A Busy Few Days

[qswi271]

Hello, first thanks for all the posts here, without this forum I would have sold my Gal on by now.

 

It all started when our Zafira got too small for the family, we went looking for a Grand Voyager but came home with a 2005 Galaxy Ghia, leather, DVD player, auto box, with only 99,000 on the clock, turned out to be an ex-taxi (well airport service). All was well for the first week then we started to find the faults, how many of these do you recognise - going into limp mode, heater fan does not work, aux heater does not fire up, oil leak from somewhere in the engine, and a new one I could not find here - front tire shreaded about an inch of rubber down the motorway (lucky we were in limp mode at the time).

 

Having taken it to 2 garages, it was obvious they either did not have a clue or knew too much to mend it. So after not touching a car for the last 15 years I dusted the socket set off, tried to get my jacks to work again, and came here.

 

So far I have changes the timing belt, tensioner, water pump, to assess my technical competence, a garage would quote about 4 hours? I started at 9.00am and finished at 6.00 pm - which involved much coffee and head scratching - why do my mole grips open enough to take the hose clips off, but not enough to get them back on again (new tool in the post). Good news was that the car started first time.

 

Right sort the limp mode, so inlet manifold off and turbo out. What a job, I remembered why I stopped working on car, every nut and bolt was hard to get off, there must have been a few engine designers who had a few too many lagers at the Oktoberfest, "Ve will put the EGR flange so that nobody vill ever be able to dismantle it, haa then sell it to ford". 2 day later I have a classic inlet manifold with a tiny hole and a ton of black grunge. The day ended well as the 5 bolts on the turbo came straight off so I could split it.

 

Tomorrow it's clean up time, and maybe I'll get it back on the road Tues, parts willing - yea the oil tube to the turbo broke. Been taking a few photos so hopefully I find time to post them.

 

Howard

[ggobin]

Good work. :)

[chrispb123456]

Hello, first thanks for all the posts here, without this forum I would have sold my Gal on by now.

 

It all started when our Zafira got too small for the family, we went looking for a Grand Voyager but came home with a 2005 Galaxy Ghia, leather, DVD player, auto box, with only 99,000 on the clock, turned out to be an ex-taxi (well airport service). All was well for the first week then we started to find the faults, how many of these do you recognise - going into limp mode, heater fan does not work, aux heater does not fire up, oil leak from somewhere in the engine, and a new one I could not find here - front tire shreaded about an inch of rubber down the motorway (lucky we were in limp mode at the time).

 

Having taken it to 2 garages, it was obvious they either did not have a clue or knew too much to mend it. So after not touching a car for the last 15 years I dusted the socket set off, tried to get my jacks to work again, and came here.

 

So far I have changes the timing belt, tensioner, water pump, to assess my technical competence, a garage would quote about 4 hours? I started at 9.00am and finished at 6.00 pm - which involved much coffee and head scratching - why do my mole grips open enough to take the hose clips off, but not enough to get them back on again (new tool in the post). Good news was that the car started first time.

 

Right sort the limp mode, so inlet manifold off and turbo out. What a job, I remembered why I stopped working on car, every nut and bolt was hard to get off, there must have been a few engine designers who had a few too many lagers at the Oktoberfest, "Ve will put the EGR flange so that nobody vill ever be able to dismantle it, haa then sell it to ford". 2 day later I have a classic inlet manifold with a tiny hole and a ton of black grunge. The day ended well as the 5 bolts on the turbo came straight off so I could split it.

 

Tomorrow it's clean up time, and maybe I'll get it back on the road Tues, parts willing - yea the oil tube to the turbo broke. Been taking a few photos so hopefully I find time to post them.

 

Howard

My you have been busy :) the booster heater on your model year are prone to ECU failure as well as the glow plug, you need to scan it with vagcom first.

You also want to make sure the electric circulating pump (run on pump) is also working as the booster and rear compartment heater wont run correctly without it.

[qswi271]

Thanks - more work. I ran VagCom on the heater and got glow plug open circuit and glow plug short to ground. I'll check the run on pump.

 

Anyhow issue this morning is I have sheared one of the tork screws inside the turbo - must be a high tensile screw as the drill hardly touches it. Made a management decision and rebuilt the unit with only 2 of the 3 spacers that set the gap for the vanes, all seem to work at room temp, will it last - I suppose I'll find out.

 

Inlet manifold nice and shiny again, all I need is for the new gasket to arrive, along with the turbo oil tube (bargain at

[chrispb123456]

Thanks - more work. I ran VagCom on the heater and got glow plug open circuit and glow plug short to ground. I'll check the run on pump.

 

Anyhow issue this morning is I have sheared one of the tork screws inside the turbo - must be a high tensile screw as the drill hardly touches it. Made a management decision and rebuilt the unit with only 2 of the 3 spacers that set the gap for the vanes, all seem to work at room temp, will it last - I suppose I'll find out.

 

Inlet manifold nice and shiny again, all I need is for the new gasket to arrive, along with the turbo oil tube (bargain at

[qswi271]

Chris - Spot on the electric circulation pump does not work, I pulled off, stuck it on a 12V supply and it worked for a few seconds then died. I guess reading the posts the brushes go. This is starting to get expensive! I can not begin to imagine how labor charges would have been at the local garage.

[qswi271]

After waiting for the bits to arrive the whole job took 6 days, I recon around 15 hours of labour, but I am slow and spend a massive amount of time figuring the simple stuff out.

 

The end result is staggering, it is like driving a new car. She used to struggle, now its vroom vroom.

 

Thanks again for all hints, still not sure what made the biggest difference cleaning the gunk out the inlet manifold/EGR valve/butterfly or cleaning the turbo?

 

I think if I had to do it again I could get it down to around 6 hours. I now have 3 sets of hex keys of different lenghts but still struggled to get the EGR tubes back together again.

 

Finally the run-on pump now works so the car heats up :-) All I need is to mend the Aux heater when I can get a new glowplug - they appear to be out of stock because, wait for, it's winter and demand goes up, yes the manufacturers have not worked out that winter happens this time of year.