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Old 11-18-2002, 06:15 PM
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80 amp fuse

My glow indicator light has been inconsistent. When it does come on the car starts. If it doesn't light up the engine will crank for 5-10 sec before starting--even if the key is kept in pos. # 2 for at least 20 sec before attempting to start. It's strange that it worked this morning at 30 F. Then after parking the car for a few hours, no glow light. After searching the forum I found that the 80 amp fuse should be checked for any bends. However, I got a nice spark when I took a phillips to the screws. Should I unplug something first?

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Old 11-18-2002, 07:00 PM
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Join Date: Jan 2001
Location: California
Posts: 2,068
Rule: Unplug the negative battery cable before doing any electrical work!
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Old 11-18-2002, 09:25 PM
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Join Date: May 2001
Location: Michigan
Posts: 1,373

I had this problem and took a pliers to the fuse to flatten it. Worked for awhile and had the same issue develop.
Bought a new fuse for a whopping 50 cents or so but still had intermittant issues.
Now I have to tap the side of the glo relay box when it happens. I think I have a short in there. Bought a $35 replacement box from a junkyard but haven't swapped yet.

'84 300DT 298k (Aubrey's)
'99.5 Jetta TDI IV 251k (Julie's)
'97 Jetta TDI 127k (Amber's)
'97 Jetta TDI 186k (Matt's)
'96 Passat TDI 237k (Don's
'84 300D 211k Mint (Arne- Undergoing Greasecar Conversion)

'82 240D 229k (Matt's - Converted-300DT w/ 4 speed
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Old 11-19-2002, 03:06 PM
lrg lrg is offline
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Join Date: Jul 2001
Location: San Francisco
Posts: 1,163
I had a similar problem with my 124 in that the glow cycle would work sometimes and not others. I traced it to the 80A fuse. Although it looked OK and appeared to have power on both sides it had corroded or just plain "gone away" in a very thin line right at the edge of the retaining screw. It was an odd thing to happen, it showed no sign of thermal stress (Melting) but it was clear that it was no longer in one piece and the break was hidden at the edge of the screw head (I wonder if the PO may have tightened the screw too much). I replaced the fuse and my problem was fixed. By the way, if you're careful you shouldn't need to remove the battery cable but it is a good idea, a poorly placed screwdriver can fry wires verrrry quickly.
1987 300D Turbo 175K
2006 Toyota Prius, efficent but no soul
1985 300 TDT(130K miles of trouble free motoring)now sold
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Old 11-21-2002, 08:55 AM
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The bar fuses will sometimes separate at the ends due to vibration. They will be intermittent and appear to be okay. It would be worth the $.50 to replace it.

Good luck,
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Old 11-21-2002, 10:56 AM
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Join Date: Aug 2001
Location: USA
Posts: 8,074
Doc Booth on the diesel list swears by replacing this fuse every 5 years or so, regardless of if it looks good or not, AND keeping a spare in the glove box. It's cheap - just replace it!

Boise, ID

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