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Author Topic: '99 Mk1 Galaxy engine related behaviors  (Read 622 times)

Offline clm

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'99 Mk1 Galaxy engine related behaviors
« on: June 08, 2019, 09:21:05 PM »
Hi.

The car was bought without trying it on higher speeds as it was working well in the city streets.
But once I got it and took it to highway, it wouldn't have any power going slight uphill. 80km/h is the top for it. On level ground and slight downhill it goes up to 160km/h or so.

First it went to mechanic who changed the fuel filter, checked the air filter and replaced the high pressure fuel injection pump as it was leaking too much. Also notified us that the turbo leaks oil. Also said that the vacuum pipes were connected wrong way somewhere so he rerouted them.

The car started moving slightly better (and didn't stink of diesel any more), but still doesn't go long slight uphills on highway. Same as initially.

It's pretty noticeable how it switches to limp mode between 3-4k rpm. Until then it keeps pulling ok
on 4th gear when riding hard on it, but then there is a slight hesitation (choking) after which there is no more proper acceleration. Similar behavior on other gears with slight different rpm. Easy to replicate. After engine shut off it seems to reset.

As the air filter was clean and it got a new fuel filter my next step was checking/cleaning the MAF sensor.
I took it off together with the air hose part it attaches to. And first thing I noticed was the inside of the
hose covered in black oil (definitely shouldn't be there). Just a slight film of it, but fresh and very black.
And of course the sensor was covered with it as well.

As the mechanic told us that the turbo is leaking oil, I guess it's on the intake end and it blows it back all the way to the maf sensor.

I doused the sensor with electrical cleaning spray until it looked squeaky clean.
Upon test driving the car the behaviors were the same as before. I can't say that I noticed any big difference with the MAF cleaning. The limp mode still kicked in as described above.

Thus our next plan is to take it back to the mechanic for a turbo check/fix/clean, or possible replace if former are not options any more.
As the turbo location is far behind the engine it's really hard to see or feel it. I wanted to try to push the lever that movers the vanes, but unable to get to it from the top of the engine.

I'm not able to confirm if the vanes are stuck, but given the behavior of the limp mode it would suggest it. Also the previous owner was an old guy living in a big city. So it never got proper riding to keep everything clean.
In my other post I mentioned fixing a horn that was stuck shut. Probably because he didn't exercise that enough either :D

Also not sure if the turbo fix would deal with the limp mode. Is the MAF now working or not is hard to tell.



On a side note, would it be reasonable to also take off and clean the EGR valve? Hopefully I would be able to get it off with limited toolbox.

Or other suggestions?



Aside from all this, I would like to ask about another behavior that I feel like is maybe not as it originally was intended to.
It's about turning on and shutting off the engine. They both feel a bit rough for the absence of a better word for it. More noticeable with shut off when turning the ignition off, the engine shuts down quite abruptly and with decent shake. Normally with other cars it feels like the engine is spooling down smoother (more with gasoline engines). This one feels like doing half a turn and done, together with a jolt.
Similarly when starting up, the starter turns for a second or so, and then then engine 'jumps' on with a bit of a sudden shake also.
Is this normal with all old diesel engines? Overall the engine itself actually runs smooth and quiet (couple people have even noted that). Something is supposedly re-built in it also, so it may be in quite a good condition.



And final question or thing I noticed is that when turning on the ignition switch, the glow plug light comes on for only a split second (not more than second). Before I didn't see it at all, but as I have been dealing with fixing other small stuff it started showing. Maybe it had something to do with the engine coolant fuse that was not present in the fuse box. I added it and possibly started seeing the temperature needle move.. although not into the 'norm' temp zone. Just at the beginning of it. Although I haven't been riding more than 10km at a time so maybe it doesn't get hot enough with this time. Or it may have some issue as well as not measuring the temp correctly.
Not sure how long the glow plug light should stay on, but I feel that with a cold engine it should be at least a bit. Living in South of Europe where it's 20'C around my area.

Thank you for any advice.


Offline SirDavidAlhambra

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Re: '99 Mk1 Galaxy engine related behaviors
« Reply #1 on: June 08, 2019, 10:05:06 PM »
Does it ever go into limp mode at lower speeds?
I drive a Seat Alhambra 1.9Tdi which has 115bhp and an automatic gearbox.

I am happy to help you with all your questions. I am not a qualified mechanic but seem to be better at fixing my car than even the most experienced garages.

