manual glow plugs
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Mountain Pass
Joined: Jan 2006
Posts: 162
Likes: 3
From: oregon
manual glow plugs
I would like to use a push button for my glow plugs. I know some of you guys are familiar with this. are some ways better than others? will it work only with key "on" ? any pics and advise would be appreciated.
Post Fiend
Joined: Nov 2003
Posts: 21,285
Likes: 16
From: Nutter Fort, WV
The 94 has power supplied to the relay trigger coil by the ignition switch.
So the easiest way does require the key be on to use them, and provides a bit of safety that the glow plugs can not be activated when the key is off.
Remove the white wire, attach a wire to that terminal and run it in the cab to a momentary switch.
Attach another wire to the momentary switch and run it to a good electrical ground.
Done with the install.
Turn the key on, press momentary switch for 10 seconds, start the engine.
What problem are you having with the controller?
If the glow time for the first start of th eday is less than 10 seconds, you probably have burnt out glow plugs.
Manual control will not fix that.
Keeping the plugs on longer will burn out the remaining plugs that are working now.
Check the glow plugs with a multimeter, .5 to 1 ohm resistance on each plug, check them seperately.
Replace any that are outside that range with Motorcraft/Beru ZD 9 glow plugs.
So the easiest way does require the key be on to use them, and provides a bit of safety that the glow plugs can not be activated when the key is off.
Remove the white wire, attach a wire to that terminal and run it in the cab to a momentary switch.
Attach another wire to the momentary switch and run it to a good electrical ground.
Done with the install.
Turn the key on, press momentary switch for 10 seconds, start the engine.
What problem are you having with the controller?
If the glow time for the first start of th eday is less than 10 seconds, you probably have burnt out glow plugs.
Manual control will not fix that.
Keeping the plugs on longer will burn out the remaining plugs that are working now.
Check the glow plugs with a multimeter, .5 to 1 ohm resistance on each plug, check them seperately.
Replace any that are outside that range with Motorcraft/Beru ZD 9 glow plugs.
Thread Starter
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Mountain Pass
Joined: Jan 2006
Posts: 162
Likes: 3
From: oregon
my truck is only operating on 7 gp's. it has a tip broke and stuck in one hole. its been this way since I've owned it. 2.5 yrs, 20k mi. I discovered this shortly after my purchase. the previous owner had cut off the end of a old plug and screwed it in over the broken tip as a cap and didn't hook the connector back up. I put in 7 new motorcraft plugs. the truck starts OK but is fussy when its freezing out. right now the glow time is maybe 5 seconds at best. I thought maybe a manual button would help warm them up a bit more. I'm going elk hunting in a couple weeks and its gunna be COLD!
so basically my switch provides a ground for the terminal the white wire was hooked to? do I just tape up the end of the white wire and let it be?
so basically my switch provides a ground for the terminal the white wire was hooked to? do I just tape up the end of the white wire and let it be?
Postmaster
Joined: Apr 2008
Posts: 4,802
Likes: 1
Don't even need to tape it off, it only sees power from the relay - if it's off the relay it won't see any current through it. Personally I'd just slide a piece of heat shrink over the ring-terminal, then tuck the wire away from the relay, maybe ziptie it to some other wires?
Post Fiend
Joined: Nov 2003
Posts: 21,285
Likes: 16
From: Nutter Fort, WV
The white wire normally has no current on it.
When the glow plugs are to come on, it goes to ground through the controller.
About the only way it would cause a problem is if it came in contact with the battery or ignition power wires.
Leaving it hooked up will not cause a problem.
I would pull out the cut off glow plug and see if the tip is still there.
More than once I have read about members driving with the glow plug top being loose or not there when tips break off.
Several have had the broken tips blow out in a very short amount of time, then just screw in a new glow plug.
Just be aware, if you try that, don't let anyone stand on that side of the engine or under the hood while it is running.
When the glow plugs are to come on, it goes to ground through the controller.
About the only way it would cause a problem is if it came in contact with the battery or ignition power wires.
Leaving it hooked up will not cause a problem.
I would pull out the cut off glow plug and see if the tip is still there.
More than once I have read about members driving with the glow plug top being loose or not there when tips break off.
Several have had the broken tips blow out in a very short amount of time, then just screw in a new glow plug.
Just be aware, if you try that, don't let anyone stand on that side of the engine or under the hood while it is running.
