Description

This is a fully reconditioned Garrett GT15 (GT1549V) turbocharger for the 110HP Ford Galaxy TDI fitted with the AFN engine code, covering models from 1996 to 2002. It is a direct-fit, OE-spec replacement for part number 454083-5002s, built and balanced in our Birmingham workshop.

As a variable nozzle turbine (VNT) unit, this turbocharger uses adjustable internal vanes to control exhaust gas flow, providing excellent response across the engine’s rev range. The most common failure mode for this specific model is seizure of this VNT mechanism. Carbon and soot deposits from the exhaust build up over time, causing the vanes to stick. This can result in two distinct symptoms: if stuck open, the vehicle will suffer from significant low-end lag and poor performance; if stuck closed, it will create an overboost situation, often causing the engine management system to trigger a ‘limp mode’ to protect the engine.

Other potential failures include standard bearing wear due to oil contamination or starvation, or failure of the vacuum actuator diaphragm which controls the vane movement.

At Gap Turbos, this listing is for a reconditioned exchange unit. We supply you with a fully rebuilt turbo from our stock, and you return your old unit to us. Our reconditioning process involves a complete strip-down, ultrasonic cleaning of all components, and replacement of the core assembly (CHRA) with brand new, OE-grade parts. The complete unit is then precision-balanced to standards exceeding the original manufacturer’s specifications. For customers in the West Midlands, we also offer a full diagnostic, removal, and fitting service. We strongly recommend cleaning the EGR system and intake manifold when replacing this turbo to prevent a repeat failure from excessive soot.

What this turbocharger fits

• Brand: Ford
• Model: Galaxy TDI
• Engine Code: AFN
• Horsepower: 110 HP
• Year Range: 1996-2002
• Fuel: Diesel
• OE Part Number: 454083-5002s
• Alternative Part Number: 1002829

All our reconditioned turbochargers are built to OE specifications in our Birmingham workshop and come with a comprehensive warranty. Please contact us for a precise quote and to confirm stock availability.

Specifications

Vehicle fitment

• Ford Galaxy TDI

Common faults & troubleshooting

• Sudden loss of power during acceleration (limp mode): This is a classic symptom of overboost, caused by the VNT vanes being seized in the ‘closed’ or maximum-boost position.
• Sluggish performance and poor power below 2,000 RPM: This indicates an underboost condition, likely caused by the VNT vanes being stuck in the ‘open’ position.
• High-pitched whistling or siren noise from the engine bay: This usually points to a boost leak in the pipework between the turbo and the engine, or in a failing intercooler.
• Excessive black smoke from the exhaust under load: A lack of boost pressure from a failing turbo results in an incorrect air-fuel ratio, causing unburnt diesel to exit as smoke.
• Blue/grey smoke, especially on start-up: This is often a sign that the turbocharger’s internal oil seals have failed, allowing engine oil to leak into the intake or exhaust system.

Fitting notes for this unit

• Mandatory Oil Feed Pipe Replacement: The oil feed pipe must be replaced with a new one. The old pipe can become restricted with carbonised oil, which will starve the new turbo of lubrication and cause immediate failure.
• Prime Before First Start: Before connecting the oil feed pipe, use a syringe to squirt new, clean engine oil directly into the turbo’s oil inlet port while slowly turning the compressor wheel by hand.
• Check Oil Drain: Ensure the oil drain pipe is completely clear of blockages and sludge. Any restriction here will cause oil to back up and pass through the turbo seals.
• No Sealant on Gaskets: Do not use any form of liquid gasket or sealant on the oil or exhaust gaskets. The supplied gaskets are designed to be fitted dry.
• Initial Run-in: Once fitted, start the engine and allow it to idle for at least five minutes to establish full oil circulation and pressure before revving or driving the vehicle.
• Check Actuator Function: Before installation, it is good practice to connect a hand-held vacuum pump to the actuator to confirm the VNT lever moves smoothly through its full range of travel without sticking.

Alternative part numbers

This turbo is also referenced by:

• 1002829 — Ford Turbocharger OEM 1002829 (Ford Galaxy TDI, AFN, 110hp)

Frequently asked questions