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Inside the box: VDO Glow Plug Relay 5 Zyl
Hey everyone,
Forum member yuke was kind enough to send me a his old glow plug relay to see if I could figure out why it was sticking on after he shut his car off. PN: 001 545 98 32, from 04/1985 Here's some pictures of the unit: It looks like something happened at the contacts. It looks like the unit can be salvaged but I'm not sure on how to repair the bad contact pad on the relay... Credit goes to scottmcphee for this modification, originally performed on a 6-cyl glow plug relay: I didnt have a 56 ohm resistor so I put a 22 and 33 together. It works out better because I now have a 1-watt resistor. I decided to install it on top of the PCB as there was little room to nicely install two resistors on the bottom. If you just got one resistor you could probably do it on the bottom just fine.
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Cruise Control not working? Send me PM or email (jamesdean59@gmail.com). I might be able to help out. Check here for compatibility, diagnostics, and availability! (4/11/2020: Hi Everyone! I am still taking orders and replying to emails/PMs/etc, I appreciate your patience in these crazy times. Stay safe and healthy!) 82 300SD 145k 89 420SEL 210k 89 560SEL 118k 90 300SE 262k RIP 5/25/2010 90 560SEL 154k 91 300D 2.5 Turbo. 241k 93 190E 3.0 235k 93 300E 195k |
#2
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Clean the contact and try silver soldering it. If it looks like that isnt going to do it, there is always JB weld or Devcon.
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1985 300D 198K sold 1982 300D 202K 1989 300E 125K 1992 940T "If you dont have time to do it safely, you dont have time to do it" "The democracy will cease to exist when you take away from those who are willing to work and give to those who would not." |
#3
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Hey James,
With a little luck there will still be a bit of hard metal left on the relay contacts. In years gone by we used to clean/dress ignition points with a points file. Havent seen one for years. The cheap alternative for you would be to fold over a strip of 120 wet&dry paper & use it as a double sided file. A little water on it helps. If you do it with the contacts in place ~ assembled relay, you will have good contact, that is parallel faces, when you smooth the bumps off. Good Luck !!
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Grumpy Old Diesel Owners Club group I no longer question authority, I annoy authority. More effect, less effort.... 1967 230-6 auto parts car. rust bucket. 1980 300D now parts car 800k miles 1984 300D 500k miles 1987 250td 160k miles English import 2001 jeep turbo diesel 130k miles 1998 jeep tdi ~ followed me home. Needs a turbo. 1968 Ford F750 truck. 6-354 diesel conversion. Other toys ~J.D.,Cat & GM ~ mainly earth moving |
#4
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Quote:
I put the relay in my one 300SD it seems to work fine. The light mod seems to work as well. Other than the contacts being beat up, I didnt see anything else wrong with the unit.
__________________
Cruise Control not working? Send me PM or email (jamesdean59@gmail.com). I might be able to help out. Check here for compatibility, diagnostics, and availability! (4/11/2020: Hi Everyone! I am still taking orders and replying to emails/PMs/etc, I appreciate your patience in these crazy times. Stay safe and healthy!) 82 300SD 145k 89 420SEL 210k 89 560SEL 118k 90 300SE 262k RIP 5/25/2010 90 560SEL 154k 91 300D 2.5 Turbo. 241k 93 190E 3.0 235k 93 300E 195k |
#5
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600 will take for ever !!!
If you can borrow a emery nail file board, it may work. you know, the type girls use & throw away when their done.
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Grumpy Old Diesel Owners Club group I no longer question authority, I annoy authority. More effect, less effort.... 1967 230-6 auto parts car. rust bucket. 1980 300D now parts car 800k miles 1984 300D 500k miles 1987 250td 160k miles English import 2001 jeep turbo diesel 130k miles 1998 jeep tdi ~ followed me home. Needs a turbo. 1968 Ford F750 truck. 6-354 diesel conversion. Other toys ~J.D.,Cat & GM ~ mainly earth moving |
#6
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Quote:
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Java Developer/Linux SysAdmin Current: *1984 300D ~200K,1989 MR2 250K, 2012 Ford Fusion 4.5K (fiance's car to replace the uber-unsafe cavalier) ---------------------------------------------------------------------------------- Past: 1998 Chevy Cavalier ,2005 Saab 9-3 2.0T, 1996 Mazda Protege, 1974 Porsche 914 2.0, 1997 Land Rover Discovery 4.0L/5Speed, 1995 Jeep Wrangler |
#7
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WOW, that contact took a LOT of heat...
cleaning it up will likely get it working for a short time, but that plate is shot. it'll just keep failing.
