Electrical Problems

[Pmmaster]

Hi Guys,

 

Hope someone might be able to help! I own a 96 Mk1 Galaxy TDI.

 

Problem 1:

 

Last week I saw the start of some weird electrical problems. Firstly after some heavy rain overnight the Galaxy refused to start the following morning. It was spinning over and wouldn't fire. So I checked the fuel, that was fine. Checked the fuel pump solenoid and it had less than a volt of power. I checked battery and it was fine so I ran a cable direct from the battery to the solenoid with a switch. It started perfectly so I took it for a drive and found it ran ok but was VERY sluggish in 1st and second gear. I also noticed the second problem which I'm not sure is related or whether it is a seperate problem also caused by the rain.

 

Problem 2:

 

The speedo, rev counter are now working only intermitantly along with the temp gauge and fuel gauge. Each cycle between working or reading incorrectly, it seems random. The current situation is no speedo, no rev counter engine temp half way, fuel gauge half way despite engine being stone cold and me knowing there is only a little bit of fuel in the tank. More rarely the handbrake light and abs/airbag lights have lit up and also the oil light once or twice started flickering on and off.

 

I've spoken to a helpful local ford specialist who has recommended I check the engine control unit under the passenger seat as they can become submerged in water. I have also seen the dash "POD" earth strap mentioned in another thread but I've no idea what the POD is or where to find it.

 

If anyone has any ideas I would really appreciate any help, I'm fairly sound with mechanical stuff but I've only really dabbled when it comes to electrical problems! We really cant afford an auto electrician so I'm gonna have to figure it out myself so any help would be really appreciated!

 

Thanks

 

Paul

Edited November 1, 2012 by Pmmaster

[dlt1617]

Hi the dash pod is the instrument cluster i.e. the main bit with the speedo etc in, it sounds like earth problems could be the cause so I would start with tht and work from there.

Also worth mentioning is the relay problem you can get which causes the fuel pump not to work (have a look I think on your age of vehicle it's 26 and 30) best to do a search on the forum and confirm

 

 

Best wishes

 

Dave

[viperclive]

Do you have a sun roof, if so the pipes that allow water to escape from the leak tray below roof glass may have come off, causing rain water to fill the compartment below front passenger seat where ford in their infinate wisdom put all kinds of very expensive electrical modules n stuff, my 97 2.3 ghia x has the window and central locking one, in a heavy storm it flooded shorted out and all the windows opened lol

[Pmmaster]

Hi Thanks Dave, I have got the Instrument cluster out but as yet not had a chance to look very far. That said, when connected I can hear a small humming sound coming from it even if the ignition is off and key removed!? I couldn't see any obvious earthing points to check behind it, but will have a better look when I get five mins. I changed the Relay 601 in the main fuse box (on right hand side below steering wheel) but not had any effect to the starting. I also checked under the passenger seat and found a control module of some kind, but it was bone dry under there and someone had also wrapped it in an air sealed bag for good measure! Could the cluster itself be faulty?

 

Viper Clive, thanks for your input, I dont have a sunroof and as I mentioned it is bone dry under the passenger seat. Annoying, any other ideas welcome!

 

Can anyone tell me the best way of checking the earths? I have looked in the Haynes manual but the earth strap locations are pretty sketchy. Looking at the wiring diagram I think I need to be looking on the bulkhead or the engine. Any help on this would be hugely appreciated!

 

Thanks

 

Paul

[Pmmaster]

Just reviewing the electrical diagrams, it seems to be pointing towards earth point 20, described as Left Hand Engine. I have had a look around for it but its not immeadiately obvious where it is. Has anyone got any experience of it to give me a clue whether its front, back top bottom etc on the left hand side? I assume it is left hand as in when you are sitting in the car?

 

Thanks

 

Paul

[dlt1617]

Hi Paul the earth point on the later Mk2 Galaxy is behind the plastic that holds the expansion bottle so you have to remove the battery and then the plastic trim to gain access.

 

Best wishes

 

Dave

[Pmmaster]

Thanks Dave,

 

Mine is a Mk1, i guess it'll be the same tho, is that the main earth strap? (number 1 on haynes diagram). I may give that a clean as a matter of course. I have a mini update, I managed to find an earth strap on the gearbox end of the engine block connected to the circular wiring connector bracket. I found it was corroded to hell and not registering any continuity with the body. I cleaned it all up and applied some petroleum jelly, I also opened the round connector and used some contact cleaner spray in there. Checked continuity and it was good and hey presto!, all my gauges are now working! It looks like there were three wires on there the speedo, temp gauge and fuel gauge are my guess, certainly according to the Haynes wiring diagrams the temp gauge and vehicle speed sensor earth at that point. Anyway chuffed they are working again and thanks for the help, it seems you were spot on about it being an earthing problem! The humming sound I reported from the cluster has also stopped so it seems pretty conclusive, result!

 

Still got the starting issue though. I removed the multi plug from the fuel pump that supplies the stop solenoid and goes onto the MAF sensor I believe. I was previously seeing 0.7v on both power feeds and got a good earth. I'm now seeing 12v on the MAF feed and 8.5v on the stop solenoid supply. I still have my bypass cable straight from the battery which when energised starts the car no problem supplying 12.5v. So I know the solenoid is good and I have fuel etc. I am just wondering if anyone has any idea why I am only getting 8.5v on the existing suppy loom? I'm guessing the 8.5v is not enough to activate the solenoid and thus its not starting without my homemade loom. The car is usable but I would much rather not have to keep switching the direct power on.

 

Any advice greatly recieved. I will post some pics later on of the earth straps (I found a couple!) for future reference for anyone else who has the same problem.

 

Thanks for the help so far

 

Paul

Edited November 12, 2012 by Pmmaster