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  #1  
Old 04-28-2006, 03:42 PM
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Location: Geographically challenged on the S.W shores of Lake Michigan in S,E Wisconsin
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glow plug harness

had a case of hard starting and no gp light. all the plugs checked out so only only more thing to try. yep.


the top 2 connectors are dead on mine.

phil says 3 weeks from deutschland.

dealer says mega bucks.

anyone got one to sell?

can the wires be replaced by off the shelf wire or is it mb unobtainium?

its for the 81 tdt wagon.

pm me or post here.

thanks
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currently
[1981 300 td tdidi 165500 dark brown/palamino-Brownie-mine-3k miles of ownership
1983 240d 162+++ Anthricite grey w/ henna red interior and hella lights-wifes car-Red

the above two cars are for sale
and can be seen on the cars for sale thread here. pix also available.


240d-144+ Manilla Yellow w/ palmino interior-greasecar kit-Blondie-the college kids car

23" gt 21 speed still on original tires-still got the nubs
21" khs tandem
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  #2  
Old 04-28-2006, 07:50 PM
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Location: Geographically challenged on the S.W shores of Lake Michigan in S,E Wisconsin
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is this relay plug like the top of the mono valve? are the caps inside just there to make contact with the wires to carry current? if so then we can replace all the wires, save the caps and put a virtual new harness on the car, right?
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currently
[1981 300 td tdidi 165500 dark brown/palamino-Brownie-mine-3k miles of ownership
1983 240d 162+++ Anthricite grey w/ henna red interior and hella lights-wifes car-Red

the above two cars are for sale
and can be seen on the cars for sale thread here. pix also available.


240d-144+ Manilla Yellow w/ palmino interior-greasecar kit-Blondie-the college kids car

23" gt 21 speed still on original tires-still got the nubs
21" khs tandem
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  #3  
Old 04-28-2006, 07:52 PM
Craig
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I'm confused, are you talking about the wires between the relay and the glow plugs? How do you know the problem is with the wiring harness?
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  #4  
Old 04-28-2006, 10:44 PM
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Location: Geographically challenged on the S.W shores of Lake Michigan in S,E Wisconsin
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craig,


the glow plugs all test correctly. when i pulled the 5 pin plug i re glowed the plugs. the top 2 caps in the plug on the relay box did not register current. the other 3 read .5 and below hence the deductiion that the plug/harness is bad. i am guessing a pinched or broken wire in the harness which brings me to getting new wires for the harness and redoing the whole thing but with an old cap plug at the relay.
__________________
currently
[1981 300 td tdidi 165500 dark brown/palamino-Brownie-mine-3k miles of ownership
1983 240d 162+++ Anthricite grey w/ henna red interior and hella lights-wifes car-Red

the above two cars are for sale
and can be seen on the cars for sale thread here. pix also available.


240d-144+ Manilla Yellow w/ palmino interior-greasecar kit-Blondie-the college kids car

23" gt 21 speed still on original tires-still got the nubs
21" khs tandem
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  #5  
Old 04-28-2006, 11:13 PM
Craig
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Quote:
Originally Posted by 83-240D
craig,


the glow plugs all test correctly. when i pulled the 5 pin plug i re glowed the plugs. the top 2 caps in the plug on the relay box did not register current. the other 3 read .5 and below hence the deductiion that the plug/harness is bad. i am guessing a pinched or broken wire in the harness which brings me to getting new wires for the harness and redoing the whole thing but with an old cap plug at the relay.
OK, it sounds like you may have a couple of broken wires. Do you get a resistance measurement of "infinity" between these two sockets in the cap and the corresponding contacts at the glow plugs?

If it is broken wires, I don't see any reason that you couldn't solder new wires between the existing "cap" and the glow plug connectors. In the longer term, I would buy a new harness, or at least try to find a good used one.
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  #6  
Old 04-29-2006, 01:18 AM
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82,

Might be corroded connections. Plug the connector at the end of the GP harness in and out of the GP relay 10 times. Then check for 11 volts at each of the GP when the GP relay is clicked on.

P E H
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  #7  
Old 04-29-2006, 02:29 AM
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Location: CA... No. of S.F.
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Glow Plug Relay Harness... wires from relay to glow plugs!

If, as I suspect, a M-B made wiring harness is that expensive, I personally would not hesitate to make a new set of wires using multistrand sire that is equal to or heavier than the old wires. I have already replaced the circle connectors on my because they were frayed wity some of the wires broken.

So I went a step further and added two small SS flat washers... one below and one above the circular connectors and then reinstalled the nuts on each plug. The washers are to help insure you have minimal loss at this connection. I like to first crimp such connectors as they are designed...
but then I also solder the wires to the connector.

