Aux Heater which Glow Plug to order?

[brummygit]

I'm working my way through the faults on my Galaxy. This winter the Aux Heater has failed to start having not missed a beat since it was replaced by Ford about 12 months after I bought the car.

I've check on VCDS and it keeps coming up with

01409 -  Repeated Flame-Out

        35-00 -   -

I can hear the fan running, and feel the air from the exhaust. In fact the air coming out was warm but I guess that was just heat from the coolant circuit as the engine was pretty much at normal temperature when I tried. I could also hear the familiar tapping noise from the fuel pump so I am hoping its the the glow plug.

I plan to try replacing the glow plug myself, but would prefer to order one in advance. Is there any way to know for sure which plug to order - its a late 2005 car and as I say Ford replaced the whole Aux Heater in winter 2006.

If anyone can help me be pretty certain of the part number and suggest where to buy - probably online - it would be great.

[Chrispb]

Usually a glow plug that's not working at all will throw up an open circuit fault.
Repeated flame out could be down to a fuel supply fault.
You say you can hear the dosing pump ticking but is it actually pumping any fuel? if this has been repeated a few times you will normally see diesel dripping from the exhaust connection on the heater.

[brummygit]

That's a good point as I did try a few times but there was no dripping or smell.

Is there a filter or can the fuel line need bleeding?


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[Chrispb]

Filter is in the inlet end of the dosing pump connection.
Usually system bleeds itself, but bare in mind the pick up pipe for the heater and engine fuel supply although seperate are toward the rear of the tank, so under a Ã,¼ of a tank on a steep downward facing slope does cause fuel supply issues as I found with my mk2 many times, in the end I would always park facing uphill if fuel is lower than a Ã,¼ full.

[brummygit]

That's interesting - I tried last night with a virtually empty fuel tank.

First step I think is to fill up, then I will drop the heater and check if I get fuel by removing the pipe.

[brummygit]

Sorry, one more question - is the dosing pump external to the heater, or do I dismantle the heater to get to the filter?

[Chrispb]

The dosing pump is under the drivers side front end of the diesel tank totally separate unit, after you have filled with diesel and cleared any codes try it again before dismantling.

[brummygit]

OK, I've spent a few cold hours under the Galaxy today.

I took the fuel line off the inlet side of the dosing pump - couldn't see a filter as the bore is so narrow - I also didn't have masses of diesel pour out as I'd expected, but there was fuel there so I reassembled.

With the booster dropped from the car I tried again and I could feel the slow tapping of the doser which got faster and then stopped during a lighting cycle.

I took the fuel line off the heater and tried a starting cycle but was surprised that I didn't see any fuel squirt out - I'm guessing that it doesn't actually use much. Yet when I refitted the pipe the heater lit and ran for around a minute at around 75 degrees. It lit once more and then went back to not lighting although there was the occasional puff of diesel smoke from the exhaust.

I tried to take the covers off but someone (not sure who or when) has stripped one of the long torx bolts holding the the end plate on.

I couldn't get the plastic top off - I removed 4 torx screws but it seemed very unwilling to lift at the point where the fuel entry pipe is. Do I need to loosen all of the black plastic - I was assuming it was 2 separate pieces?

I ran out of daylight and time, but I'm still thinking that I might have a defective glow-plug, but would really like some advice - should I be looking for squirting fuel from the disconnected fuel line during a starting cycle?

Also last thing this evening I got a couple of controller internal memory errors logged - I've not seem these before.

I would like to order all the parts I need and get to fitting them next Saturday if possible.

[Chrispb]

The quantity is quite small delivered and would be seen as a pulse in time with the ticking.
By what you have said I would say you have a fuel supply fault not the glow plug
Am assuming you now have plenty of fuel in tank.

Things to consider.

1 Pick up supply to pump, no blockages or drawing air
2 Condition of pump ability to pump
3 Heater control module controls rate of pump
4 D5WZ-F models known for failure and send misleading diagnostic codes.

If I was you now I would disconnect the pump from the tank and get a jam jar with some fuel and with a piece of tube see if the pump/heater will run OK, if it does there may be a blockage in the tank pick up pipe, if it doesn't pick up fuel from the jar then pump is at fault.

