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Author Topic: New Big Black Galaxy  (Read 12836 times)

Offline egg

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New Big Black Galaxy
« on: July 16, 2016, 07:50:16 PM »
Hi all, and thanks for having me here.

Just took the plunge and bought a tdi. Love it already, done 150  miles today already just spinning around.
Car is driving well pulls through all the gears, no knocks or bangs........ but :P

It has 220k on the clock, and after connecting to vcds lite i got some codes back.

Any and every bit of advice is well appreciated, i've owned a mk1 2.3 before which i loved and gave me zero problems.

Do i need to remortgage? Here we go ???

VCDS-Lite Version: Release 1.2
Saturday, 16 July 2016, 17:43:31.

4 Faults Found:
17571 -  Fuel Temp Sensor (G81): Open or Short to Plus
            P1163 - 35-10 -   - - Intermittent
18077 - Shareware Version. To Decode all DTCs
            P1669 - 35-00 - Please Register/Activate
16688 - Shareware Version. To Decode all DTCs
            P0304 - 35-00 - Please Register/Activate
17552 -  Mass Air Flow Sensor (G70): Open or Short to Ground
            P1144 - 35-00 -   -
 Thanks all  :) :) :)
As you slide down the banister of life, may the splinters never face the wrong way.

Offline johnnyroper

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Re: New Big Black Galaxy
« Reply #1 on: July 16, 2016, 08:30:14 PM »
In first instance I would clear and see if they return,if they do then more checking required.

Offline egg

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Re: New Big Black Galaxy
« Reply #2 on: July 16, 2016, 08:46:22 PM »
Righto :P, Just reading the kiddies a story then ill clear em...i take it they can be cleared with vcds lite.

As you slide down the banister of life, may the splinters never face the wrong way.

Offline bigdave982

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Re: New Big Black Galaxy
« Reply #3 on: July 16, 2016, 08:50:10 PM »
Yup, just clixk the clear fault codes button

Offline Mirez

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Re: New Big Black Galaxy
« Reply #4 on: July 17, 2016, 01:09:41 PM »
There is a pdf lookup sheet of vcds codes in the library if you want to decode those :)
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 egg

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Re: New Big Black Galaxy
« Reply #5 on: July 17, 2016, 07:55:05 PM »
Hi back again, just been out again and cleared the codes. Went for a spin and they didn't return.

So.... i have more problems ???

VCDS-Lite Version: Release 1.2
Sunday, 17 July 2016, 19:36:06.

3 Faults Found:
01189 -  Front Air Distribution Flap Motor (V145)
        009 -  Open or Short to Ground
00926 - Shareware Version. To Decode all DTCs
        002 - Please Register/Activate
01271 - Shareware Version. To Decode all DTCs
        009 - Please Register/Activate


Did a scan of the 08-auto HVAC system and the above codes came up and wont clear. The air con doesn't blow cold, and the engine temp showed 90c without the 2 fans kicking in.
I have been trying to get the 2 fans to work, both work when wired directly to a power source, so its not the actual fans.
I checked the forums, and a search  came back with the 419 controller possible being to blame. Thing is i checked where it should be and there was nothing there. Incidentally i checked the fuse board to see was a fuse at fault and fuse 33 doesn't have any contacts in the fuse board.
Kinda confused... :-\


As you slide down the banister of life, may the splinters never face the wrong way.

Offline johnnyroper

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Re: New Big Black Galaxy
« Reply #6 on: July 17, 2016, 08:38:01 PM »
If you have any knackered distribution motors all I can say is good luck changing them.
I had the temp mix flap motor and a heater matrix to change last year, dash out job I'm afraid and that is a mission.

As for the fans they won't kick in until it's hotter than 90,do you have any over heating issues?

Air con wise does anything happen with it,can you hear the compressor clutch operate?

Apart from distribution flap code I have no idea what others are as it gives no description as shareware vcds, could be just low pressure?

Offline egg

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Re: New Big Black Galaxy
« Reply #7 on: July 17, 2016, 10:00:16 PM »
If you have any knackered distribution motors all I can say is good luck changing them.
I had the temp mix flap motor and a heater matrix to change last year, dash out job I'm afraid and that is a mission.

As for the fans they won't kick in until it's hotter than 90,do you have any over heating issues?

Air con wise does anything happen with it,can you hear the compressor clutch operate?

