I love my old truck, but I'm mechanically challenged and other then changing oil I usually get help. Recently I attempted to change out my glow plugs and ended up farming it out to a friend that had the tools and experience to do it right. He told me the original relay was bypassed and he bought a part and fixed the old relay. It worked great for awhile, but now intermittently, when I turn the key the plugs don't charge. No light on the dash, no click, nothing. I think I might just have a bad connection or a loose wire, but this dummy doesn't even know where to look. Anybody have a picture of the relay, or where most likely I should be looking for a connection that might be the problem?
Thanks,
Kevin

http://[IMG]http://i35.tinypic.com/168aant.jpg (http://nl.tinypic.com/r/168aant/4)http://i35.tinypic.com/168aant.jpg

OK I found the controller and cleaned the connections. But I think the problem was with the connection on this part with the posted picture. It's located toward the back of the engine close to the firewall. Looks like I've got it fixed, but this dummy still has no idea what that thing is??

Glow Plug Inhibit Switch. Cuts off power to the glow plug relay when coolant temp is warm enough for the engine to start without the aid of the glow plugs. Good idea in theory, it works until mileage and normal engine wear come into play. As the engine compression gets lower with wear, the heat of compression isn't quite enough to ignite the fuel in the pre-chamber. It requires a "boost" from the glow plugs.

The inhibit switch can be bypassed if the glow plugs are AC 60G's or a similar self-regulating type. When bypassed, the glow plugs will come on, even on a warm start. Most often, the controller will keep them off when the engine is hot but after a short soak, they'll come on.

Glow Plug Inhibit Switch.

Thanks!

Glow Plug Inhibit Switch. ....

The inhibit switch can be bypassed if the glow plugs are AC 60G's or a similar self-regulating type. When bypassed, the glow plugs will come on, even on a warm start. Most often, the controller will keep them off when the engine is hot but after a short soak, they'll come on.

OK I put in Bosch 80034 Duraterm Glow Plugs. Would I be better off bypassing the inhibit switch?

youd be best off wiring in a manual override controller. that way you can glow them all day long with a push button and start that truck in any weather.

you've got the best glows in that truck IMO. I've got a set in my 6.5 pickup and i love them.

I"ll get a photo of what i plan to do. I'm going to leave the factory controller hooked up, but also wire in a pushbutton setup for those really cold starts. This way when i don't need the extra glow time i can let the factory setup do it's thing, and when i need more glow it's there at the push of a button.

I've still got this in the theory stage as i've yet to try it out. Should work however.

i already run a glow overide switch for my 1985 6.2 system. its really simple. all you need is a solonoid switch off a older ford truck, some heavy wire like #8? not sure on that, some smaller wire #16, a momentary pushbutton(i used one off a 60's 4020 john deere since i had it kicking around plus its chrome so it looks nice).

The inhibit switch can be bypassed if the glow plugs are AC 60G's or a similar self-regulating type. When bypassed, the glow plugs will come on, even on a warm start. Most often, the controller will keep them off when the engine is hot but after a short soak, they'll come on.

I'm still having a lot of trouble with the inhibit switch and would like to bypass it.

When I unplug it nothing works which was the problem after an initial charge when plugged in.

How do I take it out of the loop and still get my plugs to fire?

Thanks.

i already run a glow overide switch for my 1985 6.2 system. its really simple. all you need is a solonoid switch off a older ford truck, some heavy wire like #8? not sure on that, some smaller wire #16, a momentary pushbutton(i used one off a 60's 4020 john deere since i had it kicking around plus its chrome so it looks nice).

I'll get photo's of my setup once it stops pouring. I have it set up so that the factory system still works, but i can override it for more glow time at the push of a button.

dave ill do it mines setup exactly the same. the factory system works and my override works when it has to. plus its not raining here. :D

push button
http://i644.photobucket.com/albums/uu162/4320diesel/Glowplugsfordp001.jpg

relay
http://i644.photobucket.com/albums/uu162/4320diesel/Glowplugsfordp002.jpg

the factory glowplug relay with the wires on it :
http://i644.photobucket.com/albums/uu162/4320diesel/Glowplugsfordp005.jpg

http://i644.photobucket.com/albums/uu162/4320diesel/Glowplugsfordp006.jpg

http://i644.photobucket.com/albums/uu162/4320diesel/Glowplugsfordp007.jpg

My next mod. Done it on all my past ones.

http://[IMG]http://i35.tinypic.com/168aant.jpg (http://nl.tinypic.com/r/168aant/4)http://i35.tinypic.com/168aant.jpg

I think my controller is OK. At this point I think all I need to do is bypass the above inhibit switch...per Fred482 "The inhibit switch can be bypassed if the glow plugs are AC 60G's or a similar self-regulating type. When bypassed, the glow plugs will come on, even on a warm start"...
I was hoping that it wouldn't be too hard just to bypass this...but I'm not sure how to do it.

The picture shows the temperature switch which opens around 100+ degrees. I'm not sure what it does on later years in addition to sending a signal to the glow plug controller. On earlier models, it also activated the high speed idle solenoid on the IP and advanced the IP timing.

If you add a manual glow plug switch, you don't have to disconnect this switch.

Here's a drawing of a manual glow plug setup:

http://www.dieselplace.com/forum/attachment.php?attachmentid=90690&d=1252353831

dave ill do it mines setup exactly the same. the factory system works and my override works when it has to. plus its not raining here. :D

Works for me.:D Yes your system is identical to mine. I'm still messing with my starter issue and i can't find the camera anyways.

I think my controller is OK. At this point I think all I need to do is bypass the above inhibit switch...per Fred482 "The inhibit switch can be bypassed if the glow plugs are AC 60G's or a similar self-regulating type. When bypassed, the glow plugs will come on, even on a warm start"...
I was hoping that it wouldn't be too hard just to bypass this...but I'm not sure how to do it.

I am sure all you have to do is hook the two wires together since it is an inhibit switch. Unplug it and jam a loop of wire into the two terminals to verify.