I have lots of friends here and very much enjoy talking with you all.

Always remember, a motor car is a serious tool and should be treated with respect. Put your safety first, always.

Offline clm

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Re: '99 Mk1 Galaxy engine related behaviors
« Reply #2 on: June 08, 2019, 10:45:07 PM »
Nope.

The speed doesn't seem to matter so much. It's the rpm that throws it off. I would assume that 3-4k rpm it gets too much boost and switches it to safe mode.

Offline brianh

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Re: '99 Mk1 Galaxy engine related behaviors
« Reply #3 on: June 09, 2019, 12:08:36 AM »
Glow plug sounds about right to me - clouds of smoke and difficult starting would be expected if they weren't working.

Does sound like the turbo is past its best, might improve with cleaning it, various posts here about doing so but the first suggestion your likely to get is to give it a blast as far as you can - holding it in 3rd or 4th at higher revs if you can get it to do so for about 10 minutes (ideally you want a stretch of clear road that you can do some speed on for this, no good doing it whilst stationary).

There is a lot of coolant in the Galaxy system, and they don't tend to run particularly warm - hence the booster heater fitted to them. Though its worth checking the coolant is actually getting pumped around - theres a return to the expansion tank via the small hose, that should be a constant dribble when the engine is running. Also worth checking if you have a run on pump (will be on the bulkhead near the expansion tank) that its running as well with the ignition on (should be able to hear a slight humming from it)

If the MAF is suspected to be a problem, then the usual advice is to try unplugging it to see if it improves any. But if the air intake is coated in oil, then its likely the MAF is as well. So might be an idea to try and clean that (can of Carb cleaner probably the easiest option first).

Offline SirDavidAlhambra

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Re: '99 Mk1 Galaxy engine related behaviors
« Reply #4 on: June 09, 2019, 08:01:46 AM »
Why would the car only cut out at high speeds but not at low speeds?
I drive a Seat Alhambra 1.9Tdi which has 115bhp and an automatic gearbox.

I am happy to help you with all your questions. I am not a qualified mechanic but seem to be better at fixing my car than even the most experienced garages.

I have lots of friends here and very much enjoy talking with you all.

Always remember, a motor car is a serious tool and should be treated with respect. Put your safety first, always.

Offline clm

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Re: '99 Mk1 Galaxy engine related behaviors
« Reply #5 on: June 09, 2019, 10:18:04 AM »
It may go into limp mode with lower speeds also if pushed to high rpm at 1st-3rd gear. I just tend to push it harder on 3rd and 4th. Mostly based on the way of driving.

We have been actually doing some highway runs on higher rpm to exercise the turbo in hope of getting it moving more. And whatever else that needs to be exercised as it has been riding in city all the time. Would say that it feels a bit better than in the beginning, but definitely still has limp mode issue.

The MAF got cleaned when I found the tube having oil inside. But I would assume it would get covered with it over time again until the turbo gets fixed.

Thinking about checking/cleaning the EGR valve if I can get it off.

Regarding starting and stopping. It starts with not much issue (no smoke) besides the sudden shake or jump. Same shake when stopping with very short spooling down time.
I may have to check the engine mounts, as there are other small symptoms that could relate to those.

One quite noticeable thing is that the manual gears don't always go in smoothly and where you would expect the shifter to go.
The other day I noticed that the clutch pedal was at half position. And I have had some grinding gear shifts, which required the pedal to be pushed all the way to the floor. Usually you can disconnect somewhere before hitting the floor.
This could relate to clutch cylinder? Or inside clutch issue? It's not slipping though, in any gear or speed, feels ok.
Finding 1st and 3rd gear sometimes feels a bit off, together with resistance to go in smoothly. Could be because of the clutch, shifting mechanism or would a bad engine/transmission mount also affect the situation?

Offline brianh

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Re: '99 Mk1 Galaxy engine related behaviors
« Reply #6 on: June 09, 2019, 04:12:54 PM »
With the pedal symptoms, first thing is to check the level of the brake fluid as it comes off the same reservoir, That may be the cause of the difficult changes, but could also be related to the selectors or cables. The selector on some of them can be a problem area, but I think mk1 is usually ok for this (the fix I think is check for a loose bolt, and clean up the selector area with wd40 usually). But if the clutch is the cause, then the gears will select easily without using the clutch with the engine stopped, which should allow you to narrow down the cause.

