Ford galaxy 1.9tdi mk2 2005 aircon

[Terry Johnson]

Right folks, thanks for this great site and I hope someone with some knowledge will be able to help me.
I purchased my car a 1.9tdi Mk2 galaxy in December, anyways since buying the aircon has always been warm. Had it regassed at Kwikfit and all went through no leaks but aircon still warm, so I started doing some digging and noticed the compressor clutch wasnââ,¬â,,¢t kicking in so I had the system drained down and removed the compressor to have a look, upon inspection I noticed past burning on the clutch and a lot of black sut and corrosion within the clutch. Luckily I managed to source a brand new compressor from nissens and had that delivered fitted it and regassed wala! Cold air. But after 2 days noise from clutch and smoke!! So I disconnected the compressor so the clutch donââ,¬â,,¢t engage. Now I donââ,¬â,,¢t reallg want to ruin another clutch compressor from a brand new compressor. Can someone shed some light on why this would be happening?? I have snap on diagnostic computer and nothing coming up on here. And just to say itââ,¬â,,¢s also had a brand new condenser also. I really need some help as Ã,£500 has already been spent and Iââ,¬â,,¢m really worried 😟

Thanks to all for any helps

[johnnyroper]

Seems odd to have same thing with 2 compressors, only thing I can think is a supply issue to the compressor causing clutch not to fully engage? Get a meter on the wiring and measure to see if thereââ,¬â,,¢s a steady 12v to it

[brianh]

As above, only thing i can think to add is to check you've got nothing leaking onto it (engine oil, coolant etc) and do you have the undertray installed?

[Terry Johnson]

As above, only thing i can think to add is to check you've got nothing leaking onto it (engine oil, coolant etc) and do you have the undertray installed?

Hi thanks for your input, I will check this today and report back,  and heââ,¬â,,¢s the car has undertray. Thanks

[Terry Johnson]

As above, only thing i can think to add is to check you've got nothing leaking onto it (engine oil, coolant etc) and do you have the undertray installed?

Thanks I will check this today and report back. Thanks

[brianh]

Did have another thought - Which of the 2 levels of fill did they use? The higher figure is for if you have rear air con (which very few do have - you should have roof vents if you have this in the back). If its been filled to the dual system level and its actually only a single system, that will cause problems as the pressure gets too high and locks the compressor up, which would account for the burnt clutch your getting. I think from when others have had that happen, it works ok for a few minutes then problems start, though usually quite noisy problems.

The sticker should be on the front panel once you open the bonnet with the levels. Some places will record the values on a printout, others don't bother, hopefully you either know what level it was filled to or the paperwork will tell you, if not it might be worth a check with the garage that did the recharge.

[Terry Johnson]

Did have another thought - Which of the 2 levels of fill did they use? The higher figure is for if you have rear air con (which very few do have - you should have roof vents if you have this in the back). If its been filled to the dual system level and its actually only a single system, that will cause problems as the pressure gets too high and locks the compressor up, which would account for the burnt clutch your getting. I think from when others have had that happen, it works ok for a few minutes then problems start, though usually quite noisy problems.

The sticker should be on the front panel once you open the bonnet with the levels. Some places will record the values on a printout, others don't bother, hopefully you either know what level it was filled to or the paperwork will tell you, if not it might be worth a check with the garage that did the recharge.

I know it was filled for dual aircon as it has vents in the back in roof so assuming it is dual aircon. But Iââ,¬â,,¢ll look after work and check under bonnet to see what it says. Thank you for this.

[Terry Johnson]

So Iââ,¬â,,¢m a little confused. Yes I have vents in back above seats but looking under bonnet it says ââ,¬Å"evaporator1 700 + 50
                     Ã¢â,¬Å"Evaporator2 1050 +50

Also nothing is dripping from any pipes onto the compressor. Waiting on a meter to check voltage. Still stumped. Thanks for any help.

[brianh]

Yes they all say that, and thats why it gets filled incorrectly sometimes

Evaporator 1 is for single zone
Evaporator 2 is for dual zone

Why they couldn't put the appropriate sticker on the car for single or dual zone is beyond me, but whats said when its come up in the past is that vents in the roof mean you have the rear air con, so it should be the higher figure.

Of course, that assumes that you not only have it, but that its actually connected as well just in case someone has disconnected it to repair a leaking section (well not really repair it, more stop it leaking), it might be worth having a close look over the pipework to verify its still intact, only other suggestion I've got is to try switching it on again and see if you can identify which bits get cold to see if you can locate where the problem is. Though it would be worth trying to rule out the suggestion above about the electrical side of things, I'd be inclined if there is 12v there to put a bulb or similar across the connections to try and confirm you have a good supply of power to it, could be corroded and showing 12v with nothing connected, but failing to provide enough electricity under load to hold the clutch in fully, allowing it to slip.