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Author Topic: Aux heater and air-con  (Read 3941 times)

Offline sebhopley

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  • Posts: 2
  • Thanked: 0
  • Model: Sharan Mk2
  • Spec: 04 tdi 130
  • Region: East Anglia
Aux heater and air-con
« on: March 27, 2016, 08:41:02 PM »
Hi everyone,

My first post here, I just bought a 2004 Sharan (a 130 TDI), and from reading here it would appear that it has the usual suspects wrong with it:

1. Aux heater doesn't work with the error glow plug open circuit.
2. Run on pump in-op
3. A/C doesn't work.
4. Bit of free play and red dust on the intermediate drive shaft.

I've ordered a new intermediate shaft from Poland, hopefully it will go on easily when I attempt it next week, don't really fancy getting stranded when the current one goes so going to pre-empt that one.

For the aux heater, since that is the only code currently I'm hoping that a new glow plug will fix things up. Is there any way of knowing by looking at the unit which glow plug I will need, or is it best to pull the unit and look?

For the pump I'm up for trying to change the bushes, but if possible I want to buy the bushes in advance so that I don't have to bypass the pump while I try to source them. Does anyone know where I could get them. I've found bosch pumps for ~£65 so I might just replace the pump otherwise.

While on the subject of the aux heater, I've found that car really struggles to get up to temperature, I drove for about 30 minutes today ranging from 30-50 mph and when I stopped it had only just managed to get to about 80 degrees. The air temp today was about 8 degrees.
Is this normal or am I looking at a faulty thermostat or coolant temperature sender? I had a mk4 TDI with the same engine in (the ASZ) and it would easily have gotten to temperature in that time, in fact even in minus temperatures it would have. But since VW felt the need to fit an aux heater I am wondering if this is normal when the aux heater doesn't work. It does get to 90 degrees if driven at 70 for 10/20 minutes on the motorway, the only reason I ask about the temperature sender is that this is a very common failure point, but there are no codes logged currently for the engine.

Finally the air-con, the light comes on but nothing else does, no rad fan or compressor.
Now the car has manual air-con, but a quick look behind the bumper shows that it has a G65 pressure sensor (the three pin one), since there are no faults logged I am tempted to think that maybe the system has enough pressure, I was hoping that I could check the output of the sensor, but I cannot seem to find which measuring block will display it, I had been told block 137 on the engine ECU would show it but it doesn't on mine.
VCDS can talk to the heater controls, but apart from a terminal 30 error there are no faults logged. It would seem that the wiring for the air-con on the 130 TDI is different to the other cars with manual air-con, so I am having a hard time finding out what to check or coming up with a check list. Anyone have any pointers. I'm going to get a garage to check the gas pressure this week but wondered what else to look at. From some googling the outside temp sensor seems to cause this (and not throw a code), but I'm not sure where it is on the 130.

Wow mega long first post! But hopefully I'll be able to get some useful info from you lot.

Seb

Offline SilverBeast

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  • Posts: 497
  • Thanked: 14
  • Model: Galaxy Mk2
  • Spec: '05 TDI (130) Ghia
  • Region: Yorkshire
Re: Aux heater and air-con
« Reply #1 on: March 27, 2016, 11:22:46 PM »
Aux Heater should have a part number label on it.  It should probably be visible without removing.  On the Galaxy they changed towards the end of MKII production.  If it's a D5Z-F (which my 2005 is) then seem to be more prone to control board failure than glow plug (again like mine!).  Mine showed both open and short circuits on glow plug at various times before I replaced it.  The glow plug on these models is ceramic and seems to be more reliable. My belief is that when the run-on pump fails the heater overheats (it will shut off itself due to this) but I believe the repeated raised temperatures damage the PCB.  The MKII Library has a few threads on the Aux Heater https://www.fordmpv.com/smf2/ford-galaxy-reference-library/

Have you read this thread on the run-on pump https://www.fordmpv.com/smf2/ford-galaxy-reference-library/galaxy-replacing-the-run-on-pump-brushes-(tdi-and-v6)/ The pictures are actually from when I repaired mine.

The car won't get up to temperature in slow traffic without the aux heater in cold weather as you say. When my engine temp sensor went intermittent it did log and error in VCDS-LITE.

I've no experience with manual air-con, all my problems were with the Electronic Climate Control.

Offline johnnyroper

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  • Posts: 2953
  • Thanked: 148
  • Model: Galaxy Mk2
  • Spec: 02 tdi 115 ghia
  • Region: South West
  • Country: United Kingdom
Re: Aux heater and air-con
« Reply #2 on: March 28, 2016, 12:00:48 AM »
I think the manual air con does not use the outside temp sensor it is only climate that does and stops air con in colder temps.

I would say low pressure stopping it working it's not uncommon to have leak from failed hose on the Galaxy,get the fridge checked before delving in to wiring,switches etc and take it from there.

As above get the run on pump sorted and find out what heater is fitted to determine if glow plug or PCB fault.

Offline sebhopley

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  • Posts: 2
  • Thanked: 0
  • Model: Sharan Mk2
  • Spec: 04 tdi 130
  • Region: East Anglia
Re: Aux heater and air-con
« Reply #3 on: March 28, 2016, 01:22:44 PM »
Thanks for the replies guys,

I completely agree with you about the aircon, need to confirm that there are no leaks before pulling the electrics apart. From what I have read there is an outside temp sensor, as even with manual aircon, evaporator freezing can occur if the outside temperature is too low. I can see a wire that disappears off behind the bumper from the same bundle as the G65 sensor so I expect that's where it is, and I'll have to take the bumper off to check it. But I will wait until the mobile aircon guy has been to check for leaks.