Apart from distribution flap code I have no idea what others are as it gives no description as shareware vcds, could be just low pressure?

Okay, the main issue now is the water system is pressurizing. The coolant light came on and stayed flashing on a short trip where i left the car running as i waited for a Chinese takeaway. I got home took the cap off, and the water bubbled out of the tank..
The bottom pipe out of the rad seems cool whilst the top pipes are roasting and the engine is very hot, but no fans kicking in.
Didn't even eat my takeaway.. Got a very sick feeling in my gut.
 :( :(
As you slide down the banister of life, may the splinters never face the wrong way.

Offline johnnyroper

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Re: New Big Black Galaxy
« Reply #8 on: July 17, 2016, 10:17:35 PM »
Due to the PD engine having very little waste heat you will struggle to get bottom hose hot unless under serious load or long motorway journey.

As for the pressurising check the restrictor in small bore hose to top of expansion bottle it should have a 2mm hole in it.
But in my experience pressurising is due to head gasket passing between cylinder and coolant jacket due to head bolts stretching over time.
But you need to start with basics first like the restrictor and water pump impeller.

Offline egg

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Re: New Big Black Galaxy
« Reply #9 on: July 17, 2016, 10:35:18 PM »
But you need to start with basics first like the restrictor and water pump impeller.

Thanks johnnyroper for the help.
Have read about the return pipe and the restrictor posssibly clogged alright, and will do that first thing tomorrow.
Is it hard to get to the water pump impeller? I have jumbo sausage fingers.. :P
The weather is supposed to hold until Wednesday though, so better get my finger out, or in i'm assuming in this circumstance. Will it be a very tight place??

As you slide down the banister of life, may the splinters never face the wrong way.

Offline johnnyroper

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Re: New Big Black Galaxy
« Reply #10 on: July 17, 2016, 10:53:06 PM »
Pop thermostat housing off its where bottom hose connects by alternator.
The 115 auy is common for head bolts stretching over time on certain years,your one like mine is that year range.I read on a vw forum about some people tightening them an extra quarter turn when engine is cold and not under pressure and it solved problem. If it does they then changed head bolts one at a time. Personally I had head off and changed gasket etc.

Offline egg

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Re: New Big Black Galaxy
« Reply #11 on: July 18, 2016, 01:59:56 PM »
Little update.

Took the auxiliary pump out and the brushes were gone. There was voltage at the plug so kinda thought that all right. so i bypassed the pump with a straight connector until i get some new brushes.

Blew through the pipe coming off the expansion tank and it was clear.

Im just ordering some brushes after 3 failed attempts to get them in shops local, after that im gonna inspect the impeller on the water pump, seems tight to get into though.

will update later.

Replacing the head gasket will require it to be skimmed, is that right? Is it an easy enough job?

Im considering doing the cam belt and water pump anyways because there is no history. Would it be wise to just replace the gasket? or should i o the whole hog and recondition?

Thanks for all the advice, really appreciate it. Ill upload some pics later.

 8-)
As you slide down the banister of life, may the splinters never face the wrong way.

Offline johnnyroper

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Re: New Big Black Galaxy
« Reply #12 on: July 18, 2016, 03:18:55 PM »
Hard to say without seeing it to be honest,mine was exact same symptoms as yours I decided to take head off and have a look. There was clear indication of it blowing between no2 and cooling jacket and bolts were not very tight. I straight edged the head and all was good so took chance with just gasket set,bolts etc. Not had a problem with it since done about 8k miles.

I wouldn't change belt kit and pump until you know either way about the head as its part of head removal anyway.

In my opinion the head is not a difficult job to just time consuming,to lift head out turbo needs to come off but to remove that requires drive shaft off. I used a massive cable tie to take weight of turbo once oil pipes and the securing nuts were removed then lifted head out.

Offline egg

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Re: New Big Black Galaxy
« Reply #13 on: July 20, 2016, 01:36:36 PM »
Sorry for the delay in the update. Short of getting a test done to see if it is the head gasket, I've arranged to have my friend help me do it at the weekend. There's a place local that will skim the head for €150, so I'm hoping there's no warping or crack and it will solve the issue. In regards actually undertaking the work diy, any advice, any help etc is greatly appreciated.

Kinda looking forward to it, kinda nervous ??? I'm on a very tight budget and need the car, no more then anyone else who lives rural. 

