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Author Topic: Ford Galaxy 1999 1.9tdi  (Read 6874 times)

Offline skinbad

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  • Posts: 3
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  • Model: Galaxy Mk1
  • Spec: 99 1.9tdi 6spd man
  • First Name: Mike
  • Region: North West
Ford Galaxy 1999 1.9tdi
« on: January 12, 2014, 10:09:40 AM »
Hi all,

I have a Ford Galaxy Zetec 1.9 Tdi from 1999, that i bought last Autumn as a get-me-by car for my growing family. It came with a couple of issues that were non major at that point, and i thought were easily repairable, however, ive hit some walls in the 4 months ive owned it, and come here now looking for help.

It came with issues of:
1st gear was hard to find ( ive found this out to be the selector cables and found one of the joints is held in place by two looped cable ties!)
Reversing lights were non existant (i assumed my luck would be in when the guy played dumb and said hed checked the bulbs but knew nothing else, but this has been a true gremlin!)

We then found pretty quick there a leak in the roof somewhere, that comes through the clock.
We also found the washer jets dont work for the front, but do for the rear.

since then, the bolt holding my selector arm to the shaft on top of my gear box sheered, and this is where ive found out a lot about what ive let myself in for. That is now all sorted, took a while, but i did it myself, and while i was in there, found the selector cable needing cable ties, and also my actual reverse light switch does work, there just is no wiring loom in the vicinity to connect to it!

We've also had the alternator go, that required replacing, long story short, snapped fan belt also had to be replaced, and since then, when on full lock right or left, the timing belt slips?

So good fun so far, right?

Gear selector cables i can sort now ive been in the front bay.

Reverse lights im stuck for, need a wiring diagram or help as to where the loom should come from to try and pick up the cables.

The leak needs finding, but i understand these had issues with blocked drainage points around the body? Do any water pipes come by the clock, or could it be round the windscreen seel?

The washer jets have two cables going to them, but i beleive these to be for mini heaters? the commons are hanging off both. When the switch is pushed for rear wiper jet, the motor works, and noise is audible, but for the front there is nothing? My money is on the pump, but just want to be sure before i wade into finding the right one on ebay!

Timing belt slipping, ive been told there may be a bolt / restricot something that will decreed the amount of turn available to the wheels, that could stop the low rev overdrive of the injector pump? or is this much more serious?

p.s. i have until Feb 14th to right the wrongs for the MOT!

Any and all help will be greatly appreciated.
Mike

Offline Mirez

  • Pondering the next mod...
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  • Posts: 3668
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  • Model: Galaxy Mk2
  • Spec: 03 115PS Ghia
  • First Name: Mark
  • Region: South West
  • Country: United Kingdom
Re: Ford Galaxy 1999 1.9tdi
« Reply #1 on: January 12, 2014, 10:50:26 AM »
Hi Mike and welcome along!

-Reverse Lights
I can get you a wiring diagram later today for them, slightly worrying the connectors missing though!

-Leek
Is it possible the car's been involved in a front shunt? Just a thought as most of your problems are front related! The blocked drains are much lower the the clock on the Mk1 (in the headlining) but windscreen seals are a possibility although its bonded in so they don't really perish. Does the car have a sunroof?

-Washer Jets
Yes the wiring to them is purely for heaters (activated with your rear demist screen) - I tend to agree that if you can hear the pump for the front yet no water appears either at the jets or under the car then the pump is probably faulty. Unless of course you have a blockage? The pump can be accessed by removing the wheel arch lining on the passenger side so you could then undo the pipe and operate the pump to see if anything is pumped out.

