I'm having a weird issue that the glow plug section at the top doesn't have an answer for that I could see. I recently replaced my controller and relay because it stopped working. For the first week truck glowed like it should and started better than it has in a long time. Fast forward a week or two, now when I turn the key it starts clicking rapidly, so my first thought was burnt out plugs. But if I cycle the key again it will glow for the regular time and start. Sometimes the second cycle works and sometimes it doesn't. Sometimes you get in and it glows correctly the first time.

I checked my wiring at the controller to make sure a wire didn't come loose after install and everything was tight and from a quick glance all my glow plugs are hooked up(one has a tendency to come unplugged every once in awhile). I am just puzzled why it glows right sometimes and then others I have to cycle it again(maybe even two or three times) and then it will glow. Is my new controller bad or is it something else simple that I am overlooking?

 

I would verify all my plugs are good with a meter or a test light then double check for clean tight connections. After that I would suspect the controller. I went manual setup and haven't looked back after 2 controllers and also bypassing the glow plug system power feed connection plug on passenger side inner fender.

 

I thought all the plugs tested ok but I need to check and make sure. Already have the engine power feed bypassed for the glow plugs.

I would like to keep it with the controller since I sometimes have other people drive my truck and do not want to train them all the time on how to use the manual system. Its hard to think a new controller would work for 2 weeks and then quit.

 

Might check the ground mine was doing some weird stuff and I found the ground was loose from the relay to the intake. The bolt had stripped and it was intermittent problems until I fixed it.

 

this.

check ALL connections including ground for clean and solid contact.

 

I'll check all connections and see what that does. Would it hurt to run a dedicated ground wire directly to the battery? Other than having an extra wire going somewhere(whats one more wire gonna hurt haha). I think that would almost be better because then I eliminated the possible ground issue.

 

the glow plug controller turns the relay on by grounding it.
if i remember correctly there is a ground wire, and a ground by bolt on the controller.

 

That's what I did, I didn't want to loosen anything on the engine so I ran it straight to the battery. No issues since

 

Tom, I knew it had a ground wire I was just wondering if it would be better going to the battery instead of the intake manifold bolt. Truck is outside right now and we are getting snow at the moment but when we get room in the shop this weekend I will run a separate ground wire and see what that does. Thank you all for the help so far. I was digging through my brain trying to think of what was causing this problem. Hopefully this works!

 

you mention you have the power (bypassed) for manual operation... the easiest way to install a push button override is to install a push button that provides a ground to the relay,, as grounding it will heat the glows...unless the controller has failed and is not powering thru to the relay a rare failure..check all connections as intermittent operation could be a bad connection...

 

What bypassed was the wires going through the engine harness connector on the passenger side. That connector melted on me and I just ran a large gauge wire with a ring terminal soldered on one end and fusible links on the other hooked directly to the battery.
I still run it with the controller instead of manual and would like to keep it that way. I did not get a chance to work on it today but hope to tomorrow sometime.

 

It works again! I ran a dedicated ground from the controller to the battery and now it glows for the correct time and fires right up. Thanks for all the help everyone!

 

.........

 

Ok... this thing has a gremlin. Went to start it Wednesday morning to go to class, back to the clicking thing again. I have not had a chance to look really hard into it. From a quick glance my ground wire I ran has not came undone. I will test my plugs again tomorrow and I have a new set I could put it. (They've been in 5 years or so but checked out fine a couple of weeks ago). Would the new controller and better glow time have finished them off? Just trying to think of some things before I tear into it tomorrow.

 

remove and clean the flat metal z shaped strap that connects the relay to the glows clean the connections with sand paper!!! don't just look at it a say to your self its good... high resistance caused buy a bad connection will make the controller malfunction...