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My 110TDi Galaxy (Feb 2000, i.e. Mk1) has almost as severe a lifestyle - 6 mile round trip, twice a day. It has also had intermittant 'limp mode' for ages. You will find a lot of info about this on this site and also on the (US) TDiclub site. Apparently the standard dealer response is

I came across this which might be of use: http://forums.tdiclub.com/showthread.php?p=844411 Not for Galaxy etc, but shows the general idea re cleaning.

Well, after another extensive search last Saturday night, I found this post by rcg1 from 20 May 2005 see here which mentioned relay 114. The pics I took, showed this at the lower right of the 2nd level. Dismantled again, removed relay, checked on bench and yes, although it clicks, both contact sets remain open circuit. I took it apart for interest, and one of the contact sets had overheated and melted surrounding plastic, hence jamming it off. For anyone who needs to know, the VW part no. on the relay is 701959141A. Contrary to the post by rcg1, Fords do supply this - my local dealer came up with the number (after a 10 min search). Ford part no. is 7203550 (Air Con Blower Relay) and they ordered it from Ford UK for me. They were slightly cheaper than VW as well.

Back again. I've just spent the evening dismantling the fuse box to get to the second and third levels, which went reasonably ok. However, there was nothing obviously wrong and the relay numbers are even more wildly different (than the fuse info) to both the handbook and Haynes. So - can anyone tell me what relay number I should be looking for please?! (or what else I can do). Its getting a bit urgent as we are off on holiday soon. Scorpiorefugee: I should mention that I have done quite a lot of searching past topics, but still missed your/seatkids posts on the fuse box wrt glow plugs (found it now, thanks). Also, as suggested elsewhere, I went back and checked every fuse (on the first level) to no avail. Re the turbo problems, have had this for a long time (>1 year) and learned lots of stuff from past topics over a lot of that time (eg seatkid again on vacuum piping etc), but not fixed it ... The fault is intermittant and isn't really a problem going round the lanes on the school run, which is the Gals main use. I changed the MAF initially (tried cleaning first). Since then I've been over all the vac pipework (except one bit - see below) and changed the charge pressure control valve (for one from a scrap yard as Fraud wanted

Ron, Thanks for the reply and advice. I saw the clip at the top as well, but couldn't work out how it undid. I think I shall end up doing the same as you. If the ECU is behind there as well, I have a second reason, as I need to check the condition of part of the rubber pipe that I believe goes to a pressure sensor integrated with the ECU. This is in connection with a long standing problem of intermittant turbo shutdown (17958 Charge Pressure Control Deviation)... I could do with an accurate circuit diagram for the climate control stuff. All I have is the car handbook and the Haynes manual at the moment. Various people mention 'TIS'. I presume this is the proper Ford workshop info - any idea how I can get hold of a copy? - or perhaps some kind person can confirm whether I have the relay and fuse numbers right etc.

Both front and rear air con fans have stopped working at the same time. The climate control panel flashes for a while when ignition is turned on, so I checked for Vag.com codes and got: 01273 - Fresh Air Blower (V2) 35-00 - - I'm guessing that it isn't the fans themselves; unlikely for both to fail together. I've checked various fuses - 21, 22, 27, 33. (Handbook says 34, but this one isn't fitted) Next idea is relay 12. Am I on the right track or are there other things to try? If the relay is likely, how do I get access to level 2 in the fuse box? I've seen the post describing access for a Mk2 - is a Mk1 easier or is it still essential to remove all the surrounding trim... It looks as if the top level should swing out of ther way, but I've failed so far. Car is a Feb 2000 (Mk1) Galaxy TDi Ghia X