-Aux belt noise
It's not the timing belt but the aux/fan belt (if it was the timing belt the engine would have gone bang :) ) - this is nearly always caused by the alternator pulley being seized.  When you replaced the alternator did you fit new or second-hand?
03 Ford Galaxy 1.9 TDI 115 Ghia in Spruce Green Metallic
With cream leather interior, Full Bodykit, Remapped at 145bhp, Lowered on 18's
14 VW Tiguan 2.0 TDI 177 AWD R-Line in Deep Black Pearl
With panoramic sunroof, bi-xenon headlights remapped at 205bhp.
08 Ford Transit 2.2 TDI 115 in Frozen White
With retrofitted everything except another slidey door! :)

VCDS HEX/CAN - Scans/Coding done in Wiltshire in exchange for winegums! :)

Offline skinbad

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  • Posts: 3
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  • Model: Galaxy Mk1
  • Spec: 99 1.9tdi 6spd man
  • First Name: Mike
  • Region: North West
Re: Ford Galaxy 1999 1.9tdi
« Reply #2 on: January 12, 2014, 11:06:36 AM »
Hi Mirez, thanks for the reply.

Wiring diagram would be a great help, thank you, and regarding the leak, thats pretty much answered my question. There is no sunroof, and only question i ask about the windscreen seel, is the tax holder is an autoglass one, so id assume its been replaced, either way, i know its an external hole or split etc.

The washer jets, there is no noise for front jets, but noise and works for rear. ill check for blockages though, hadnt done that.

With regards to the belt, its the belt to the outside of the alternator attached fan belt? when the wheels are on full lock, it slips visibly on the lower  of the 2 pulleys.

Regards,
Mike

Offline Mirez

  • Pondering the next mod...
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  • Model: Galaxy Mk2
  • Spec: 03 115PS Ghia
  • First Name: Mark
  • Region: South West
  • Country: United Kingdom
Re: Ford Galaxy 1999 1.9tdi
« Reply #3 on: January 12, 2014, 11:20:31 AM »
No worries I'll aim to get one added by the end of the day for you.

There should be a white manufacturing marker on the windscreen somewhere (normally bottom left or top right) which will say who makes the glass. Ford only use two manufactures so have a look and see who makes it as Autoglass generally use Pilkington on their replacements. Sounds like it has been replaced though and not quite bonded in correctly.

Check fuses 20 and 24 as whilst the pumps are one unit, the front and rear motors are supplied different electrical feeds so if there is no noise it could be that its not getting any voltage. Again, when you have the arch liner off it would pay to unplug the connector and measure voltages. You'll have a three pin connector - one ground wire (normally brown) and two supplies, one for forward and one for rear. Actually, on the Mk1 it appears to only have a two pin connector which is reverse fed to get the direction. Green/Red and Brown/Yellow. Its supplied 12V on the Green/Red (with Brown/Yellow at ground) for the front wash and 12V on the Brown/Yellow (with Green/Red at ground) for the rear.

The belt, I think we need to wait for Chrispy to come and cast his advice here as I have little experience with the AFN engine.
03 Ford Galaxy 1.9 TDI 115 Ghia in Spruce Green Metallic
With cream leather interior, Full Bodykit, Remapped at 145bhp, Lowered on 18's
14 VW Tiguan 2.0 TDI 177 AWD R-Line in Deep Black Pearl
With panoramic sunroof, bi-xenon headlights remapped at 205bhp.
08 Ford Transit 2.2 TDI 115 in Frozen White
With retrofitted everything except another slidey door! :)

VCDS HEX/CAN - Scans/Coding done in Wiltshire in exchange for winegums! :)

Offline Chrispb

  • Mindsaysyesbodysaysnono
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  • Model: Galaxy Mk2 Auto
  • Spec: 52reg TDI 115 Ghia
  • First Name: Chris
  • Region: South East
  • Country: United Kingdom
Re: Ford Galaxy 1999 1.9tdi
« Reply #4 on: January 12, 2014, 12:08:00 PM »
Hi Mike  welcome5

Reverse lights.

Hopefully the connector hasn't been cut off and just needs finding/connecting although there may have been problems with the reversing lights which is why they were disconnected, a common problem with the wiring in the tailgate gaiter wiring breaking and shorting together causes all sorts of issues, is there any other problem at that end EG. rear wiper, heated window, fog lights, number plate lights.

