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Author Topic: Differences in the design of the air filter box of AUY and ASZ engine models?  (Read 1024 times)

Offline Roger T

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  • Posts: 6
  • Thanked: 0
  • Model: Galaxy Mk2
  • Spec: 03 TDI 1.9 PD 130
  • First Name: Roger
  • Region: South West
  • Country: United Kingdom
Hello everyone,

This is my first post here and I have a few questions about my 2003 MK2 Galaxy 1.9TDI which I am hoping someone out there may be able to help with.

Since I bought the car a year ago I have been plagued with the 17965 Positive Deviation fault code which is still affecting the car despite my garage replacing the coolant sensor, the N75 Valve and the brake light switch plus my replacement of the MAF, more of which shortly.

 According the the V5, the engine type is ASX1, indicating it to be the 130PS version with, I understand, a higher Nm rating than the other ASZ without the 1 suffix. But, when I gave the reg number to my insurers on buying the car, they advised me that it is actually 115PS and that is how it is currently insured.

Now, I have had a 2001 Mk 2 Seat Alhambra 1.9 TDI 115PS and a 1998 MK 1 VW Sharan 1.9 TDI 115PS(Red i) before the Galaxy and loved them both but the MAF proved troublesome on each and once changed led to great performance for the rest of the time I had the vehicles.

When my current Galaxy started with what I believed to be identical MAF symptoms (i.e. limp mode on reaching a slight incline, reset after ignition cycle until the next time, no Engine management light etc) I merrily changed it with a genuine Bosch item for the 115PS engine as I had done with the others only to find.....that the problem didn't go away.

However, after browsing this and other sites, I am now confused as to exactly what engine I have fitted, and whether or not I have actually fitted the correct MAF. Engine code aside, the car has the boot lid TDI badging entirely in red although the V5 describes the motor as a TDDI(?) which I always understood to be the more 'agricultural' VW PD 115PS derivative. The Bosch MAF for the 130PS Galaxy is clearly different in design to the 115PS version, although the latter fitted straight on to my air filter box in minutes. Are the two MAFs (Part Number 0 281 002 461 - 130PS and 0 280 217 121 - 115PS) interchangeable despite appearances,  given the air box/intake manifold relationship or is there a different shaped box for the 130PS version? I have yet to take off the engine cover and look for the code on the block +/or the sticker on the timing belt cover but no matter what I find there, the issue with the MAF model type still remains in my mind. Would fitting the 'wrong' MAF cause the symptoms I have been getting? Btw, the engine idles perfectly and is extremely quiet.

Sorry for such a long and rambling post, but there seem to be so many variables to this problem that it is difficult to know when to stop.

 

Offline marcushamblin1976

  • *
  • Posts: 81
  • Thanked: 3
  • Model: Sharan Mk2
  • Spec: 2003 tdi 115 pd
  • First Name: Marcus
  • Region: East Anglia
  • Country: United Kingdom
The 17965 deviation fault from my experience is a pain in the a. On the older ve diesels 90bhp 110bhp its usually hoses split. Or n75.
 
On pd engines its more likely vnt sticking, from my understanding its from requested boost pressure vs actual boost pressure. 

Check actuator on turbo, check vnt moves freely, maybe a removal and clean out.
Plenty of info on youtube

Sent from my SM-G930F using Tapatalk


Offline Roger T

  • *
  • Posts: 6
  • Thanked: 0
  • Model: Galaxy Mk2
  • Spec: 03 TDI 1.9 PD 130
  • First Name: Roger
  • Region: South West
  • Country: United Kingdom
Hi Marcus,

Thank you for the reply. Yes, it is a pain, and although I am no mechanic I have taken the car to the workshop often enough now to realise that the cause could be any one of, or still worse a combination of, any number of things. I have been told that the actuator rod is moving freely and within the usual tolerances so concluded from that that the turbo vanes are not blocked to any appreciable extent. That said, it is 15 years old but has done less than 95K so lack of use my indeed be leading toward that issue so in a bid to forestall it I have recently added some Forte Turbo Cleaner to the tank, and driven some 200 miles but with no appreciable difference to date. I know that opinion is divided on these miracle potions but thought it worth a punt anyway. And to complicate things still further, sometimes after going into limp mode, no fault codes are shown at all.....

