First of all, my truck is an 89 F250 4x4. It is getting cold here, and it is having a very hard time starting. I have had the truck for almost a year, but have never messed with the glow plugs. It had the same problems last year, but I just kept it plugged in at night, as I could not afford to fix the problem.

I'm pretty sure that the glow plug controller works, as the wait to start light stays on for 10-12 seconds on cold mornings, and I can hear clicking. I changed out the glow plugs tonight with new motorcraft plugs, they were autolite (they appeared to be brand new, except for black soot on them).

I bought a Haynes techbook diesel engine repair manual, hoping to help me figure it out, but I'm confused. If I'm reading it correctly, there is no gp relay solenoid on my truck? From what I have read here, I was thinking there was? Do I have a relay? Is it located up beside the passenger side battery? How exactly do I test it? Where do I get one if it needs replaced, or can I fix it somehow? Is there a different manual somewhere that would be better to get for this truck, especially something showing more than just the motor itself? I already have a haynes manual for 87-96(I think) ford f-series and bronco.

Also, when replacing the glow plugs, all the little boots that go over the glow plugs (I'm pretty sure they are supposed to be rubber?) were very brittle. Most of them had parts falling off. I'm pretty sure the coating is just to keep from a shock hazzard, and should not affect performance, correct? Also, I found another "boot" that looked to be the correct size to go on a glow plug, but it was not hooked to anything. It was closest to the front cylinder on the passenger side, close to the fuel filter. Where is this supposed to hook up, somewhere on the filter? Is it even supposed to be there? If the harness needs replacing, where do I have to get that? How much would I be expecting to spend?

Lastly, even though I don't think my gp's are cycling, even in warm weather, I have to wait for the wait to start light to turn off before cranking, otherwise it cranks for 20 seconds or better to get started. What could be causing this? Could this be a leaking return line? I've read a little about them on here, but I'm not even sure where to find them, is it just rubber fuel line? Are they expensive to replace?

Thanks for any help you can give me

Dwayne

ddetrick

 

the glo controler should be mounted on the passenger rear of the motor over the valve cover. as for the plug near the fuel filter, that should be the water in fuel sensor plug. it goes on the bottom of the filter housing.
as for the wait to start, you need to wait for the light to go out at all times. it can be 100 degrees out, and if the light is on my diesel will not start till the light goes out.

 

So would my truck have a gp relay or not? Where would I even look? What about my fuel return lines? are they metal, or are they rubber? Where do I find them? The plug you are saying is the water in fuel sensor plug, should it be in the same wiring harness as the gp's? That's where I found the little plug.

 

d ... the return lines are right on top of each injector connected by plastic caps. beneath each plastic cap is 2 rubber o rings. there are kits available, either on line or at injection shops or international dealers to replace the return system parts. get the whole kit.
the water in fuel wire will connect to a fitting on the bottom plate (a push on deal) of the fuel filter.

also, if you are using the block heater, you should be able to hear the water begin to heat up when you first plug the heater in. The heating element is mounted in one of the soft plug holes on the pass side of the block over the starter. You should hear it cooking if you listen at the pass front wheel well.

hope this helps.