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I own an '02 7.3 350, CC, SRW, 4x4. This moring its was pretty cold, about -5F. My truck wouldn't start, despite having it plugged in overnight. When I turned the key to the start position, I noticed that my battery warning came on. I am pretty concerned, because we are expecting -5 to -15 below temperatures here in Wyoming for the next 4 or 5 days. When I went to turn it over this morning, the truck sounded cold, like it hadn't been plugged in at all. Is there anyway to tell if the block heater is working? I would like to think it was just my batteries. Thanks for the help.
You should be able to feel some heat near the oil filter, that's where the heater is located. If not then maybe you cord is bad or the heater. I think another post on here had the ohm value listed to check the heater itself. You could also plug something into the cord to make sure you have power from the house or barn.
The easiest way to tell is have someone plug the block heater in and you watch your electric meter on your house...it draws about 12-15 amps and the meter will start to spin faster when the block heater is plugged in. If it doesn't spin faster, then I would test the outlet that your cord is plugged into. If that outlet is hot, then your block heater is toast.
Try turning your truck to the ON position and then go under the hood and jump the GPR (the two large posts) with a screwdriver and hold it on there for about a minute and then try to start it. If it starts, then the GPR needs to be replaced GPR-109 at NAPA. If it doesn't start, it may be the glow plugs that are bad.
I'd guess that the block heater is not working on your truck, the batteries may be toast, and the glow plugs/GPR need to be checked. I think, if the glowplugs /glow plug relay were working correctly and you had good batteries in it, it would start (even if the block heater was not working). I never plug my truck in and it always starts right up at sub-zero temperatures. Are you running 15-40W oil? I'd switch to 5-40W with winter lows as cold as yours...it will make the engine start much easier (less wear and tear on the starting system).
Good luck and post any questions you have...also do a search for "hard starting" for more info.