There's a few different gaskets available, which one will I need? And apart from the head bolts, will there be anything else I need 8-)

Forgot to say I checked the water pump and thermostat as instructed, and all seemed fine. Pump has the metal impellers and was sound. Thermostat was on good working order, plus I asked a mechanic on my course in college, who has seen this before on these engines and agreed entirely with the suggestion that if the water system is pressurising, then it will be the head gasket.
« Last Edit: July 20, 2016, 01:44:28 PM by egg »
As you slide down the banister of life, may the splinters never face the wrong way.

Offline johnnyroper

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Re: New Big Black Galaxy
« Reply #14 on: July 20, 2016, 02:42:16 PM »
It's a bit time consuming to do but not too hard.

The gasket has holes punched in to it indicating thickness of you don't have a skim then fit same one if you have a bit taken off then go for next hole up. I.e if you have 2 holes then go for 3. From memory it is at front on right hand side kind of below no4 glow plug.

You will need head bolts,head gasket set,oil and filter,about 8 litres of Vw coolant if pre mixed or 4 if neat. Also put a new thermostat in it as having head off.
If you disturb any other bolts inside rocker cover they will also need to be replaced. If having skimmed they will need it stripped so will need injector seals,injector hold down bolts,camshaft cap bolts,rocker shaft bolts.
Injector removal guide


  https://www.darksidedevelopments.co.uk/account.php?action=download_item&data=ODIzODQsNjgzLDQwNjkyLGMzZjJjODFkYzFlMGY5ODc2OTZjZDFhMWUwZDkxZWQ1LDQxLDkxMjg0Njk2NTc4Mjc0ODQ4NDIwMzI2MzAzNzQzOTM5MDI2OQ==

Torque settings

http://www.justanswer.com/uk-car/1vwwf-2001-ford-galaxy-cylinder-head-bolts-injector-camshaft-engine-code.html




Offline egg

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Re: New Big Black Galaxy
« Reply #15 on: July 20, 2016, 03:43:26 PM »
Many thanks  :D

When you say head gasket set, is there more needed then just the head gasket? Plus, cause I'll be doing the cam belt and water pump, is there any tools I will need/make.

It's an hour spin to the motor factors, and they are closed half day Saturday.

After chatting to my mate, he reckons the drive shaft may be a struggle.

We're going purchasing a gazebo tomorrow, always bloody raining here.
 >:(

 

As you slide down the banister of life, may the splinters never face the wrong way.

Offline johnnyroper

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Re: New Big Black Galaxy
« Reply #16 on: July 20, 2016, 06:00:31 PM »
Yes the set comes with all gaskets and seals for cylinder head.
As for timing belt ideally you need a locking set so can and crank can be fixed,you can use a 6mm drill bit for cam and paint mark crank sprocket and engine casing. Can't recall if arrow on crank lines up with a mark on block or if it's just for lining against arrow on locking tool?

The offside drive shaft removes quite easily I think,have a look in ref library for offside drive shaft replacement it explains it in there,also look at turbo clean post as it explains turbo removal including the oil pipe which can be a pain.

Offline egg

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Re: New Big Black Galaxy
« Reply #17 on: July 21, 2016, 05:32:44 AM »
Sound advice. Gonna get printing everything, and will hopefully get lots of pics. May interest/help someone  ;)
Incidentally, the car seems fine apart from pressure building in the water system. I've done 500 miles with no overheat. Still; unlike the majority of people, I couldn't sell it on knowing it has a fault...
Bloody conscience  :D
Thanks again Johnnyroper.
As you slide down the banister of life, may the splinters never face the wrong way.

Offline johnnyroper

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Re: New Big Black Galaxy
« Reply #18 on: July 21, 2016, 06:57:41 AM »
Mine was like that when I got it pressurising but no overheating, fingers crossed you find gasket gone/head bolts loose and head don't need skimming like mine was.

It seems daunting to do head gasket but once you get stuck in you will find its not too bad to do.

Offline egg

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Re: New Big Black Galaxy
« Reply #19 on: July 21, 2016, 09:37:35 AM »
Fingers crossed, moneys tight. Anyways, I'll keep you updated. Sure if there's any head scratching I may be asking ya some more questions  :P

Just gonna take our time and take lots of pics so nothing gets missed etc.
As you slide down the banister of life, may the splinters never face the wrong way.

