From what I can tell, that controller in the head still goes into that loom that the glow plugs are in, so can I just unhook that? Is it possible they are trying to cancel one another out,

I apologize for sounding like a total noob, this is one thing I apreciate much more now on my powerstroke.

I'm going to change them all any ways, since I have one burned out and no history on when they were changed.

Thank you all very much for your help and paitence!

 

Yes, right now your truck has BOTH controllers. The one behind the head is the stock one.

The one they put on the fender, the one that the relay mounts to and is connected with the Z bar is the new style.

IF it's wired correctly the one in the back behind the head isn't doing anything other than plugging the hole in the heads.

The new style you have on the fender is correct for the new style glow plugs you have.

 

Ok, thats great news, I just tested it again, its just clicking on and off, I'll get a set coming, and we will go from there. Thank you very much for your help.

 

It would be a good idea to unplug that old controller, no telling how the PO wired that system up. And Tom's correct, the old style controller can fail in the 'on' position and fry all of your glow plugs.

Just to clarify too, the newer system originally was in back of the engine behind the air cleaner. Someone just installed it in your where your original relay was. Not a bad idea anyway, it's easier to work on there and if you ever go turbo it won't get in the way or have to be moved.

In the end when you have it all figured out you just need to pick which system you want and go with the proper wiring and parts. Since the newer system is in there I'd just double check the wiring, redo if necessary and stick with it. Just get parts for an '87+ GP system.

I hate it when people that have no business touching wiring do half-assed jobs like that. When converting all the old stuff should have been removed or disconnected and tied off at least.

My truck is an example of that too. Somewhere during it's life someone swapped in a 6.9 from an '87. Since the '87 had the new system they/he/she/it wired it to the original relay on the fender. So I had the new controller and relay wired through the factory relay and when they couldn't figure out why it didn't work they installed a manual push button.

And they had 7 bullet GPs and 1 spade GP.

 

Yeah from what it sounds like, the new system is the way to go, I will do what I need to to get it going. Sorry again for all the confusion.

Just pulled all the glow plugs, they were all autoswells. Have a set of ZD-9s on the way, should be here shortly. Hopefully this will fix the problem!

I hear you on the wiring, I, myself, am quite particular on how things are wired, they had a speaker wire hooking things in that harness up, that was fixed promptly.

Only other thing I don't understand on this truck is why it doesn't shut off when you turn the key off, they have a toggle switch which looks like it has 12v on one side and the other goes to the injection pump (I'm assuming theres some sort of shut off solenoid in there?) That will be next.

Thank you again for all of the help. Once again this forum rules!!!

 

that sounds like the ignition actuator may be broken in the column. i have seen a couple break in a no shut off way.

 

Mine did that. I installed a master relay and master on-off switch to work around it, until I could pull the column apart.
Now, I have that master on/off relay *and* a working ignition switch(though when I did my 'repair', I never reinstalled the key or housing, so I just have a lever to push with my fingers).

 

I can live with it, but I cant live with how the morons wired it, wires running right across the manifold, and they are speaker wire. Someone had no business touching any wiring on this thing.

Other than that, changed the glow plugs, it cycled, and started right up. We will try it again tomorow morning when its a little cooler, I'm praying it doesn't have any air intrusion issues.

 

Orange Beach, Alabama

 

Well, been driving it a few days, seems to run very well!

Its going to need a water pump, its not leaking yet but Its getting loose. When I do the pump I plan on adding a coolant filter with some SCA.

Other than that, seems to run very well, cold starts in the morning are still a little rough, it usually starts, then stalls, and then takes a bit to get running again, but once its run, its good for the rest of the day.

Gotta love the simplicity of these engines! Don't get me wrong I love my PSD, but I'm quickly becoming a believer in these IDI's as well.

 

uh oh.your catching the idi bug.careful there is no cure known to man.not even modern day power seems to be able to lick it!
pure old time simplicity,dependability,affordability and reliability trumps the big hp diesels power every time.this is why the 7.3l will forever be legendary.

 

AIR INTRUSION!!! but this is nothing a return line kit and a duralift pump will not cure.

 

Yeah thats what I thought, looks like they replaced a couple return lines but the rest are original, I'll have to get a kit for it. How easy is it to install? I've done o rings on my PSD, so thease should be pretty easy right?

 

yup, the hardest part is getting the fuel lines off and back on without cross threading them

 

And most of us don't stop at owning one. There has to be at least two. I'm guilty as well