I did take a look at the thread you linked to, and the job itself seems easy enough. But I don't want to have to bypass the pump while I take the remains of the bushes around town looking for someone that has replacements, unfortunately the ebay link in the thread doesn't work anymore. I might see if I can get some based on the sizes given in the thread and give that a go.

My heater is a D5W Z, does that mean its the older style heater, if so is it possible to know which glow plug it has, or is it best to pull the heater off first.

Seb

Offline johnnyroper

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  • Posts: 2953
  • Thanked: 148
  • Model: Galaxy Mk2
  • Spec: 02 tdi 115 ghia
  • Region: South West
  • Country: United Kingdom
Re: Aux heater and air-con
« Reply #4 on: March 28, 2016, 02:42:21 PM »
http://m.ebay.co.uk/itm/BERU-GH-001-GH001-GLOW-PLUG-HEATER-WEBASTO-FORD-GALAXY-SEAT-ALHAMBRA-VW-SHARAN-/321704379784?nav=SEARCH

This is the glow plug you need for a D5WZ heater you will also need to clear codes once changed as they lock out. I would also bypass the ambient temp switch and fit a manual switch on dash so you can run over summer to prevent combustion fan motor seizing.

As for the brushes these will do the job just fine all you will need to do is file a small groove on rear to hold spring as they are rear entry and not side entry. I did this with mine as couldn't get side entry and its performed perfectly fine for nearly a year.
http://m.ebay.co.uk/itm/Replacing-5mm-x-5mm-x-11mm-DC-Electric-Motor-Carbon-Brush-2pcs-/222020881799?nav=SEARCH

What does ambient temp on dash say? I think the same ambient temp sensor is used for dash and climate. I know frost protection is built in to climate but I am fairly sure the manual air con does not have this,however I may be wrong? Either way waiting for fridge pressure/leak check is best plan before going any further.

Offline johnnyroper

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  • Posts: 2953
  • Thanked: 148
  • Model: Galaxy Mk2
  • Spec: 02 tdi 115 ghia
  • Region: South West
  • Country: United Kingdom
Re: Aux heater and air-con
« Reply #5 on: March 28, 2016, 02:57:34 PM »
I stand corrected just done a Google and it seems the pressure switch should be closed so 12v out and it looks like feed in comes via the outside temp sensor which is located behind bumper.

Without seeing wiring diagram would think the feed to temp sensor will be from air con switch it then goes through the temp sensor and high/low pressure switch interlocks to energise air con relay which then energises the compressor clutch. Not sure if the high and low pressure switches run in series,on rail vehicles they operate like this so would expect cars to also? Hopefully your air con man knows about the electical side of things aswell as gassing so he can diagnose if pressure is good.

Offline Chrispb

  • Mindsaysyesbodysaysnono
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  • Posts: 3024
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  • Model: Galaxy Mk2 Auto
  • Spec: 52reg TDI 115 Ghia
  • First Name: Chris
  • Region: South East
  • Country: United Kingdom
Re: Aux heater and air-con
« Reply #6 on: March 28, 2016, 03:59:40 PM »
If you want/need to fit the ceramic plug with wires attached the VW number is 7M3963319A or Ford 1417618 this can be used to replace the GH001 Beru plug
2009 Kia Sedona GS In Black 2.9CRDI 183PS. 5 Speed Manual WAV.
2003 MK2 Galaxy Ghia In Solid Black 1.9 TDI 115PS. 5 Speed Automatic.

Upgraded Eberspächer booster heater  to independent heating with 7 day timer.

With VCDS lite (full version) need a code clearing or want to scan for faults in the north kent area, PM me.
All for a pint of Strongbow.

The FordMPV.com Forum - The free forum for questions and answers relating to the Ford Galaxy, S-Max and C-Max

Offline johnnyroper

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  • Posts: 2953
  • Thanked: 148
  • Model: Galaxy Mk2
  • Spec: 02 tdi 115 ghia
  • Region: South West
  • Country: United Kingdom
Re: Aux heater and air-con
« Reply #7 on: March 29, 2016, 03:30:28 PM »
If you want/need to fit the ceramic plug with wires attached the VW number is 7M3963319A or Ford 1417618 this can be used to replace the GH001 Beru plug

Didn't realise the ceramic plug could be fitted to old type heater,had I known that 6 months ago I would have opted for that instead of the standard beru..... Will bare that in mind when plug will no doubt need changing again for next winter.

Offline Chrispb

  • Mindsaysyesbodysaysnono
  • *
  • Posts: 3024
  • Thanked: 112
  • Model: Galaxy Mk2 Auto
  • Spec: 52reg TDI 115 Ghia
  • First Name: Chris
  • Region: South East
  • Country: United Kingdom
Re: Aux heater and air-con
« Reply #8 on: March 30, 2016, 12:40:23 PM »
Didn't realise the ceramic plug could be fitted to old type heater,had I known that 6 months ago I would have opted for that instead of the standard beru..... Will bare that in mind when plug will no doubt need changing again for next winter.
A bit more info for you, below is a genuine Eberspächer glow plug with instructions removing the old GH001wiring loom from the internal plug and refitting with the ceramic plug

4229-0
2009 Kia Sedona GS In Black 2.9CRDI 183PS. 5 Speed Manual WAV.
2003 MK2 Galaxy Ghia In Solid Black 1.9 TDI 115PS. 5 Speed Automatic.

Upgraded Eberspächer booster heater  to independent heating with 7 day timer.

With VCDS lite (full version) need a code clearing or want to scan for faults in the north kent area, PM me.
All for a pint of Strongbow.

The FordMPV.com Forum - The free forum for questions and answers relating to the Ford Galaxy, S-Max and C-Max

 

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