Thread Starter
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Mountain Pass
Joined: Jan 2006
Posts: 162
Likes: 3
From: oregon
I'll have to try blowing it out before I go to the switch.
Do you think a 10 sec. glow time will harm 7 glow plugs?
I'm running motorcraft plugs.
thanks for the help. Vince
Do you think a 10 sec. glow time will harm 7 glow plugs?
I'm running motorcraft plugs.
thanks for the help. Vince
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Post Fiend
Joined: Nov 2003
Posts: 21,285
Likes: 16
From: Nutter Fort, WV
Just minus one plug, you should be fine.
But if you lose one or two more, with a manual button you will have no way to know they burnt out.
That was one of the better features of the new style controller, it told you that a glow plug had burnt out every time you cold start the engine.
The old style system worked off a timer, so it kept on working normally till they were all burnt out and the engine would not start.
But if you lose one or two more, with a manual button you will have no way to know they burnt out.
That was one of the better features of the new style controller, it told you that a glow plug had burnt out every time you cold start the engine.
The old style system worked off a timer, so it kept on working normally till they were all burnt out and the engine would not start.
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Thread Starter
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Mountain Pass
Joined: Jan 2006
Posts: 162
Likes: 3
From: oregon
well, I pulled the cap out of the broken off glow plug hole, and the broken off tip was gone 
. I have no idea how long its been gone. don't think it hurt anything. I cleaned out the threads and installed a new one. She fires off better and the glow time is longer. Its a bit short of 10 sec. though. I may play with a manual switch anyhow.
. I have no idea how long its been gone. don't think it hurt anything. I cleaned out the threads and installed a new one. She fires off better and the glow time is longer. Its a bit short of 10 sec. though. I may play with a manual switch anyhow.
Senior User
Joined: Nov 2007
Posts: 110
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I've been having a similar problem with my 94 7.3 IDI. I've checked all GP's and replace one bad one (Autolite) with a new Motorcraft. I have also replaced my fuel return lines and T's. Still slow to start.
I did notice that some of my GP terminal insulators are in pretty bad shape, one is completely gone. Will that affect starting?
Also, what is the best way to test the solenoid and the GP controller to make sure that I am even getting the correct voltage and amperage to the GP's?
I did notice that some of my GP terminal insulators are in pretty bad shape, one is completely gone. Will that affect starting?
Also, what is the best way to test the solenoid and the GP controller to make sure that I am even getting the correct voltage and amperage to the GP's?
Post Fiend
Joined: Nov 2003
Posts: 21,285
Likes: 16
From: Nutter Fort, WV
The missing insulators will have no effect on the glow plugs working.
When the relay clicks to turn the glow plugs on, does you volt meter drop several volts?
The contacts in the relay can burn up over time.
The relay still clicks like it is operating but little or no current is going to the glow plugs.
I just replaced my original relay last year for this exact reason.
When the relay clicks to turn the glow plugs on, does you volt meter drop several volts?
The contacts in the relay can burn up over time.
The relay still clicks like it is operating but little or no current is going to the glow plugs.
I just replaced my original relay last year for this exact reason.
Fleet Owner
Joined: Jul 2006
Posts: 20,362
Likes: 824
From: Mi'kma'ki
Just minus one plug, you should be fine.
But if you lose one or two more, with a manual button you will have no way to know they burnt out.
That was one of the better features of the new style controller, it told you that a glow plug had burnt out every time you cold start the engine.
The old style system worked off a timer, so it kept on working normally till they were all burnt out and the engine would not start.
But if you lose one or two more, with a manual button you will have no way to know they burnt out.
That was one of the better features of the new style controller, it told you that a glow plug had burnt out every time you cold start the engine.
The old style system worked off a timer, so it kept on working normally till they were all burnt out and the engine would not start.
would my truck have this?
Post Fiend
Joined: Nov 2003
Posts: 21,285
Likes: 16
From: Nutter Fort, WV
87 thru 94 uses the new style controller.
It indicates a burnt out glow plug by short cycling the glow cycle ( less than 10 seconds of wait to start light).
When you have two or three burnt plugs, the relay will no longer try to heat the glow plugs or the wait to start light does not come on just flashes on then back off.
It indicates a burnt out glow plug by short cycling the glow cycle ( less than 10 seconds of wait to start light).
When you have two or three burnt plugs, the relay will no longer try to heat the glow plugs or the wait to start light does not come on just flashes on then back off.
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