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So, we installed the new glow plugs. It went flawlessly. I had a buddy who's a former diesel tech help me do it (show me how, for next time), However, the glow plugs aren't firing. We ran a cable from the battery terminal to the glow plugs for a couple seconds, and then it (when I cranked) started right up. It seems to run okay, though the transmission sounds like it (hopefully just) needs fluid. Anyway, does anyone have any tips with electrical gremlins? I'm planning to go get a manual for it in the next few days, and that'll help, but any known-issue things would be nice. The relay seems fine, according to my friend. He seems to think it's either a wiring or timer issue?

The temp sensors on the thermostat housing play a role in the glow cycle. The ends of the wires et brittle and many times break inside the insulation at the sensors. There are a couple of wires on the buss bar (connects to glow plugs together) that run back to the glow controller. Corroded connections at the heavy wires going to the glow relays and to the drop resistor(located behind the left headlight..alum box w/ two wires) are also culprits. Take the connectors apart and clean them up. Pinching the female ends of the connectors shut more to be sure they grab the other end tightly will help too.

I'll point this out to my friend. He seems to think it's the timer, since the relay clicks on, then immediately off. The other option we're considering is just completely routing around the key, and setting up a series of switches to turn on/off/accessory the car, and another to control the glow plugs.

Matt--

Andy is right on this. The glow controller WILL click off right away if there are corroded contacts in any of the (very many) large wire connectors that feed the glow plugs. This includes the blue fusible link in that circuit.


It will also click off right away if the yellow wire temperature switch in the thermostat housing is shorted. You can test for a shorted switch by pulling apart the bullet connector in the yellow wire.

Paul