I finally got around to testing my GPR per PonyboyChris' directions in the sticky thread on winter cold starts.

The batteries were freshly charged and cleaned with good tight connections. when the key was turned there was a distinct click from the GPR and my volt meter read abt 10.6 volts then slowly raised to 10.9 volts before clicking off abt 30 seconds later. The outside temp was abt 70 deg. I ran the test 4 or 5 times but didn't time the turn off until the last try.

Unless someone tells me otherwise I am gong to assume that my GPR is good and will go on to testing the GPs.

 

Sounds about right. Are you having cold start issues or just being pro-active?

 

The GPs on the passenger side test good with the ohm meter. Now I just have to figure out how to get to the harness plug on the drivers side. (There just is no room in that van.)

My commute to work is 5 miles it is always dark in the winter mornings and late in the winter it is often dark on the way home, if I work OT. That and a monthly scout camping trip is about the only time I drive this van.

Winter #1 (08/09): I purchased the Van in Dec of 2008. (The guy I bought it from was keeping it in a storage area in some caves - 55 deg year round.) About Jan I was having problems with it starting anytime it wasn’t plugged in and temp was less than abt 32-35. I had the batteries checked at Wal-Mart and the second battery was bad so I replaced it (the main battery looked new the second battery was quite old). No more problems that year.

Winter #2 (09/10): The next year when it got cold I started having the same problems. I took it back to Wal-Mart and had the batteries checked again. This time the main battery was bad. I had both batteries replaced and no more problems that year. I did keep a solar battery maintainer plugged into the power output most of the winter.

Winter #3 (10/11): Last winter the solar maintainer was no good and there were two times at work where the van wouldn’t start in the cold. (I kept it plugged in at home.) As each winter before it would turn over a few times until it didn’t have the power to start and then it would need a jump. (It has always started okay with a jump once the batteries were charged.) I made a habit of any day the temp was below 40 I would go out to the van at lunch and let it run for about 20 minutes or so. That got me through the winter. This is my first diesel. I figured the batteries were only a year old and that it must be the glow plugs. In the spring I bought a motor cycle as transportation and was planning on checking/changing the glow plugs over the summer. (Just now getting around to it.)

This Fall (2011): The only time I have driven this van during the spring/summer is our monthly scout camping trips and a few errands. Last month (late Sep) it hadn’t been started in about 6 weeks when we took our scout camping trip. It started okay Friday night drove 2 miles to the pickup point shut the van off and waited for everyone to get there then it started good and we drove abt 5 miles to the campsite. Saturday morning as we were leaving the engine would crank but not start. The over night low was abt 38-40 and at the time it was abt 42-45. I tried starting it about 6 or 7 times. It almost started on the 3rd try but didn’t make it (I guess I released the key to early). I was surprised that the batteries had enough juice to crank the engine as many times as they did. They were getting quite week and the cranking was quite slow when the van did finally start. Drove the van 5 miles to the pick up point to wait for parents and meant to keep it running but forgot. About 15 minutes later all the scouts were picked up and the van started well. I drove 2 miles home and parked the van in the driveway. The next weekend I took the batteries out of the van and cleaned and checked them they were reading about 9-10 volts. I charged them both up and left them in the garage they both have held the charge for two weeks now. It was a good 20 months ago that they were originally installed and have not been messed with until this fall. The connections were not new but they really weren’t bad either. Their was some corrosion on the second battery terminals (It lives on the passenger side undercarriage under the side doors of the van). The positive post of the second battery was black (similar to a piece of steel that has been black oxide).

My current plan is to finish checking the GPs if they are good I will move on to the starter and clean and have that checked and make sure the connections are good when I reinstall it. If the GPs and starter check out good then I will reinstall the batteries with corrosion inhibitor pads and a battery maintainer that I will keep plugged in when I am at home. If everything checks out good and I have starting issues again/still I’ll take it somewhere and have the injectors checked.

 

Couple of things I can think of.
#1 - Rule of thumb, replace batteries in pairs. There is no "main" and "second" battery per se, they work together equally. If one goes bad, it increases the work of the other and compromises it's life. Even though the good battery "checks out" it still is being weakened by the bad battery hence the reason by replacing in pairs. Or else you will be constantly in a cycle.
#2 - It doesn't sound like you drive the van much so over time, the batteries are discharging causing a hard start problem. That alone can cause your condition.
#3 - Most likely it's NOT your injectors. There's sooooo many stories of folks taking their vehicles in for diagnostics and the first thing shops want to do is change injectors at the tune of a couple grand. I say it's your battery condition.

You are on the right track to check connections and the GP system. It sounds like your GP's are ok (once you get the other harness off - it can be a pain) and your relay is working too. 9-10 volts is not enough to start these engines - 11+ volts is the minimum. My recommendation is a new pair of batteries that are rated for our trucks. Good luck and post back your progress.

 

Thankyou PonyBoy,
I will follow up.

 

The glow plugs on the drivers side are good each measuring 1.4 ohms. Now I will take off the starter clean it and get it checked. then I will reinstall everything with corrosion inhibitor pads on the batteries and a battery maintainer. I just need to figure out how to get to the top bolt on my starter???

 

The starter tested good at the local auto parts store. So I will put it all back together with the CCV mod, change the oil, and wait for some cold weather. If you don't hear back from me then everything is doing well. Thank you all for all your help in this thread and others.

 

Good Luck and keep your batteries nice and fresh. I don't drive my truck daily anymore but start it and drive it around every weekend and sometimes take it on an hour drive on the highway to keep everything fresh and happy.