Yeah, theres definatly some issues, it starts hard cold, so I'm sure theres some bad glow plugs, it did start and run, and then started right back up after it had been sitting for a moment.

If glow plugs test ok, then I'm thinking air intrusion of some sort. I noticed some bubbles coming from the passenger front most injector, tightened it a little not sure whats going on there, is there o rings or somthing that you can change on them injectors?

 

Oh yeah, the injectors have O-rings under those caps. Search here for injector o-rings and you'll go cross-eyed with all the info on 'em.

 

I tweaked it a little with a wrench and it seemed to slow it down.

I'm also thinking someone may have converted the glow system at one time, been doing some reading and the glow plugs that are in it do not have the spade connectors, but the round ones like the ZD-9's.

Sorry, kinda learning as I go, kid I got truck from was usless when it came to any info about it, so its kinda learn as you go. haha.

 

You may have just found your problem. If the truck has the newer style GPs and the old style controller I'm pretty sure they're not compatible. I do not recall which is which, but one system used 6 volt GPs, the other 12 volts.

Is your truck still using the factory controller screwed into the rear of the driver's side head?

Nothing to apologize for, helping is what we're all here for!

 

Yeah there's still a controller there, looks like someone spliced the round connectors in.

 

i think Niles hit your problem square on the head Thomas. ZD9's will not work properly with the old style glow plug controller.
i would convert to the new controller anyway, the old screw in the block controller likes to stick on and burn out the glow plugs.

 

On second look it looks whole. I'll post some pics of my findings in a moment. 7 of 8 GPS tested good, found one bad connector. Always entertaining when getting a new project to work on.

 

So maybe someone just swapped in the harness then. This is all starting to make sense.

 

does it have the old style screw in controller, or the newer style controller with a relay and heatsink controller under it

 

Heres what I found:



Tweaked this a little with a wrench, seemed to make it stop, it was the only one I could see leaking.




Anyone ever heard of this?




The GP Connectors




On pass fender well, is this just the relay?




Controller In the head, appears to be still hooked up.




Bad connector in the very back.

 

that is the old style controller.
and you need a return line kit. the o-rings under the return line caps are probably leaking a bit.

the racor is an aftermarket water separator used to replace the stock firewall mounted water separator that liked to let air into the system.
a much better filtering system than stock.

 

Ok, now I'm real confused, dont the zd-1s have spade type connector?

 

yup.
ZD-1 spade connector
ZD-9 bullet connector.
they probably put the ZD-9's in because they had a set laying around and just changed the connectors on the wires. those are crimp connectors, the stock ones are soldered on, and had a rubber covering on them.

 

<!--[if gte mso 9]><xml> <w:WordDocument> <w:View>Normal</w:View> <w:Zoom>0</w:Zoom> <w:PunctuationKerning/> <w:ValidateAgainstSchemas/> <w:SaveIfXMLInvalid>false</w:SaveIfXMLInvalid> <w:IgnoreMixedContent>false</w:IgnoreMixedContent> <w:AlwaysShowPlaceholderText>false</w:AlwaysShowPlaceholderText> <w:Compatibility> <w:BreakWrappedTables/> <w:SnapToGridInCell/> <w:WrapTextWithPunct/> <w:UseAsianBreakRules/> <wontGrowAutofit/> </w:Compatibility> <w:BrowserLevel>MicrosoftInternetExplorer4</w:BrowserLevel> </w:WordDocument> </xml><![endif]--><!--[if gte mso 9]><xml> <w:LatentStyles DefLockedState="false" LatentStyleCount="156"> </w:LatentStyles> </xml><![endif]--><!--[if gte mso 10]> <style> /* Style Definitions */ table.MsoNormalTable {mso-style-name:"Table Normal"; mso-tstyle-rowband-size:0; mso-tstyle-colband-size:0; mso-style-noshow:yes; mso-style-parent:""; mso-padding-alt:0in 5.4pt 0in 5.4pt; mso-para-margin:0in; mso-para-margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:10.0pt; font-family:"Times New Roman"; mso-ansi-language:#0400; mso-fareast-language:#0400; mso-bidi-language:#0400;} </style> <![endif]--> Okay, the good news is someone did upgrade that to the new system. See that black box under the relay on the pass fender? That’s the new style controller. So if it’s wired correctly the old controller behind the head isn’t doing anything other than plugging the hole in the head.

So your problem could be simple. The new style controller ‘short cycles’ the glow plugs when more than one is burned out. Obviously you have the one since that one is disconnected, so if any of the other 7 is dead then it’s going to short cycle and not function properly.

So I’d start with fixing that connector, a bullet connector will work, and then test the glow plugs.

 

This thread here: https://www.ford-trucks.com/forums/1...-tutorial.html

second post down, that looks like my controler, it looks like the old system just had a solenoind,

Not trying to contradict, just I'm really confused now...lol.