Offline Dave F

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Re: New Big Black Galaxy
« Reply #20 on: July 21, 2016, 11:23:28 AM »
I had the same type of problems with water pressure so flushed system several times but pressure still there and no heat from cabin blowers at tic over so started checking all hoses including restrictor then after more checking found that the hose in pic was totally blocked tried blowing down it, tried forcing coolant down it then had enough so got tyre pump attached to hose and switched on for a few secs and hay presto coolant started to flow with ease.
Not sure if this is of any help but cant hurt checking before the big work starts :)

Offline Mirez

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Re: New Big Black Galaxy
« Reply #21 on: July 21, 2016, 01:47:50 PM »
Just to comment on that, if the coolant system has been distubed, the 1.9 is a proper pig to bleed properly. It needs to be filled VERY slowly, with stops every 10 seconds or so else air pockets will trap which dont clear.
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 egg

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Re: New Big Black Galaxy
« Reply #22 on: July 21, 2016, 07:03:37 PM »
Going to take apart the hoses and double check, sure its no harm before the big work begins as you said. Plus im going to hook up a hose and let it flush through the system for a half hour.
Called in to the engine reconditioning shop where to get head skimmed/reconditioned. Basically told me that even though the head may not be warped, the gasket itself will cause slight damage to the surface which will shorten the life of the seal considerably, and needs to be done.
He advised to get it done, kinda can see his point of view too. Do it right if doing it at all.
He said he would strip out the injectors etc as well, which would make life a hell of a lot easier, and would guarantee a good job. Trouble is he's off on holiday for 2 weeks form tomorrow. Don't fancy stripping out the head, kinda seems daunting and don't want to mess it up, bite off more then i can chew.
I've been in contact with a mechanic and im arranging a sniff test or chemical analysis. Just wondering how conclusive this will be as well?
The chap i spoke to earlier said he'd a good few PD engines with exact symptoms that showed no leak from a pressure test, yet was leaking between cylinder 2 and 3 after checking the gasket. Thing is the car isn't overheating or showing any other symptoms apart from pressure in the coolant system. Very tempting to just leave it and see what happens.
After college tomorrow going to get started, and will update the flush/slow fill and hose check.
Cheers all. 8-) 8-)
As you slide down the banister of life, may the splinters never face the wrong way.

Offline johnnyroper

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Re: New Big Black Galaxy
« Reply #23 on: July 21, 2016, 07:19:31 PM »
The PD rarely shows a fault with sniffer as leak occurs after driving.
Honestly all your symptoms are classic PD head gasket,even with pressurising you will struggle to get overheating unless on long motorway run st speed or towing a caravan.
Personal experience my gasket went on no2 causing what you have got it wasn't warped and didn't need a skim,all it needed was a good clean and polish up.
The main problem with 115bhp engines is poor quality torque to yield bolts stretching with the heating and cooling cycles decreasing head to block clamping force.

I honestly think you need to bite the bullet and take it off, I exhausted all other options like restrictor,pump impeller and flushing out. Pressurising cooling system can only really be head related on either options check out.
I am willing to bet head bolts will not feel as tight as they should when removing and you will have a black stain between head/block and gasket when it's off.

Offline egg

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Re: New Big Black Galaxy
« Reply #24 on: July 21, 2016, 07:31:02 PM »
I appreciate your advice and will bin the sniff test then, as for checking the hoses and slow filling, it will cost me nothing and will just reinforce the fact its most likely the head gasket and bolts like you say. I mean its a natural thing to insist the head being skimmed if your an engineer, and like to dot the t"s and all that. I want to keep the car for a good while, and i suppose this kinda ensures a bit of longevity. Plus i will be doing some towing, so it needs to be 100% especially if you have a pony in tow, and kids on board. Just pricing up head gasket kit and cam kit now.
As you slide down the banister of life, may the splinters never face the wrong way.

Offline johnnyroper

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Re: New Big Black Galaxy
« Reply #25 on: July 21, 2016, 07:44:19 PM »
Defo get it checked but if it's flat then no need to skim it for sake of it.

Oh yes for sure check the hoses etc as it needs to be sound whether head gasket gone or not.

Offline egg

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Re: New Big Black Galaxy
« Reply #26 on: July 22, 2016, 08:22:22 PM »
Another little update. Looking at toolage etc
Gonna be getting a timing locking set, and marquee to work in. Also want to know if a angle torque gauge is necessary?

