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Author Topic: fuse box  (Read 5787 times)

Offline redbull2k

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  • Model: Galaxy Mk2
  • Spec: 2004 TDI 130PD
  • Region: South Wales
fuse box
« on: December 12, 2016, 10:27:27 AM »
The top wire the one that gets melted/burnt out, what wire will i need to replace it?

Offline johnnyroper

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  • Model: Galaxy Mk2
  • Spec: 02 tdi 115 ghia
  • Region: South West
  • Country: United Kingdom
Re: fuse box
« Reply #1 on: December 12, 2016, 02:25:07 PM »
You will also need new fuse box.

As for the cable need some high amp alternator/starter cable and a couple of ring lugs. 1 m8 and 1 m6.
You can get a made up cable from vw but when I did mine I used some cable and lugs. Either way make sure you solder the lugs.

I may have some cable and lugs left if you want them? Give me an hour or so and will check in garage

Offline johnnyroper

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  • Region: South West
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Re: fuse box
« Reply #2 on: December 12, 2016, 03:22:29 PM »
I have got a length of high load cable and a couple of lugs that will do the job,exactly same as I used on mine earlier in year. It is high quality brand Rex cable as used on railway engines so man enough for the job.

5 posted if you want it,can also solder the lugs on for you if you wanted?
Only thing you will need to do is trim the gold coloured lug slightly to fit in the fuse box. I would also suggest swapping the cable and fuse to different position so the 2 high draw ones are not next to each other,my alternator one is bottom of box and the cabin fuse box lead is top of the box.

Drop me a pm if you want it.

Offline redbull2k

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  • Model: Galaxy Mk2
  • Spec: 2004 TDI 130PD
  • Region: South Wales
Re: fuse box
« Reply #3 on: December 12, 2016, 04:54:14 PM »
johnny your inbox is now full. Where did you get your fuse box from and how much?

Offline johnnyroper

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  • Model: Galaxy Mk2
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  • Region: South West
  • Country: United Kingdom
Re: fuse box
« Reply #4 on: December 12, 2016, 07:19:51 PM »
Sorry I shall clear some messages.

I caught mine in time to save the box so used old one.
I don't know how much they are but vw dealer your best bet unless @Mirez has a decent used one off the sharan he is breaking?

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: fuse box
« Reply #5 on: December 12, 2016, 07:27:13 PM »
Yup I have one, fairly sure its all good but will double check.
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
06 VW EOS 2.0 T-FSI 210 Sport in Deep Black Pearl
With red leather interior with full Caractere bodykit, Remapped at 255bhp and sitting on 19's
14 VW Tiguan 2.0 TDI 177 R-Line in Deep Black Pearl
With black leather interior, panoramic sunroof and bi-xenon headlights.
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 redbull2k

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  • Posts: 44
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  • Model: Galaxy Mk2
  • Spec: 2004 TDI 130PD
  • Region: South Wales
Re: fuse box
« Reply #6 on: December 12, 2016, 07:33:28 PM »
will the sharan fuse box fit my 130pd

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: fuse box
« Reply #7 on: December 12, 2016, 07:44:03 PM »
Yes, the fuse box is the same for all diesel varients - the fuses change but thats it.
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
06 VW EOS 2.0 T-FSI 210 Sport in Deep Black Pearl
With red leather interior with full Caractere bodykit, Remapped at 255bhp and sitting on 19's
14 VW Tiguan 2.0 TDI 177 R-Line in Deep Black Pearl
With black leather interior, panoramic sunroof and bi-xenon headlights.
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 redbull2k

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  • Posts: 44
  • Thanked: 0
  • Model: Galaxy Mk2
  • Spec: 2004 TDI 130PD
  • Region: South Wales
Re: fuse box
« Reply #8 on: December 12, 2016, 07:49:54 PM »
how much are you wanting for it?

Offline Mirez

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  • Model: Galaxy Mk2
  • Spec: 03 115PS Ghia
  • First Name: Mark
  • Region: South West
  • Country: United Kingdom
Re: fuse box
« Reply #9 on: December 13, 2016, 06:11:20 PM »
Hows 20 delivered sound including the alternator cable?
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
06 VW EOS 2.0 T-FSI 210 Sport in Deep Black Pearl
With red leather interior with full Caractere bodykit, Remapped at 255bhp and sitting on 19's
14 VW Tiguan 2.0 TDI 177 R-Line in Deep Black Pearl
With black leather interior, panoramic sunroof and bi-xenon headlights.
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 redbull2k

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  • Posts: 44
  • Thanked: 0
  • Model: Galaxy Mk2
  • Spec: 2004 TDI 130PD
  • Region: South Wales
Re: fuse box
« Reply #10 on: December 13, 2016, 08:54:38 PM »
I bit the bullet and bought another fuse box trying to get car done asap for xmas shopping. Pressure from her to get it done. sorry.