Yes - assuming the oil is coming from the turbo then the MAF will be coated again, but its worth checking its not getting there via the breather as well just in case (not sure what the arrangement for that is on the diesel engines, would expect it to feed into the bottom of the air filter box though, so if its coming from there the filter will be oily too).

There are various posts on here suggesting mr muscle can be used to help with the turbo vanes, Never done that personally so suggest you have a read around and see if you think it will help. There are many posts on turbo problems, but if its leaking oil then it probably wants replacement anyway.

Offline clm

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Re: '99 Mk1 Galaxy engine related behaviors
« Reply #7 on: June 09, 2019, 04:48:25 PM »
The air filter itself is clean, as that was the first thing we checked related to the 'choking' and low power.
The oil originates from the turbo. Just sticking my hand behind the engine to search for the turbo I got it all black from the leaked oil.

Unfortunately the location of it requires access from below and better tools than I currently have available. Thus it has to go to the repair shop. There they can decide if it's worth cleaning or it needs replacement.

I will check the clutch and gearbox related details as instructed.


Offline clm

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Re: '99 Mk1 Galaxy engine related behaviors
« Reply #8 on: June 09, 2019, 05:42:39 PM »
Switching the gears by themselves (engine off) they feel ok. Feels like going in better than when driving.
I have noticed that when driving the first gear goes in when the level is pulled all the way to the left side as much as it can go. Right now checking at stopped position it went in at a 'normal' position when pulling to the left.

Another thing I notice down at the gear shifter is that one side of this white ball looking this is moving up an down while the other side seems to be staying in place. This is with just moving the 'free play' area, not full left to right push. I will take the assembly apart and check if everything seems to be in one piece. Also some lubrication for smoother movement.
I made a short clip about it:
6601-0

Offline SirDavidAlhambra

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Re: '99 Mk1 Galaxy engine related behaviors
« Reply #9 on: June 09, 2019, 06:52:04 PM »
Could the turbocharger actuator arm need winding out a bit
I drive a Seat Alhambra 1.9Tdi which has 115bhp and an automatic gearbox.

I am happy to help you with all your questions. I am not a qualified mechanic but seem to be better at fixing my car than even the most experienced garages.

I have lots of friends here and very much enjoy talking with you all.

Always remember, a motor car is a serious tool and should be treated with respect. Put your safety first, always.

Offline clm

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Re: '99 Mk1 Galaxy engine related behaviors
« Reply #10 on: June 10, 2019, 08:37:04 PM »
I disconnected the MAF cable before going to a ride.
Took it to the highway and had the same behavior as before. Limp mode kicked in when pressing it hard.

What does this say about the MAF? Is it working when connected, or not working? If the problem lays possibly in the turbo then what behavior to expect with connected or disconnected sensor?

Cleaned the gear shifter mechanism also. Was totally dry and full of crud. But the shifting didn't really change which means it's down at the gearbox. Not a big issue, just small annoyance when the shifting has some extra resistance.
Brake fluid was at optimal level.

Offline SirDavidAlhambra

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Re: '99 Mk1 Galaxy engine related behaviors
« Reply #11 on: June 10, 2019, 08:45:00 PM »
Is it an air leak on the InterCooler
I drive a Seat Alhambra 1.9Tdi which has 115bhp and an automatic gearbox.

I am happy to help you with all your questions. I am not a qualified mechanic but seem to be better at fixing my car than even the most experienced garages.

I have lots of friends here and very much enjoy talking with you all.

Always remember, a motor car is a serious tool and should be treated with respect. Put your safety first, always.

Offline brianh

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Re: '99 Mk1 Galaxy engine related behaviors
« Reply #12 on: June 10, 2019, 09:27:11 PM »
I disconnected the MAF cable before going to a ride.
Took it to the highway and had the same behavior as before. Limp mode kicked in when pressing it hard.

What does this say about the MAF? Is it working when connected, or not working? If the problem lays possibly in the turbo then what behavior to expect with connected or disconnected sensor?

Cleaned the gear shifter mechanism also. Was totally dry and full of crud. But the shifting didn't really change which means it's down at the gearbox. Not a big issue, just small annoyance when the shifting has some extra resistance.
Brake fluid was at optimal level.

