insanitybeard

Is this jacket something that affixes to the underside of the plastic top cover? My 130ps TDI has the slightly different type of top cover to the plain black plastic one, and the only insulation is the foam insulation on the reverse side of this cover.

Do you mean the 'beautification' cover that sits on top of the rocker cover, or are you meaning what I assume may be number 4 here? Or is it something else entirely?!

Confusingly, I think 'superheating' was just one of Ford's terms for the booster heater. If you have one fitted I would think you'd have to have an auxiliary water pump fitted to circulate the coolant through the booster heater and rear blower box effectively.

Remember the turbo doesn't boost all the time, and certainly not straight from idle, so yes, the manifold pressure will be positive sometimes when the turbo is boosting but equally will be negative whenever it isn't. I think the turbo only really starts to boost when the engine speed hits around 1500rpm.

On the Mk1, the ambient air temp sensor used for the air con and temp readout looks like it's number 23 here, don't 100% trust the part numbers but it should be a reasonable guide. This diagram is for a Mk2 Galaxy as the link for the Mk1 diagram is busted but I believe shows the sensor (number 1, even though it says 'sensor- air conditioning' in the description!) in the wiper linkage area used by the booster heater to determine if it starts up or not. They are different sensors I believe.

Be careful if you buy a Bosch one (secondary water pump) from the 'bay, I nearly got caught out by somebody selling Bosch pumps with square connectors for earlier models, make sure the one you buy has the same part number as your old one- most of the Mk2's have a pump with a rounded connector and the part number 392 020 073, I got a pukka Bosch one from the USA as even with the import charges it only cost me about 70 quid including postage- checking now there's one here in Germany (for example) so you won't even have import charges to worry about, you may be able to get 'em for similar money in the UK from a Bosch agent but I wouldn't know where to look.

Yeah, the O.E driveshafts were likely made by GKN so you shouldn't go wrong there.

Did you change the bearings underneath the top mounts as well as the top mounts themselves?

Diesels especially with EGR suffer from oily gummed up inlet tracts especially after a few miles, the recirculated exhaust gas mixes with oil vapour forming horrible thick oily sludge which sticks to the internals downstream of the EGR valve. The breather hose isn't worth fussing about too much unless it's really sloppy or obviously split, the leakage from the EGR valve isn't unusual, it's just oil/sludge buildup in the inlet tract- mine's like it to a lesser extent, if you want to address that then you need to remove and decoke the valve and ideally the inlet manifold, a messy and time consuming job.

Yep, I had two fault codes on mine, as you- glow plug short to ground and also glow plug open circuit. If you've got a Z-F model heater then I'm 'fraid it sounds like your ECU has packed up to me..... Last winter my booster operated on perhaps 2 or 3 occasions, and that was it. When it did run, it was fine- no smoke or anything, so for me that as good as confirmed that my ECU had had it.

Have you checked to see if there are any fault codes stored? As Silverbeast said, on a 2005 reg yours has got a good chance of having a D5Z-F model booster heater which are prone to ECU failure, my '54 plate has this model and needs a replacement control unit.

There's the usual suspects like GSF and Euro, though looking at GSF I couldn't see a speed sensor listed. Failing that, if you want it delivered, you can find most things on the 'bay........

Some discussion on it here............

Ford do seem to have started charging a premium on some fast moving Galaxy parts (probably because many of them are VW sourced- call me an old cynic but it wouldn't surprise me if they don't want to warehouse some of it any more so have an agreement with VW so that when you order a part from Ford it actually comes from a VW warehouse.........) - I bought a replacement alternator to battery junction box cable (a commonly failing part that overheats at the junction box terminal) backalong and the latest level part number had a list price that was a damn sight more expensive that the previous one! Having just said that, of course the 2.3 petrol is a Ford sourced engine so what I said above isn't relevant in that case of a thermostat.... Sometimes I think the manufacturers just figure they can charge a premium for stuff, especially when there isn't an aftermarket alternative and you're stuck with paying whatever the hell the manufacturer decides to charge for it.

Under the skin and away from the obvious styling differences between the Galaxy, Alhambra and Sharan (and different engines and related items in some models) I think the majority of mechanical components are shared between the 3 models, allowing for differences in spec etc. Even the basic bodyshell is the same to my knowledge, the different looks mostly being due to different tailgates, wings, bonnets and front bumpers between the models!