Offline Mirez

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  • Posts: 3571
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  • Model: Galaxy Mk2
  • Spec: 03 115PS Ghia
  • First Name: Mark
  • Region: South West
  • Country: United Kingdom
Re: fuse box
« Reply #11 on: December 13, 2016, 09:47:58 PM »
Hey no worres, I get closer to 40 when I sell them on eBay ;D
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
06 VW EOS 2.0 T-FSI 210 Sport in Deep Black Pearl
With red leather interior with full Caractere bodykit, Remapped at 255bhp and sitting on 19's
14 VW Tiguan 2.0 TDI 177 R-Line in Deep Black Pearl
With black leather interior, panoramic sunroof and bi-xenon headlights.
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 Jay Ali

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  • Model: Alhambra Mk3
  • Spec: 2012 tdi 170 SELUX
  • First Name: Sarfraz
  • Region: Yorkshire
  • Country: United Kingdom
Re: fuse box
« Reply #12 on: December 15, 2016, 10:36:46 PM »
Bought one from seat dealer last year cost me 46 squid Inc vat. Good advice changing the two high load cables, 2nd that keep them apart. Id also check your alternator make sure it's charging at the right rate, i had two fuse boxes melt on me due to a faulty regulator and possible bad alternator cable.

Sent from my Nexus 6P using Tapatalk


Offline johnnyroper

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  • Model: Galaxy Mk2
  • Spec: 02 tdi 115 ghia
  • Region: South West
  • Country: United Kingdom
Re: fuse box
« Reply #13 on: December 19, 2016, 08:22:42 PM »
@redbull2k how did you get in with the repair was the lead I sent all ok?

Offline redbull2k

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  • Model: Galaxy Mk2
  • Spec: 2004 TDI 130PD
  • Region: South Wales
Re: fuse box
« Reply #14 on: December 21, 2016, 02:45:11 PM »
parts i received have done the job, thanks. on examining the parts that was removed, i can see the full extent of the damage. There is a long split right down the wire,  which exposed the internals. However though this is not the end of my problems. I have a problem starting the car, but will start when hooked up to another car, but will soon cut out not long after. i believe from reading on here that this could be a relay 30 issue, which im going to replace (have you got one @Mirez )

Offline johnnyroper

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  • Region: South West
  • Country: United Kingdom
Re: fuse box
« Reply #15 on: December 21, 2016, 07:13:31 PM »
If it starts from another car I can't see it being relay 30 as if that was faulty it wouldn't matter if another car was used to jump it.
Have a good check over fuse box and make sure the other large cable is in good condition as that also suffers from damage caused by over heating. Also check the main earths around battery.

Offline redbull2k

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Re: fuse box
« Reply #16 on: December 21, 2016, 08:14:38 PM »
it started from another car because my battery was flat.
to explain further, when picking my car up i jumped in and turned the ignition, you can hear it turning but didnt fire up, after a good few tries, the battery was dead, the fuel filter was checked, and the filter was completely empty, so i got some fuel and put it in the car, i had no means to fix my dead battery issue that evening so i waited for following day. i returned to the car hooked it up to another waiting some few minutes then the car turned over, so i jumped in drove away and with in 10 minutes driving down hill coming to a junction while braking i could feel the car lose power. i pulled over to the side and turned the key once and i could hear the fuel pump but it didnt stop like it usually does it just kept going, there was 2 pitches to the sound, like "nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn" "ahhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhh" if that makes sense, then on other attempted key turns there is no noise, it was very inconsistant
i have had these symptoms before with a golft hat i had and that turned out to be the fuel pump relay.

Offline insanitybeard

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Re: fuse box
« Reply #17 on: December 21, 2016, 08:17:20 PM »
I think relay 30 is a supply relay which powers engine management etc but relay 167 is the fuel pump relay and like relay 30 has been known to cause trouble. Wiring diagram here.

EDIT: I see it's a TDI that you've got, only the petrol engine models are fitted with relays 30 & 167 so it's not that!
« Last Edit: December 21, 2016, 08:20:44 PM by insanitybeard »
Always learning..... Often by mistakes!

Offline johnnyroper

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  • Spec: 02 tdi 115 ghia
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Re: fuse box
« Reply #18 on: December 21, 2016, 09:00:41 PM »
Was it ok prior to fuse box change?

