnetic drive) for the compressor had become dirty/rusty and so when the air con was switched on - the plates wouldn't engage magnetically. They just cleaned the inside surfaces with a bit if wet and dry and hey presto - it all started working again. Can anyone tell me if I can do this myself? and where to look to do it? cheers Graham

Hi, could someone mail me a copy? I had to replace the battery (see other thread) and as yet have been unable to locate the radio code from the previous owner! thanks a million Graham graham.dobson@orange.net

Hmmm...not sure its the same, but we had our air-con fixed recently from what seemed like an intermittent problem. turned out the magnetic clutch plates for the compresser had become covered in a surface rust/muck through lack of use (and where the compressor is located is exposed to the elements somewhat) when the electromagnet is energised, because the plates are dirty - the compressor doesn't engage. not sure the plates were cleanable - but repeatedly switching on and off the air con was enough to get it working again. we just bought the car a little while ago - and know the previous owner - who said they hadn't used the air-con in ages - and therein lies the problem.... you gotta keep using your air-con - even during winter - otherwise it all stops working Graham PS. this might all be bollcoks (other than you really should keep using your aircon - at least 5 minutes a week) but this what was relayed to me via the previous owner when they took the car to Ford.

funnily enough - in august we went camping - with a plug in fridge, and we accidently left it on and flattened the battery! ...all makes sense now. Graham