The Marquee is going to be a temporary workshop; the weather has been brutal. Only thing is its gonna put back the job to next weekend.

Can anyone think is there any particular extension bars or other tools that might come in handy?  :)

Also going for gates belt/pump kit. Just a bit unsure about ordering off ebay, in case of fakes or poor quality.
Any advice in this regard would be great, as i can order from the uk now as i have a bit more time, rather then pay a premium at the local motor factors.




Should get a good bit of use out of the marquee, maybe not so much out of the locking set and torque angle.  ;D
As you slide down the banister of life, may the splinters never face the wrong way.

Offline insanitybeard

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Re: New Big Black Galaxy
« Reply #27 on: July 22, 2016, 08:30:08 PM »
Just in case you've not seen it, have you taken a read of this? I have the locking tools which I am happy to lend if you're prepared to pay for the postage both ways, though I guess that probably won't be much less than you just buying them!  ::)
Always learning..... Often by mistakes!

Offline egg

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Re: New Big Black Galaxy
« Reply #28 on: July 22, 2016, 09:13:46 PM »
Thanks very much for the offer, really sound of you. The locking tool will be £15.94 delivered, probably not much more then the 2 way postage to Ireland :D

The guide is extremely good. Just been having a read.

The torque angle gauge is around £30. Will it be needed? I mean will it be hard to judge a 1/4 turn? And how accurate will it have to be?  ???

Gonna have to ask around a few mates to see can i scrounge some bits.
As you slide down the banister of life, may the splinters never face the wrong way.

Offline johnnyroper

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Re: New Big Black Galaxy
« Reply #29 on: July 22, 2016, 10:55:30 PM »
I have angular torque gauge but far easier to do 90 degrees without using it in my opinion.
You will need just normal hand tools and a set of decent spline (triple square bits for head bolts etc.

Offline insanitybeard

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Re: New Big Black Galaxy
« Reply #30 on: July 23, 2016, 09:16:22 AM »
For angle tightening quite often I'll just use a little tipex pen to put a dot at the 12 o' clock position and work from there, it's fairly easy to gauge approximate angles.
Always learning..... Often by mistakes!

Offline niall

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Re: New Big Black Galaxy
« Reply #31 on: July 23, 2016, 09:32:39 AM »
Hi Lad...

I got the Timing belt from here....http://www.ebay.co.uk/itm/Genuine-Gates-Timing-Belt-Kit-VOLKSWAGEN-Sharan-1-9-TDi-Diesel-AUY-09-05-/350755133303?hash=item51aaa29777:g:ApYAAOxyQj9RV0My

Cheapest I could find...they are in Enniskillen...and the quality is 100% and def. genuine. Cheaper post if you use ParcelMotel as well....and arrives faster.

BTW...not related to them in any way!!!

Offline suffolkadam

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Re: New Big Black Galaxy
« Reply #32 on: July 23, 2016, 09:49:46 AM »
hi guys just been reading your thread and thought id just drop in, my old gal has the same problem and ive been on here and asked all the questions that you have , i actually drove her to france earlier in the year and it lost about a pint of water over the 700 mile journey. i too changed the brushes in the aux pump now all working and didnt help with the pressure build up also changed the thermostat and the little pipe going to the expansion bottle and it still pressurises. i even flushed the system when the themostat was out from top to bottom and even took the pipes off the rear heater near the n/s rear wheel and it still pressurises. ive basically tried everything. it will be your h/g . i aint done mine cos it dont seem to be a problem once it pumps out the water from max down to the min mark it seems to stop and the engine never goes above 90 deg.just thought id tell you all this cos it might save you a bit of agro. i will do mine but my job is a right ball ache at the mo so time off is at a premium. i've just had the a/c compressor clutch fail so just bought a brand new compressor at £170 and while i was under it noticed my front discs where all marked and nasty and starting to flake so just changed them as well Brembo discs and pads £100 now just going down to the aircon place to have it charged up £40.00. the joys of owning an Galaxy just go on and on and on and on. best of luck to you and hope all goes well.

Offline johnnyroper

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Re: New Big Black Galaxy
« Reply #33 on: July 23, 2016, 10:24:34 AM »
It's a very common problem on these lumps ain't it?

