2003 Ford Galaxy (Sharan) 1.9 ASZ TDi Fan Control Module Issues.

[krautmender]

I've temporally come out of retirement to help out a very close friend, who's having issues with the coolant fan starting up with just the ignition being switched on! I've pretty much checked everything I can think of (connections etc), and yes it does point to the the fan unit J293. I was loaned another fan unit off another galaxy (same year) and connected that to the car and exactly the same thing happens. Which makes me think, what are the chances that BOTH could be US!

So anyway here's a complete scan using VCDS:

Monday,19,February,2024,17:26:49:55488
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 7 x86
VCDS Version: 23.3.1.0
Data version: 20230421 DS346.2
Ross-Tech: Home


Dealer/Shop Name: Airmec Engineering
Workshop Code: 444 12345 012345






Chassis Type: 7M - VW Sharan (1996 > 2010)
Scan: 25 01 02 03 08 09 15 16 17 18 19 22 29 35 36 37 39 45 55 56
          76
 
   Mileage: 211870km-131649miles
-------------------------------------------------------------------------------
Address 01: Engine        Labels: 038-906-019-AJM.lbl
   Part No: 038 906 019 LD
   Component: 1,9l R4 EDC G000SG  1595  
   Coding: 00002
   Shop #: WSC 00020  
   VCID: 64CCB68CF4837FB34F-4A6A


1 Fault Found:
18080 - Coolant Fan Control 1 
            P1672 - 35-10 - Open or Short to Ground - Intermittent
Readiness: 0 0 X X X 


-------------------------------------------------------------------------------
Address 03: ABS Brakes        Labels: 7M3-907-37x-ABS.clb
   Part No: 7M3 907 379 D
   Component: ABS FRONT MK25      0102  
   Coding: 0007689
   Shop #: WSC 00020 000 00000
   VCID: 3E7824E46AAF7563F9-50AC


No fault code found.


-------------------------------------------------------------------------------
Address 08: Auto HVAC        Labels: 7M3-907-040.clb
   Part No: 7M5 907 040 L
   Component: CLIMATRONIC MPV GP  0005  
   Coding: 00011
   Shop #: WSC 00020  
   VCID: 397237F82381525BCC-254E


No fault code found.


-------------------------------------------------------------------------------
Address 09: Cent. Elect.        Labels: 7M3-962-258.lbl
   Part No: 7M3 962 258 AD
   Component:    Multifunkt.Einh  0001  
   Coding: 04113
   Shop #: WSC 00020  
   VCID: 7CFCEEEC6C33A77397-5038


2 Faults Found:
00955 - Key 1 
            09-10 - Adaptation Limit Surpassed - Intermittent
00973 - Switch for Heated Rear Window (E15) 
            28-00 - Short to Plus


-------------------------------------------------------------------------------
Address 15: Airbags        Labels: 6Q0-909-605-VW5.lbl
   Part No: 1C0 909 605 F
   Component: 0E AIRBAG VW61 0Q0M 0003  
   Coding: 12357
   Shop #: WSC 00020  
   VCID: 2756E180C535D4ABAA-5072


1 Fault Found:
00532 - Supply Voltage B+ 
            07-10 - Signal too Low - Intermittent


-------------------------------------------------------------------------------
Address 17: Instruments        Labels: 7Mx-920-xxx-17.lbl
   Part No: 7M5 920 920 S
   Component: KOMBIINSTRUMENT VDO V59  
   Coding: 13401
   Shop #: WSC 00001  
   VCID: 428050144E5711839D-508E


No fault code found.


-------------------------------------------------------------------------------
Address 18: Aux. Heat        Labels: 7M3-815-071.clb
   Part No: 7M3 815 071 A
   Component: HEIZG. B/D5W       0001  
   VCID: 2E5814A4EACF85E369-50E6


5 Faults Found:
01492 - Function Lock-Out 
            35-00 - -
01409 - Repeated Flame-Out 
            35-00 - -
01409 - Repeated Flame-Out 
            35-00 - -
01409 - Repeated Flame-Out 
            35-00 - -
01409 - Repeated Flame-Out 
            35-00 - -


-------------------------------------------------------------------------------
Address 19: CAN Gateway        Labels: 6N0-909-901-19.clb
   Part No: 6N0 909 901 
   Component: Gateway K<->CAN    0001  
   Coding: 00006
   Shop #: WSC 00020  
   VCID: 70E4CADC307BD3133B-508E


No fault code found.


-------------------------------------------------------------------------------
Address 76: Park Assist        Labels: 7M3-919-283.clb
   Part No: 7M3 919 283 
   Component: Parkingsyst. SH RDW D02  
   Coding: 00117
   Shop #: WSC 00020  
   VCID: 77F6F1C05515842BFA-50AC


1 Fault Found:
01546 - Sensor for Parking Aid; Rear Mid-Left (G204) 
            37-00 - Faulty


End-------------------------(Elapsed Time: 05:25)--------------------------

[Crasher]

From what I can see it is different to the VW system but possibly the fan controller YM21-8C616-AA

[krautmender]

Thanks Crasher

Been going through all the wiring tracks for a 2003 Sharran TDi with the same Engine code, but I cant help but think Fords have 'personalised' VW's fine work just to make the vehicle slightly different!

[mickeybo]

theres a reasion for this. The cooling fan/fans has to be contr0lled s0 that allows the engine to maintain a constant running temperature

[krautmender]

So here's the latest, I've still got this damned motor stuck up my ****!

So after buying a 20 quid multimeter off Amazon that reads PWM & Hertz I was then able to read of the signal from the ECM, which was giving around 0.25 volts & 5% Hz. When the engine runs, this signal doesn't move which then makes the fan run flat out. Next move was to buy a PWM generator module off Amazon, (only 8 quid) and after wiring this up to the fan module set at 100 Hz and adjusting the output from 5-90% still no joy, fan ran flat out.

So as these Bosch fan modules (similar to BM's and Volvo's) suffer from problems, I then decided after looking at other VAG models and their wiring tracks, I could possibly convert to a different fan and module. So a trip to Stevens VW breakers I sourced and tested with the PWM generator a Tiguan fan with a external control unit. This fan also had an identical wire code to the Galaxy.

Got this home and laid the unit across the top of the engine and connect the fan plug to it, guess what? Fan when the ignition was turned on did exactly the same as before, it started up and ran flat out! Carried a re-scan with VCDS only to find the original fault code was still there and wouldn't clear. 1 Fault Found:18080 - Coolant Fan Control 1 P1672 - 35-10 - Open or Short to Ground - Intermittent Readiness: 0 0 X X X!

So it seems there is a short or an open circuit somewhere that I'm having trouble finding somewhere, which is possibly a broken wire. Had another look at advanced measuring values on VCDS, all looks okay
except for G8, which I think is from the sump sensor, but I can't see that affecting the fan issue, or could it?




Perry.jpg

[Crasher]

Run a new “overlay” AKA bodge wire from ECU to fan module.

[mickeybo]

First check on this has to be the coolant temp sensor resistance taken at cold should read approx 2-3 k the very most likely cause of your problem with the high speed fan