My friend has a 1992 F350 Custom 4x4. This truck has a serious case of ownerdidntgivea****itis. Oil in the rad. No coolant in oil though. air cleaner was a non recognizable k&n that was the wrong size, so covered in black oil it baffled me. Well it wont start at all. I cant get power to the GP's. I cant get fuel smoke coming from the tail pipe while cranking. I checked the fuel filter, its full. It wouldnt surprise me if it is gasoline though, smells odd.

So far i have replaced the batts, gp's, air cleaner, cdr, cleaned the intake, checked the lines for leaks, cleaned all the battery terminals and grounds, changed the gp relay on the controller. Tried starting it with hot air from heat gun, wd40, lots of cranking etc. Havent tried starter fluid.

Can i use a starter relay to power the GP's? I have another relay but it is a starter relay not a gp relay, my thinking is that they are the same but i could be wrong.

Lets hear the ideas, i am running out of ideas. I cranked so long on this thing that it should have made its own heat just by friction. Its definitely cranking fast enough, just not firing. help!!

 

id crack the injector lines and see if fuel is getting to the injectors. The FSS may not be getting power. If the GPs aint workin, a little shot of starting fluid wont hurt it.

 

didnt think of the fss. which terminal is that on the ip? If it isnt getting power how can i check and then how can i fix that? Never did that one lol

 

i dont recall what terminal it is, but I think Dave S has a pic of the IP with labels. Turn the key to the ON position and unhook the wire to the FSS. You should hear a click. If not the FSS is not getting power. You can take a jumper wire from the positive terminal of the battery to the FSS to energize it and try starting.

 

Pull the front most wire off the IP, turn the key on, touch that wire back on it's terminal, does the FSS click??

Glow Plugs on the '92...
For clarity on the GP Relay:

• One small terminal is 12v+ from ignition on ... Power Terminal. (Red wire)
• One small terminal is Ground ........................... Ground Terminal. (White wire from Controller)
• One large terminal is 12v+ from Battery ......... Battery Terminal.
• One large terminal is the glow plugs ................ GP Terminal.

• Ensure you have a good controller ground. (Black wire)
• Ensure you have 12v+ to the Power Terminal with key on.
• Ensure you have good 12v+ from batteries to Battery Terminal.

1. Attach test light to GP terminal and ground.
2. Disconnect white wire.
3. Turn key on.
4. Ground the Ground Terminal.
5. Turn Key off
6. Did the test light come on??
   • No
   • Yes
     1. Disconnect ONE Glow Plug Connector.
     2. Attach test light to that Glow Plug Connector and ground.
     3. Turn Key on.
     4. Ground the Ground Terminal.
     5. Turn key off.
     6. Did the test light come on??
        • Yes.
          1. Unplug the Glow Plugs.
          2. Attach one end of a test light to 12v+ battery.
          3. Touch the other end to the terminal on the end of the Glow Plug.
          4. Does the test light come on?
             • Yes, Chances are it's good.
             • No, Replace with Motorcraft/Beru ZD1A for 83-86, ZD9 for 87-94.5.
             This test is susceptible to miss diagnoses and should only be used for a quick reference.
             To do a positive test use a volt/ohm meter and test the ohms between the terminal and base. Should be .5 to 1 ohm resistance.
        • No, Fix Glow Plug Harness.

-Enjoy
fh : )_~

 

Great info festus, thanks much!! That'll help. So can the FSS fail completely? is it likely and is it replaceable or do you have to replace/rebuild the pump? Thanks!!

 

Yes, They can and do fail as well as stick.

Failed = Rebuild/Replace pump
Stuck = Your favorite Diesel Cleaner Lubricator, fill the IP and let it set.

I did edit my previous post, I got interrupted and was unable to finish it the first time.

-Enjoy
fh : )_~

 

So I have power to the battery terminal, that's where it ends. I am not getting power to the fss but if I jump a wire across it clicks. The fss connector does not have power. The ignition wire does not have 12 v when the key is on either. If my buddy needed his truck asap, can I jump a wire to the fss and manually spark the GPs?? Is it his ignition or a fuse? I checked the dash fuses. All good.

 

Bump bump?!?!

 

Yes you can manually inject 12V to the FSS to see if it makes a difference. Won't hurt anything.

Same for the glow plugs. Jump power to the glow plugs for 10-15 seconds if they are known to be good beru glow plugs, otherwise do not pass 10 seconds glow time.

 

Make sure you use a hefty jumper to supply power to the glow plugs!! (Booster cables come to mind actually...)

 

Why do you need jumper (booster) cables to jump the glow plugs???

All one needs to do is apply 12v+ to the small power terminal on the relay, remove the white wire and ground the terminal you removed the white wire from for 10 seconds ...

If the relay is bad, replace it, jumping input to output is foolish!

Wreckinbal, what other (if any) key run position items are not working??

-Enjoy
fh : )_~

 

well for starters(pun for fun!) the wait to start light is dead. most all else including stereo works. think maybe the controller itself? its got me guessing there.

For an update, i jumped power to the FSS with 12g wire and a female spade connector, then a circle connector on the battery terminal post.
Truck runs like a top. I am going to run a toggle switch tomorrow for him so it can be in the cab, getting out to pull the terminal can be challenging if on a hill. Their e brake is........well its not....lol. so for now he will be jumping the glowplugs, switching the fuel on, and be on his way, when money comes he'll be good .

 

sounds like some things I've driven

had a couple loose wires up on the dash coming from the starter realay for about a month till I got up the motivation to find why it wouldn't work by turning the key
just touched the ends of the wires together to start

 

Split that power you have to the IP and run the spur to the Power Terminal on the relay (disconnect the red wire)... Then run a wire from the Ground Terminal on the relay (disconnect the white wire) to one leg of a push button, the other leg to ground... Manual GP's for the post 86.

*** WTS Light Test ***
Post '86
Step 1

1. Disconnect WTS light at Controller connector.
2. Ground WTS wire on harness side. (not controller side)
3. Turn Ignition Switch on.
   Does the WTS light come on?
   • Yes, WTS light works
   • No, Check WTS wiring, Replace Bulb.

Step 2

1. Disconnect WTS light at Controller connector.
2. Turn Ignition Switch on.
3. Does the WTS light come on?
   • Yes, Fix wiring.
   • No, Replace Controller

-Enjoy
fh : )_~