Once again yesterday, I was assisting in the hard cold start diagnosis of an IDI. After determining that the return lines were not leaking it was clear to me that the glow plugs and/or GP controller was at fault. The truck in question is a '93 7.3. The owner had had the GP's replaced about 10K ago and said that it has been slowly getting harder to start as the cold set in. The owner said that he used a multimeter, as shown on this forum, to determine if he had a bad GP, and that all but one proved "good" using that method. The symptoms, however, suggested otherwise. The first glow cycle was pretty non eventful. WTS light came on, for what in my opinion, is the correct amount of time, then the engine was started. Sure enough it was a pain to start and I could tell that it had about four dead holes. Post glow was the interesting part. After the engine was running, the GP controller "post glows." The symptom here was that the entire dash would power cycle. Also the GP controller was cycling on and off at about 2Hz. The dash power cycle corresponded to the GP power cycle. I suggested we remove the GP's for further investigation. I had a hunch that he had several glow plugs that had internal shorts. We removed all the GP's. Next we verified the resistance of all the plugs. It corresponded to the previous verification, using the method on this forum, that seven were good and one was bad. I next used a jump pack to ACTUALLY test the GP's. We found that he had ONE truly bad glow plug, THREE GP's with internal shorts(within the body), THREE GP's the did not glow at the tip (2 midbed and 1 only at the body) and ONE GP that actually glowed where is was supposed to. As a note all the GP's were AC Delco(for information only). The point of this rant is to urge people to approach diagnosis logically. Don't just throw a new engine in when you need to change the oil, and don't assume that something you read on a forum is THE way to test something. While he had great intentions, the method failed him, and now his truck starts the way it's supposed to. 20 minutes $100 to diagnose and replace properly. He spent 10 minutes diagnosing two months ago and potentially damaged his batteries and starter as well as his alternator and GP controller and wiring. Extended cranks cause undue wear on the starter and batteries, and the three dead shorts cause undue wear on the wiring, controller and alternator. Not to mention the ECM's probably didn't appreciate it too much either. Burnout in NOT the only failure mode of Glow Plugs. and an internal short can read 0.3Ω just as well as a GP that glows where is isn't supposed to just as well as a good GP.
End of Rant
Have a Great day!!!!

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