With a disconnected sensor it should rule the MAF out - As it will subsitute a default map (which won't be as optimal as the MAF would make it, but should be fairly close performance wise). So if it improved when MAF was unplugged, then that would suggest the MAF was bad, no improvement suggests the MAF isn't the cause.

I'd suggest since it goes into limp mode, that VCDS might be your best bet to find out why, as I'd suspect/expect it will be logging a fault code for the reason for limp mode, that would give you a good place to start from (a VCDS lite lead should be fine for looking for fault codes, don't know where you are as you didn't say, but a lead like this one should be fine
https://www.ebay.co.uk/itm/UK-USB-Cable-KKL-VAG-COM-409-1-OBD2-II-OBD-Diagnostic-Scanner-VW-Audi-Seat-VCDS/362664658036

You may need to look around for a suitable source for the lead, but it shouldn't be very much you need to pay for the basic one.

Download VCDS lite from Ross-tech - the free version is the one you want.

As far as the shifter goes, I'd try using it as it is for now, and then lubricate it again after you've driven it a bit to see if it improves. Might also be an idea to check the gearbox oil level though if you haven't already?

Offline SirDavidAlhambra

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Re: '99 Mk1 Galaxy engine related behaviors
« Reply #13 on: June 10, 2019, 10:13:43 PM »
The reason for the limp mode will be P0234 Overboost, it always is
I drive a Seat Alhambra 1.9Tdi which has 115bhp and an automatic gearbox.

I am happy to help you with all your questions. I am not a qualified mechanic but seem to be better at fixing my car than even the most experienced garages.

I have lots of friends here and very much enjoy talking with you all.

Always remember, a motor car is a serious tool and should be treated with respect. Put your safety first, always.

Offline clm

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Re: '99 Mk1 Galaxy engine related behaviors
« Reply #14 on: June 10, 2019, 10:23:15 PM »
The shifter assembly got cleaned and well lubricated so it should be fine now.
Don't have a way to check the transmission oil though as I don't have a garage or bigger tools for working on the engine.
Unless there is a dipstick for it under the hood? Changing the oil may make it work better I guess. It has 330k km on it, and we don't really know if or when it has been changed the last time.

Regarding fault codes the mechanic mentioned something about it but I don't know which code it actually was as the information has been going through another person (owner of the car, as I am the user for it in the company).

The plan is to take it to the mechanic for turbo problems anyway, so can ask to check all the mentioned details. I won't be planning to get a cable to check the codes right now, as I may not be able to do anything with the results.
This will wait a bit though until some other thing align for it. Until then I will deal with small stuff that I am able to do myself.

As there was no change with the MAF disconnected it may rule it out. But that can only be confirmed once other possible variables are checked as well.
Our biggest suspicion is on the turbo, since it was driven by an older guy in a big city. So not cleaned up properly thus the blades may be stuck in the turbo. And it's leaking oil, so possibly two issues.

Offline brianh

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Re: '99 Mk1 Galaxy engine related behaviors
« Reply #15 on: June 10, 2019, 10:37:42 PM »
What you say there sounds like the best course of action overall. The oil (assuming its a manual box - Which I think is the case) goes in through a filler on the front of the gearbox, but you'd need to remove the undertray (if its still there) to get to it. No dipstick fitted, but you don't usually need to touch it. Given the miles, theres a good chance its lost some in the past, or is leaking - the usual place for that is where the driveshafts come out of the gearbox.

If its an auto box, then the fluid does suffer over time, swap out somewhat more involved, details would be in the faq section at the top of this forum on doing it. And if the fluid is either low or in poor condition, that might effect shifting between the gears, but not sure if it would effect the gearstick - and your description suggests it isn't an auto anyway?

Offline clm

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Re: '99 Mk1 Galaxy engine related behaviors
« Reply #16 on: June 10, 2019, 10:51:45 PM »
It's 5-speed manual. Have to be checked at the mechanic.

Offline johnnyroper

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Re: '99 Mk1 Galaxy engine related behaviors
« Reply #17 on: June 11, 2019, 03:29:31 AM »
Bleed clutch if still same check shims in gear shaft,has been known they are shimmed incorrectly allowing gear shaft to move when pressing clutch.

Offline clm

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Re: '99 Mk1 Galaxy engine related behaviors
« Reply #18 on: June 12, 2019, 07:10:03 PM »
Decided to check the EGR valve today.