Leak.

I felt sure you was gonna say you had a sun roof but as you dont then windscreen sealing is likely, although I have seen a roof  damaged by a stone chip that was left untreated resulting a small hole in the roof.

Washers.

Check out the pump, may be just a wiring issue at the pump.

Auxiliary drive belt.

As Mark said it's not the timing belt as your engine would not be running. (timing belt is hidden behind plastic cover)
The power steering has it's own drive belt and has a manual adjuster but check condition of belt as it may need renewing
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 Mirez

  • Pondering the next mod...
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  • Posts: 3668
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  • Model: Galaxy Mk2
  • Spec: 03 115PS Ghia
  • First Name: Mark
  • Region: South West
  • Country: United Kingdom
Re: Ford Galaxy 1999 1.9tdi
« Reply #5 on: January 12, 2014, 12:22:08 PM »
For a 99 Mk1, C29 is the connector for the reverse switch, its a 4 pinner with only two connected (Black and Black/Blue wires). The wiring diagram isn't specific as to where the harness comes from though :( It's different for the Mk2 as well so that's no help.

1934-0
03 Ford Galaxy 1.9 TDI 115 Ghia in Spruce Green Metallic
With cream leather interior, Full Bodykit, Remapped at 145bhp, Lowered on 18's
14 VW Tiguan 2.0 TDI 177 AWD R-Line in Deep Black Pearl
With panoramic sunroof, bi-xenon headlights remapped at 205bhp.
08 Ford Transit 2.2 TDI 115 in Frozen White
With retrofitted everything except another slidey door! :)

VCDS HEX/CAN - Scans/Coding done in Wiltshire in exchange for winegums! :)

Offline Orbis

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  • Posts: 76
  • Thanked: 3
  • Model: Galaxy Mk1
  • Spec: 1999 2.3 DOHC Ghia
  • Region: Non UK
  • Country: Belgium
Re: Ford Galaxy 1999 1.9tdi
« Reply #6 on: January 14, 2014, 11:20:55 PM »
Hey,

I think the washer pump is just fine because it works for the rear. The direction of the washer fluid (windshield and rear) depends on the polarity on the pump as you can see on the diagram. I think there is something wrong with your switch. (Maybe dirty contacts)

0->27 = windshield washer
0->43 = rear washer
1954-0

« Last Edit: January 14, 2014, 11:21:56 PM by Orbis »

Offline skinbad

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  • Posts: 3
  • Thanked: 0
  • Model: Galaxy Mk1
  • Spec: 99 1.9tdi 6spd man
  • First Name: Mike
  • Region: North West
Re: Ford Galaxy 1999 1.9tdi
« Reply #7 on: January 17, 2014, 06:55:20 AM »
Thank you all for your help and advice so far!

I work a four on four Off Rota with work, I'm on day 3 of being in, so back to it soon.

Update time:

I found the loom for the reverse lights, it comes from passenger wing side, under the battery, and the reverse lights work in-hand! I just can't get the Damned thing to go back on the gear box without the actuator on the shaft from hitting the inner plastic tube of the switch housing! It's taken a couple of chunks out of it!

Washer motor I've got as far as prodding and checking the tube.

Bad news is, I'd left the undertray Off to source a few new bolts, car got front wheels stuck in mud, when towing it out, I've found a shock absorber rotted on the rear, a hole in the back box, it ran for two days fine, gears better than before, until yesterday, lots of white smoke, no power! I'm dreading it. There seems to be oil / black liquid dripping from the exhaust. I've looked under the bonnet, found a hose from the MAF had come off, and there seems to be oil coming out of a switch / sensor. I've read a lot last night, and couldn't find any definite answer, but aux heater, turbo, or Head gasket were about even. I fear the worst! But, if there's anything I can check that I can do on my drive, I'll give it a go.

Attempting to add a pic of where I refer to above, 1 being the hose off, 2 being the switch / sensor location.

Mike.

 

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