Also once running I would imagine the tandem would have enough power to pull fuel up from tank,I know some early passage and a4 never had in tank pump fitted.

I can't help thinking there is an issue with one of the fuse box wires still.

Offline redbull2k

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Re: fuse box
« Reply #19 on: December 22, 2016, 12:58:19 AM »
well i had an issue not long ago https://www.fordmpv.com/smf2/ford-galaxy/is-it-my-turbo/
the above was all done and car was running fine for a few weeks.

i had 2 codes from the car one from fuel level sensor, which according to symptoms its just a visual on dash. and the other code was for earth to ground parking aid

Offline johnnyroper

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Re: fuse box
« Reply #20 on: December 22, 2016, 05:50:52 AM »
Those codes are they what is logged now? Even so they won't cause the issue you are having.


The previous fault is a different one in my opinion as that was a collapsed turbo,this time it sounds like an electrical issue causing lack of fuel.

I think you need to get a meter on the main fuse box and check for power on fuel pump/ecu fuses when cranking. Also use meter to check voltage at battery fuse box and then compare voltage at main fuse box to see if any bolt drop. It certainly sounds like there is an issue with one of the other cables,poss it has got hot previously and has a high resistance connection with your new fuse box. After trying to start have a check to see if the other main cable in box is getting warm.

Offline redbull2k

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  • Spec: 2004 TDI 130PD
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Re: fuse box
« Reply #21 on: December 22, 2016, 01:07:29 PM »
can you recommend a cheap meter reader, i have no idea what to buy?

Offline insanitybeard

  • Greetings from Mr Chick!
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  • Model: Galaxy Mk2
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  • Region: South West
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Re: fuse box
« Reply #22 on: December 22, 2016, 01:21:06 PM »
Thinking I may have had an issue with my fuel pump priming previously I tried replacing relay 53 (the TDI fuel pump relay), there have been a few threads on this site recently regarding cutting out and stalling, if you look at page 2 of the thread I just linked above one member eventually found the fuel strainer on the lift pump was blocked causing fuel starvation, there were also a couple of other recent threads regarding TDI starting/ electrical issues here and here. If you can hear the fuel pump in the tank running and making a variable noise then there could be a fault with the pump itself or it could be struggling to draw up fuel, a blocked strainer could be a reason for this, though only one of numerous possible causes.
Always learning..... Often by mistakes!

Offline Mirez

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Re: fuse box
« Reply #23 on: December 22, 2016, 09:35:56 PM »
Yeah I do! Yours for the cost of postage (Pick one of the donation options for the site)

PM me your address and I'll get it sent to you.
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
06 VW EOS 2.0 T-FSI 210 Sport in Deep Black Pearl
With red leather interior with full Caractere bodykit, Remapped at 255bhp and sitting on 19's
14 VW Tiguan 2.0 TDI 177 R-Line in Deep Black Pearl
With black leather interior, panoramic sunroof and bi-xenon headlights.
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 redbull2k

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  • Model: Galaxy Mk2
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Re: fuse box
« Reply #24 on: December 24, 2016, 01:08:23 PM »
i thought i already responded the other day, guess i forgot to press send.
those are interesting topics, and have many similarities, going to take a look at the tank below passenger seat, as i have an error code logged to do with the fuel level sender/sensor. also im going to need to get a new battery.

Offline redbull2k

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Re: fuse box
« Reply #25 on: February 05, 2017, 12:26:48 PM »
Finally xmas has gone and a month of skint-ness, the fuel level sender has been taken out, and it surely looks to be the culprit, the connector is of no use, the metal connector has rusted away while also destroying the connecting end of the fuel sender.

My mechanic says he can get the car to start even though it dont work, which i thought id share as someone else might rule out the fuel sender because the car can still start.

Offline insanitybeard

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Re: fuse box
« Reply #26 on: February 05, 2017, 01:35:23 PM »
The Mk1 Galaxy did without a lift pump in the tank, relying purely on the drawing action of the mechanical engine driven high pressure pump. The PD engine is a slightly different setup with the camshaft driven mechanical tandem pump though, the lift pump just 'assists' the tandem pump and as you've discovered the mechanical pump is able to supply enough fuel to start the engine but not keep it running interestingly! It's good info to know, can you repair the connector or is it find a scrapper and cut/ splice in a replacement connector?
Always learning..... Often by mistakes!

Offline redbull2k

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Re: fuse box
« Reply #27 on: February 05, 2017, 04:24:59 PM »
out of the 4 pins 2 of them have corroded away. its a scrappy job for the connector then cut n splice. this should also repair another fault with the fuel indicator on dash.

 

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