Below pic of pump showing filter

[brummygit]

Hi Chris

I'm amazed at the quality of your posts - thanks for taking the time to help me 

Yes, I put Ã,£80 in yesterday so no issue with lack of diesel now.

I will plan to do this next weekend - is the filter easy enough to remove as I wouldn't want to stick a screwdriver blade through it?

My first attempt will be to drain some fuel into my jar from the tank as I'm guessing this should flow from the disconnected pipe, even if quite slowly. Do you know the trick for the metal clips on the pipes as I couldn't work out how to release them on the fuel pipe at the pump or heater ends?

Next I'm worried about the onset of internal memory errors that started at the end of the afternoon's testing. Could this be something caused by my eBay cable - I assume I can't fully reset the whole controller?

[Chrispb]

The clips on the fuel pipe are the crimped type, I usually work a small screwdriver into the loop then stretch open the loop, after refitting squeeze the loop with a pair of side cutters.
The filter in the pic just dropped out after removing connector

[brummygit]

Hi Chris

You were absolutely right !!!

I took the fuel supply pipe off the pump and other than 1 drip no fuel ran out so I attached a longer clear pipe to the pipe from the tank and sucked - hey presto I had fuel running and filled a jar.

I then ran the booster from the jar - it took ages for the fuel to get to the heater (probably about 15 lighting cycles) but now it runs reliably at 270 degrees.

So I blew air from a pump back into the diesel tank to make sure there was no obstruction. I then needed to pull diesel back through before reconnecting.

It looks like I need to make sure my booster never runs out of fuel unless I want to end up bleeding it again.

Do you know if I need the full version of VCDS to run the dosing pump manually?

Thanks for your help.




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[Chrispb]

I have doubts it will not happen again,this system will self bleed with one or two restarts the fact it took that long to draw from a jam jar suggests it's not sucking very well.
At least you know the heater/glow plug is OK.
Did you find the filter in the pump or is it missing.

[brummygit]

Yes I found the filter once I knew what to look for, but it was quite difficult to remove. It was fairly clear so it had a quick clean and was replaced.

If it happens again I will replace the dosing pump. Any idea if this means VW/Ford or if they are available elsewhere? And how much?


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[Chrispb]

Is the part number details still visible on your old pump I may sell the one I have.

[brummygit]

I'm afraid I can't remember, but if I get any more problems I'll drop the pump off again and check.

[brummygit]

I've just checked my fault log and I'm still getting some "repeated flame-out" errors so I'm guessing that the pump is indeed weak.

Would I get open circuit errors if I had a bad connection on the pump?

If you are willing to sell your pump, can you give me some details - what it is off, how old is it and how much do you want. I can dig around and check part numbers to make sure it matches.

[Chrispb]

Will PM you

[brummygit]

I've replaced the metering pump this afternoon. The aux heater fired up on the first attempt afterwards.

The car does have a full tank of fuel now so I need to wait until its empty again to be sure as there might be a problem with the fue pick-up, but so far it looks very promising.

Thanks to Chris for your help 

[brummygit]

I checked the codes on the Aux Heater today. So far there are no flame outs reported, but I did have 2 x "65535 Internal Control Module Memory Error".

Any idea if this is serious or can be ignored?

Could it be due to my eBay VCDS cable?

[brummygit]

I'm still not sure that the heater is running all of the time it should. I can hear what I think is the coolant pump buzzing from the dashboard with the ignition on and heater fan off but I'm wondering if the pump is getting lazy with over 90k on the car now, causing it to shut down due to coolant temperature.

Can anyone suggest where to buy brushes for the pump?


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[gregers]

when i down this to mine i robbed some brushes from an old multi tool,and using some glass paper smoothed them down to fit.
or try maplins for some.

[SilverBeast]

.....or eBay. Just make sure they are bigger.  They will sand down quite easily as they are quite soft (the pictures in the FAQ's are from when I did mine).  Try and get some with side entry wires, though you can manage with rear entry. I'd get more than one pair, just in case you do over sand them.
They do only seem to last about 80-90k as the motor is running all the time the engine is running.