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need advice for wiring problems

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Old Dec 26, 2009 | 06:06 PM
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need advice for wiring problems

i recently bought a new project truck its a 92 7.3 its had a motor swap for unknown reasons the owner gave up on it. so ive got it running but only with ether I have checked the gp's and their all good .relay gets no power with key forward to the brown wire so no juice to gp's. swapped out relay with an extra that came with the truck and the harness connector on the drivers fender started smoking. also i noticed when i bought it that the gp relay maxi fuse was missing. I'm stumped anyone had this sitution before. I guess I just bought someones wiring nightmare
 
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Old Dec 26, 2009 | 06:12 PM
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by the way its the two big yellows that are smoldering. the ones that go to the gp relay
 
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Old Dec 26, 2009 | 06:12 PM
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Do you like the idea of manually controlling the glowplugs with a pushbutton in the cab?
 
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Old Dec 26, 2009 | 06:14 PM
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Originally Posted by mystic04
by the way its the two big yellows that are smoldering. the ones that go to the gp relay
If they are smoking at the plug on the pass side fenderwell, then that's a common problem, the plug is burnt up. I cut the yellow wires out of the plug, put ring connectors on all 4, and then bolted them together to bypass the plug.
 
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Old Dec 26, 2009 | 06:44 PM
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they are coroded all to hell but my question is. is there a problem before the connector or is it the gp relay thats grounding out to make this happen ?
 
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Old Dec 26, 2009 | 07:35 PM
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If they were corroded that may be what caused it to smoke a bad connection will heat up seriously under the amp load of the glow plugs.
 
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Old Dec 26, 2009 | 07:42 PM
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The glowplugs draw a lot of amps, so the problem is usually at the connector. I believe the yellow wires have fusible links were they connect at the starter relay, so they will blow if something is shorted. Sounds like the glowplugs are trying to work, if you get the connection fixed.
 
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Old Dec 26, 2009 | 09:31 PM
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ok i bypassed the connector on drivers fenderwell used yellow butt connectors on the two yellow wires. now it doesnt smolder there it smolders at the relay coil but it will start now is this normal it doesnt seem that it should smolder and stink
 
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Old Dec 26, 2009 | 10:53 PM
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You may just have oil on the resister on the controller.

200 amps draw when the glow plugs are heating, that makes things get warm.
 
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Old Dec 27, 2009 | 07:57 AM
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ok she fired up last night but made an awful clanking noise so i shut it off. my guess is some cylinders arent firing due to dead glow plugs and or bad connectors. my connectors are falling apart as it is. thanks for all the help so far guys.
 
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Old Dec 27, 2009 | 01:03 PM
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What transmission do you have?
 
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Old Dec 27, 2009 | 04:42 PM
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e4od, got it running today, it takes a bit for all cylinders to fire for some reason.but when you start it with ether it starts smooth. i tested all glow plugs and they were good. so i drove it around for a while to get her hot it was fine under acelleration but idling it would sputter once in a while. maybe it just needsa to be run. I drained both tanks when i bought it put 5 gal of fuel in each tank and split a whole bottle of diesel kleen between the two tanks plus new filter and return line kit. So i dont think its a injector problem. thanks again for all the help so far
 
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Old Dec 27, 2009 | 07:25 PM
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If you used the test light method, some of the glow plugs may not be heating as well as the others are.

As for the sputter, probably needs driven some with a couple heavy doses of fuel treatment until everything gets clean and lubed up.
 
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Old Dec 27, 2009 | 10:42 PM
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well I do not own a test light so i figured theoreticaly it would be the same to put the positive lead of my multimeter in the positive terminal of a battery and touch the negative to the terminal of each glow plug and it showed the batteries volts perfectly for all of them. I hope I'm right anyway
 
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Old Dec 27, 2009 | 11:39 PM
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If the multimeter is a decent one.
Remove the wiring connector, set the multimeter to ohm's, touch one lead tot eh glow plug electrical terminal and the other to the glow plug lower body (hex nut).

.5 to 1 ohm resistance is ideal.
Repeat for all 8 glow plugs.
 
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