Once I got it off this is what revealed itself.
6611-06613-1

After thorough cleaning it showed some rust, but seemed to be working. Was able to push on the end of it and have the valve move. The spring felt stronger than I anticipated. But maybe the vacuum gets strong enough to pull it.
6615-2

As I didn't want to push the crud from the intake manifold side into it, I decided to pull off the air hose and get fingers in there to push it out instead.
But this revealed something much more.

The intake is covered in thick black tar like crud.  ??? Horrible.
6617-3

And the air hose itself is all covered in thin black oil from the inside. Same as on the other end where the MAF was covered with it.
Thus the leaking turbo is covering all the hose in oil.
And once it reached the EGR junction it mixed with carbon soot, creating thick sticky mess that covers the intake now. Yuk.

Guess the mechanic will not only have to deal with the turbo but also take off the intake and all the air hose for thorough cleaning.

On a positive note it seems like the EGR had been working before getting all caked up, otherwise there wouldn't be all this tar in the intake.

With this, the other connecting sensors and whatnot that attach to the air hose are covered in oil as well. Anyone knows what is the one electrical sensor and a vacuum connection next to it on the right side (facing the engine) attached to the main air tube?

Regarding vacuum tubes they don't look any good either. At least the back sides of them that are not visible. I see one of them going somewhere on the top right side of the engine compartment towards firewall. What is that? How easy or hard it would be to replace all the tubes when only having access to the top of the engine (working on the street with non-heavy duty tools).

Offline SirDavidAlhambra

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Re: '99 Mk1 Galaxy engine related behaviors
« Reply #19 on: June 15, 2019, 11:07:40 AM »
Respectfully, why are you spending all this time randomly hopping from gearboxes to EGR to MAF sensor to transmission oil to shifter assembly to turbo without even checking the fault code first... surely thatís the best place to start?
I drive a Seat Alhambra 1.9Tdi which has 115bhp and an automatic gearbox.

I am happy to help you with all your questions. I am not a qualified mechanic but seem to be better at fixing my car than even the most experienced garages.

I have lots of friends here and very much enjoy talking with you all.

Always remember, a motor car is a serious tool and should be treated with respect. Put your safety first, always.

Offline clm

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Re: '99 Mk1 Galaxy engine related behaviors
« Reply #20 on: June 15, 2019, 03:49:26 PM »
Because some of those things I can deal with myself without taking it to the mechanic and pay for replacements where they may not be necessary.
The fault codes would not tell me if I have worn out engine mounts, old gearbox oil or dirty dry gear shifter.
So far all those things I have focused on have needed cleaning and either eliminated or revealed next steps.

The fault code may only tell me that there is a problem with overboost. Yet the MAF is covered in oil, the EGR is completely blocked and the turbo is leaking oil plus may be clogged as well.. thus all of those need attention. If I ask mechanic to check them he would say you need new MAF and EGR, Ä300+ investment, compared to some of my own time and Ä5 worth of cleaning products spent on it, out of which I'm also getting knowledge and understanding how the system should operate and what condition it is in.

The mechanic checked it with the computer and said there was a code. But given the lack of focus on that code I would assume he knows also that there can be multiple causes for it, thus knowing the code itself doesn't help much.

Wasn't one of your own posts about investigating with multiple mechanics whom all just looked at the code and couldn't really understand or fix anything? I'm trying to avoid that. Those things I do myself I know are done properly.

Offline SirDavidAlhambra

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Re: '99 Mk1 Galaxy engine related behaviors
« Reply #21 on: June 15, 2019, 05:24:18 PM »
Good plan, itís always good to make sure everything is in good condition. Many people take their car to be serviced but donít realise that the mechanics often donít do anything other than an oil change. By keeping an eye on it yourself, you know exactly what state the vehicle is in and - lets be honest about it - can do a better job than the so-called professionals because youíre more likely to think about the problem and take care trying to fix it. I went to one garage and they couldnít even do basic stuff like pull up the carís handbrake when they parked it outside. I know almost nothing about cars yet always seem to get the right answer when the garages canít fix my car, I think ultimately it is all about owning the problem and thinking.  :)
I drive a Seat Alhambra 1.9Tdi which has 115bhp and an automatic gearbox.

I am happy to help you with all your questions. I am not a qualified mechanic but seem to be better at fixing my car than even the most experienced garages.

I have lots of friends here and very much enjoy talking with you all.

Always remember, a motor car is a serious tool and should be treated with respect. Put your safety first, always.

 

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