But, I would not hesitate to fabricate my own set of new wires from the relay plug [or near there] out to the glow plugs... and if I really wanted to make it look better I would purchase some heat shrink tubing and shrink it dow after the harness was made up.

Sam
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  #8  
Old 04-29-2006, 10:34 AM
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I bought a new GP harness. I believe I payed around $80 from Caliber Motors in California. They had it in stock and I had it in 2 days like all my parts. The new harness is quite nice. It's flexible and black and new feeling. I didn't know they came like that new!
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  #9  
Old 04-29-2006, 10:53 AM
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thanks adam i will try them. the dealer in il i like quoted 200 bucks. phil was only 74 but that looooooong wait. i will also try to put new wire in the harnes. anyone know the guage?
__________________
currently
[1981 300 td tdidi 165500 dark brown/palamino-Brownie-mine-3k miles of ownership
1983 240d 162+++ Anthricite grey w/ henna red interior and hella lights-wifes car-Red

the above two cars are for sale
and can be seen on the cars for sale thread here. pix also available.


240d-144+ Manilla Yellow w/ palmino interior-greasecar kit-Blondie-the college kids car

23" gt 21 speed still on original tires-still got the nubs
21" khs tandem
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  #10  
Old 04-29-2006, 11:19 AM
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Samuel,

You would have better off using a star washer. The sharp edges bite into the metal and make a better connection than flat washers. You only need the star washer on the side toward the GP and they keep the connector from turning when tightening the nut.

To make it easier to change the GP, I cut the connector and make it into a spade terminal. Then the connector can be removed with just a few turns of the nut and the nut left on the GP until the GP is removed. When putting the new GP in, the nut can be screwed onto the GP first and far enough so there is just enough space left to fit on the spade connector, so just a few turns are needed to tighten the nut. This way there is no chance of trying to put on the nut with the GP in place and dropping the nut and losing it.

It also makes it easier if a 12mm ratchet combination wrench is used to turn the GP. This works on a 617 engine but it might also work on a 603 engine.

P E H
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  #11  
Old 04-29-2006, 02:55 PM
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Location: Geographically challenged on the S.W shores of Lake Michigan in S,E Wisconsin
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star washers, check. yep. got and 8 and 12 rachet wrench. looks like i am going with wodnek to see an sdl in mich city in soon so no job today.
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currently
[1981 300 td tdidi 165500 dark brown/palamino-Brownie-mine-3k miles of ownership
1983 240d 162+++ Anthricite grey w/ henna red interior and hella lights-wifes car-Red

the above two cars are for sale
and can be seen on the cars for sale thread here. pix also available.


240d-144+ Manilla Yellow w/ palmino interior-greasecar kit-Blondie-the college kids car

23" gt 21 speed still on original tires-still got the nubs
21" khs tandem
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  #12  
Old 05-03-2006, 06:29 PM
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Location: Geographically challenged on the S.W shores of Lake Michigan in S,E Wisconsin
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long story short......it was the plugs. i put new in over christmas and less then 3k later they were still showing good on the meter but no glow light. i reamed the holes a couple times put new plugs in. turned the key and LIGHT!!!! now i will see how long the new gps last running bio in the car. hopefully no carboning in the chamber with bio. ya'know those old plugs were bosch 80006/9 can't remember not the crappy autolites.
__________________
currently
[1981 300 td tdidi 165500 dark brown/palamino-Brownie-mine-3k miles of ownership
1983 240d 162+++ Anthricite grey w/ henna red interior and hella lights-wifes car-Red

the above two cars are for sale
and can be seen on the cars for sale thread here. pix also available.


240d-144+ Manilla Yellow w/ palmino interior-greasecar kit-Blondie-the college kids car

23" gt 21 speed still on original tires-still got the nubs
21" khs tandem
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  #13  
Old 05-03-2006, 09:31 PM
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Exactly how much are we talking for a new harness?
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  #14  
Old 05-04-2006, 05:42 PM
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Join Date: Oct 2004
Location: Geographically challenged on the S.W shores of Lake Michigan in S,E Wisconsin
Posts: 1,160
phil qouted 74$.

knauz dealer asking 200. can you say raped and not kissed?

i called caliber in orange cty and they said 80$ but it like phils had to come from the motherland. caliber said 7-10 days. phil said 2-3 weks. neither could drop ship direct.
__________________
currently
[1981 300 td tdidi 165500 dark brown/palamino-Brownie-mine-3k miles of ownership
1983 240d 162+++ Anthricite grey w/ henna red interior and hella lights-wifes car-Red

the above two cars are for sale
and can be seen on the cars for sale thread here. pix also available.


240d-144+ Manilla Yellow w/ palmino interior-greasecar kit-Blondie-the college kids car

23" gt 21 speed still on original tires-still got the nubs
21" khs tandem
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