Hi--Thanks for all of the great sharing of information!

One day a couple of weeks ago on my 1980 300D, I had a flashing gp light on the dash and no start--not even crankable.

I took the opportunity to get the pencil style (large body) plugs, but wonder if it's actually the relay. Before I test the new glow plugs, I'd like to make sure I'm clear on a few points:

1. Disconnect the ground strap (at front of engine) from glow plug post
2. Use some heavy insulated wire to make jumpers between plugs (to replace the stiff wires)
3. Replace 50 amp fuse with 80 amp fuse? (necessary?)

And then I guess I'll see if my problem was the plugs or something with the relay; I'm thinking it might be the relay since I didn't get a crank. If that's the case, I'd be interested in a "manual" glow period with a switch on the dash, like Stevo--and so a 15 amp switch will be adequate?

Thanks!

Yes, except I did not replace the original fuse in my 77 300d and it's still working fine 3 yrs later.

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1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

If you go the manual switch route, you'll also need a starter solenoid. I would put an 80 amp fuse in there or at least have one in the glove box. I didn't go to the 80 amp right away but its proly a good idea.

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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"

"not even crankable". This would be more like a starter, battery or lose connection issue. Cranking over would not have anything too do with GPs

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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"

First - my 240D is in the need of the same conversion. So I have questions:

I can't seem to locate the old GP relay, anyone tell me where it's at? Under the black box on the driver side? Pics would be MOST welcome.

Next, I do have the Fast Glow Kit but if I can just go with newer plugs only... I'll go that route to save some green.

Or should I just install the FG Kit and get on with life? I can't seem to figure out where the wires are supposed to go.

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I'm not a doctor, but I'll have a look.

'85 300SD 245k
'87 300SDL 251k
'90 300SEL 326k

Six others from BMW, GM, and Ford.

Liberty will not descend to a people; a people must raise themselves to liberty.[/IMG]

0 250 201 044 is for the large OD plug with the pencil tip

__________________
I'm not a doctor, but I'll have a look.

'85 300SD 245k
'87 300SDL 251k
'90 300SEL 326k

Six others from BMW, GM, and Ford.

Liberty will not descend to a people; a people must raise themselves to liberty.[/IMG]

Go with plugs only. Remove the ground. Hook up the first plug to the original hot wire, then put jumper wires from the 1st plug to each of the others in turn.
Did mine years ago that way. Still working fine.

__________________
1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

I agree, your relay is most likely fine, its under the panel above your knees, drivers side, but get your car cranking over and I'm guessing all will be OK, I used #10, multi strand wire for jumpers. If you need the push button, you need a solenoid because there are too many amps to put through a 15 amp switch. With the new style you will only want to "glow' of about 5-10 seconds.

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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"

What does the existing relay look like?

__________________
I'm not a doctor, but I'll have a look.

'85 300SD 245k
'87 300SDL 251k
'90 300SEL 326k

Six others from BMW, GM, and Ford.

Liberty will not descend to a people; a people must raise themselves to liberty.[/IMG]

Ah yes, that was the case. Just got done with the GPs and still no crank--I was thinking there may be some starter-related wiring in the relay. (Still very new to this machine!)

Thanks--and if you feel up to a fuller explanation about needing a solenoid for the starter if I do install a manual GP switch, I'd love to hear it! Cheers. -n