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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread "as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do! My drivers: 1987 190D 2.5Turbo 1987 190D 2.5Turbo 1987 190D 2.5-5SPEED!!! 1987 300TD 1987 300TD 1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere! |
#8
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Purpose of the "glow plug lamp modification?"
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"Buster" in the '95 Our all-Diesel family 1996 E300D (W210) . .338,000 miles Wife's car 2005 E320 CDI . . 113,000 miles My car Santa Rosa population 176,762 (2022) Total. . . . . . . . . . . . 627,762 "Oh lord won't you buy me a Mercedes Benz." -- Janis Joplin, October 1, 1970 |
#9
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The heat may have came from arcing due to poor contact. As the contact got worse It got hotter, which made it worse, which made it hotter... The heat may have goofed up the fit between the contact pad and the part it mates with as well.
What exactly does the light modification do? Thanks for the pics!
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My occupational hazard bein' my occupation's just not around... 1980 300SD 1980 300SD |
#10
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Quote:
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1987 300TD 309, xxx 2.8.2014 10,000 mile OCI Be careful of the toes you step on today, as they may be connected to the ass you have to kiss tomorrow. anonymous “Be who you are and say what you feel, because those who mind don’t matter, and those who matter won’t mind.” Dr. Seuss |
#11
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Yes, the light modification connects the relay's output to the lamp on the dashboard. The lamp will be on at about half power indicating that the glow plugs are running. If the lamp does not turn off when you turn the car off, you'll know the plugs are still powered.
__________________
Cruise Control not working? Send me PM or email (jamesdean59@gmail.com). I might be able to help out. Check here for compatibility, diagnostics, and availability! (4/11/2020: Hi Everyone! I am still taking orders and replying to emails/PMs/etc, I appreciate your patience in these crazy times. Stay safe and healthy!) 82 300SD 145k 89 420SEL 210k 89 560SEL 118k 90 300SE 262k RIP 5/25/2010 90 560SEL 154k 91 300D 2.5 Turbo. 241k 93 190E 3.0 235k 93 300E 195k |
#12
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GRRRR !! What happened to the pics ??
__________________
1985 300D 198K sold 1982 300D 202K 1989 300E 125K 1992 940T "If you dont have time to do it safely, you dont have time to do it" "The democracy will cease to exist when you take away from those who are willing to work and give to those who would not." |
#13
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Pics are working on my end.. They are hosted on imgur.com, they might have been under heavy load at the time you viewed them. Try again, should be ok
__________________
Cruise Control not working? Send me PM or email (jamesdean59@gmail.com). I might be able to help out. Check here for compatibility, diagnostics, and availability! (4/11/2020: Hi Everyone! I am still taking orders and replying to emails/PMs/etc, I appreciate your patience in these crazy times. Stay safe and healthy!) 82 300SD 145k 89 420SEL 210k 89 560SEL 118k 90 300SE 262k RIP 5/25/2010 90 560SEL 154k 91 300D 2.5 Turbo. 241k 93 190E 3.0 235k 93 300E 195k |
#14
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I have seen that kind of contact damage when the battery is weak. Low voltage and high current.
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#15
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Hello
I have experienced the following symptoms on my 1983 300TD While driving in the dark, the headlamps would dim, the fan would slow down intermittently, so something was drawing heavy current for a few seconds and then it would disappear. This intermittent current draw could go on for quite some time. I heard a clicking noise in the front of the steering wheel in the engine compartment and discovered that it was the glow relay that was turning on intermittently while the car was running. On opening the relay I have noticed the contact to the outside live +ve was very poor so I cleaned that all up. I have the same kind of fusing going on on the left contact point as pictured above. Is there anything else I can test on the circuit board that would indicate a faulty timer? Why on earth would the relay turn on when the engine is running? Notes for information: Startup glow is normal and the light goes out No problems cold starting Battery is new Alternator is charging at 14.5 V |
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