Offline johnnyroper

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  • Posts: 2945
  • Thanked: 148
  • Model: Galaxy Mk2
  • Spec: 02 tdi 115 ghia
  • Region: South West
  • Country: United Kingdom
Will put money on the positive deviation being VNT sticking, get you hand on it and check movement. Bet you find it graunchy and stiff and probably not moving itís max travel.

Basically ECU demands X amount of boost so opens vanes to increase boost and as desired is starting to be achieved the vanes are closed to direct exhaust gas away from turbo.  When they stick you get the deviation fault as actual is not as the ecu is requesting. I

Offline Roger T

  • *
  • Posts: 6
  • Thanked: 0
  • Model: Galaxy Mk2
  • Spec: 03 TDI 1.9 PD 130
  • First Name: Roger
  • Region: South West
  • Country: United Kingdom
Thanks Johnny,

I have to say that is looking like the next thing I will need to do just to see for myself, especially as I have been reassured only a couple of months ago that this exact thing had been checked and found to be okay, at least as far as that particular garage was concerned. Or maybe despite that I am just bending over backwards here to avoid the possibility that it is indeed the turbo and that I need to man up and deal with it.

Offline johnnyroper

  • *
  • Posts: 2945
  • Thanked: 148
  • Model: Galaxy Mk2
  • Spec: 02 tdi 115 ghia
  • Region: South West
  • Country: United Kingdom
There are a few things to check along with VNT movement.
My order of checking would be.

Vac pressure from pump, looking in region of  25hg vac
Vac pipe condition
Vnt actuator,make sure it can hold a vac. Pump up to 17hg vac and make sure it does not drop.
Movement of VNT should be nice and smooth and travel from stop screw to other end. Use a mitivac it should start to move at 3-5hg and reach max travel at 17-19hg.
Also if not already check the MAP make sure itís not dirty and also EGR valve clean up.

Offline johnnyroper

  • *
  • Posts: 2945
  • Thanked: 148
  • Model: Galaxy Mk2
  • Spec: 02 tdi 115 ghia
  • Region: South West
  • Country: United Kingdom
As for the maf I am fairly sure the actual sensor is the same across the different HP engines itís just the housing itís in thatís different.
You need to check the sticker on top of timing cover and confirm engine type,I would be more inclined to believe the V5 that it is the 130 ASZ1 though.

Offline Roger T

  • *
  • Posts: 6
  • Thanked: 0
  • Model: Galaxy Mk2
  • Spec: 03 TDI 1.9 PD 130
  • First Name: Roger
  • Region: South West
  • Country: United Kingdom
What a great forum this is.

Thank you again, Johnny for your advice. I have just bought a Mityvac in anticipation of doing some checks and will do exactly what you have recommended. Thank you also for providing the appropriate pressures as this will be very useful indeed. The MAF should be clean enough, I only fitted it myself less than 2000 miles ago and it was a genuine, motor factor provided Bosch re-manufactured unit.

As an aside, another poster on the forum ( I will try to get back to the page and give him a name-check) has helpfully provided a link to https://ford.7zap.com/en/car/140/ [nofollow] which is a great resource. From the exploded diagram provided, it appears that the air filter box and MAF are the same shape/design for both the 115PS and 130PS TDI range, but their respective part numbers vary nonetheless? Go figure. Anyway, thank you very much once again for your help and advice, it is really appreciated.

Offline Roger T

  • *
  • Posts: 6
  • Thanked: 0
  • Model: Galaxy Mk2
  • Spec: 03 TDI 1.9 PD 130
  • First Name: Roger
  • Region: South West
  • Country: United Kingdom
The poster I referred to above who provided a very helpful Ford Parts resource is Rui Martin. Thank you, Rui, I am sure that this facility has been a great help to many.

Offline johnnyroper

  • *
  • Posts: 2945
  • Thanked: 148
  • Model: Galaxy Mk2
  • Spec: 02 tdi 115 ghia
  • Region: South West
  • Country: United Kingdom
Just to clarify itís the map sensor you need to check, this is the manifold absolute pressure sensor and is located in boost pipe. 1 screw and pull out job once wiring is off,these get quite dirty.

Offline Roger T

  • *
  • Posts: 6
  • Thanked: 0
  • Model: Galaxy Mk2
  • Spec: 03 TDI 1.9 PD 130
  • First Name: Roger
  • Region: South West
  • Country: United Kingdom
Thanks for the additional info. I'm going to make a start on this tomorrow, weather permitting.

 

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