Have you tried a quarter turn on head bolts to buy you some time before you get the chance and funds to do head gasket? According to vw crowd it works and once they have tried they seem to change head bolts one at a time with higher tensile studs and nuts rather than changing the gasket.

Offline egg

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Re: New Big Black Galaxy
« Reply #34 on: July 23, 2016, 10:45:21 AM »
Is there a possibility it can make it worse? I'm definitely up for trying it, i mean it will be a lot easier on the pocket and mind if its just head bolts.
Is it one quarter turn on all the bolts, or just the center 1,2,3,4? Where the leak is most likely ie between 2&3 or 2 & the water jacket in my case.

What bolts are they using then if the issue is solved? And more importantly where will i find em, and info regarding the process, and how much longer it will prolong the seal? Seems like a good option to try, seeing as im going to be doing the work anyway.

Was just going to start ordering some stuff, might put it off for a day and try it.

My rear windscreen wiper inst working, only just realized. I'm assuming its a broken wire on the tail gate? Gonna have a look now.

Always bloody raining here. ::)

Oh again, thanks for all the help from everyone.






« Last Edit: July 23, 2016, 10:48:14 AM by egg »
As you slide down the banister of life, may the splinters never face the wrong way.

Offline johnnyroper

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Re: New Big Black Galaxy
« Reply #35 on: July 23, 2016, 02:50:12 PM »
Go round the lot in the normal tightening sequence just make sure engine is cold and no pressure in cooling system.

The general opinion is it works so they change for the studs or as cheaper alternative the PD 150 head bolts are able to withstand more pressure and heating/cooling cycles so yield less over the life of engine.

For me personally I did find my bolts were not at correct torque which caused the problems that have been reported,I did however take the head off  anyway as I had plenty of time but fitted the 150 bolts when going back together. I am fairly certain tightening would have resolved the issue.
The way I see it you know gasket is leaking so worth giving it a go and seeing what happens.
As for making worse as it is multi layered steel design I see no reason why it would be made worse.

I think if I got another one with same issues I would try tightening 90 degrees and if problem went away would either change bolts one at a time with PD 150 then use the car and see how it went.

Offline suffolkadam

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Re: New Big Black Galaxy
« Reply #36 on: July 23, 2016, 05:00:41 PM »
i like your way of thinking johnyropper me thinking i'm gonna try this next cos as you say ain't got nothing to lose but everything to gain! and a lot less hassle....gotta be easier than taking the head off first.... when yours went did you ever get coolant showing around the rear heater .. n/s rear wheel area? don't know weather it coming from there or it was just pushing from the bottle running down and splashing that way whilst travelling. ie blowing under the car? i was playing with that problem at the start of april but was about to go to France fishing so had limited time so took a bottle of water with me and topped it up. only seems to be a problem if pushing hard down the motorway, since coming home haven't had a problem unless filling to the max line and it don't overheat so i turned my attention to other stuff.

Offline Chrispb

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Re: New Big Black Galaxy
« Reply #37 on: July 23, 2016, 05:14:28 PM »
The alloy pipes to the rear heater are known to corrode and leak around the wheel arch area
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 suffolkadam

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Re: New Big Black Galaxy
« Reply #38 on: July 23, 2016, 05:24:06 PM »
has anyone got a link to a diagram of the head bolt tightening sequence? fancy having a play..

Offline johnnyroper

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Re: New Big Black Galaxy
« Reply #39 on: July 23, 2016, 05:32:58 PM »
When mine was a problem it would force out and travel underneath the car not sure it made it as far as rear heater though.
If you only have a leak after it has built pressure and spewed out I would guess it's travelling down the floor pan.

Exactly if it's leaking anyway nowt to lose by giving it a shot.

Here you go

http://workshop-manuals.com/skoda/octavia-mk2/drive_unit/1.9/77_kw_tdi_pd_engine/engine_cylinder_head_valve_gear/removing_and_installing_the_cylinder_head/removing_and_installing_the_cylinder_head_(octavia_ii)/install/

Offline suffolkadam

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Re: New Big Black Galaxy
« Reply #40 on: July 23, 2016, 07:38:32 PM »
cheers mate .

Offline johnnyroper

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Re: New Big Black Galaxy
« Reply #41 on: July 23, 2016, 08:07:17 PM »
No problem, let us know how you get on giving bolts a quarter turn, I am intrigued to know if it actually resolves the issue like I think it will.

Offline egg

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Re: New Big Black Galaxy
« Reply #42 on: July 23, 2016, 08:31:32 PM »
I'll be turning the bolts tomorrow, so fingers crossed. :-\ [THANKS]
As you slide down the banister of life, may the splinters never face the wrong way.

Offline johnnyroper

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Re: New Big Black Galaxy
« Reply #43 on: July 23, 2016, 08:35:24 PM »
Make sure you have some decent quarter drive sockets to get rocker cover off,the one by egr valve is a bit of a pig to get at with egr in situ.

Offline egg

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Re: New Big Black Galaxy
« Reply #44 on: July 23, 2016, 08:38:33 PM »
Hi Lad...

I got the Timing belt from here....http://www.ebay.co.uk/itm/Genuine-Gates-Timing-Belt-Kit-VOLKSWAGEN-Sharan-1-9-TDi-Diesel-AUY-09-05-/350755133303?hash=item51aaa29777:g:ApYAAOxyQj9RV0My

Cheapest I could find...they are in Enniskillen...and the quality is 100% and def. genuine. Cheaper post if you use ParcelMotel as well....and arrives faster.

BTW...not related to them in any way!!!

Cheers, way cheaper then i could find  [WAVE]
As you slide down the banister of life, may the splinters never face the wrong way.

Offline egg

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Re: New Big Black Galaxy
« Reply #45 on: July 23, 2016, 08:42:04 PM »
I would be having a go today, only my mate has a good knowledge of motors and offered to help. Plus he has a better selection of tools and some air tools too. Might even crack a beer or 2  :P
As you slide down the banister of life, may the splinters never face the wrong way.

Offline johnnyroper

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Re: New Big Black Galaxy
« Reply #46 on: July 23, 2016, 09:17:30 PM »
Certainly worth cracking a few beers while working.

Fingers crossed it goes ok and resolves the issue.

Offline suffolkadam

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Re: New Big Black Galaxy
« Reply #47 on: July 24, 2016, 01:06:04 AM »
well my bolts were as tight as a fiddlers elbow. i used a 1/2" ratchet and give it some proper welly and probably only turned them an 1/16th if any. "i have been know to shear bolts" so decided to call it a day and not chance it any more.. and you were right the rocker cover bolt under the egr valve "what a pig to get at" small swivel joint on the 1/4 bar and managed it. on putting it back found it easier to remove the egr pipe so i could get a finger round it and guide it on. any thoughts on steel seal ? chrisb mentioned it earlier i've already tried k seal ultra and after driving the car for 45 mins had my expansion bottle full of whitish foam, didn't like that so flushed it all out.
thanks again for all the info it was well worth a go.

Offline egg

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Re: New Big Black Galaxy
« Reply #48 on: July 24, 2016, 11:25:34 AM »
Cheers for the update.Hoping its going to go a tad better for myself.  When you say 1/16, do you mean turned that much of an inch? They must have been tight as a gnats arse.

I've resigned myself to the fact the head is coming off anyhow, any other success is going to be a bonus.

A good few people have commented to me about the seal stuff (steel seal etc)
It will eff it up was the running theme. But as i never tried before myself, i'd be curious to know if anybody has had any positive results?

  cheers


« Last Edit: July 24, 2016, 11:26:45 AM by egg »
As you slide down the banister of life, may the splinters never face the wrong way.

Offline johnnyroper

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Re: New Big Black Galaxy
« Reply #49 on: July 24, 2016, 02:09:56 PM »
well my bolts were as tight as a fiddlers elbow. i used a 1/2" ratchet and give it some proper welly and probably only turned them an 1/16th if any. "i have been know to shear bolts" so decided to call it a day and not chance it any more.. and you were right the rocker cover bolt under the egr valve "what a pig to get at" small swivel joint on the 1/4 bar and managed it. on putting it back found it easier to remove the egr pipe so i could get a finger round it and guide it on. any thoughts on steel seal ? chrisb mentioned it earlier i've already tried k seal ultra and after driving the car for 45 mins had my expansion bottle full of whitish foam, didn't like that so flushed it all out.
thanks again for all the info it was well worth a go.

Ideally you need to use a half inch breaker bar in them as a ratchet would not give much leverage unless it is a long one like a breaker bar? As they are TTY bolts they will feel like they are going to give but they won't. They give that feeling when brand new during the angular torque stage

 

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