Hi Folks,
I went to start the 240d today & the glow plug indicator wouldn't light up - tried to start the car & no go!. (The engine & weather was cold)

I have power coming to the GP relay(via the big wire) & the 80a fuse is okay. When the key is in the "glow position I have no power to any of the glow plugs - or the terminals that come out of the GP relay & go to the glow plugs. I couldn't check the continuity of the glow plugs as my voltmeter won't do this. I also have voltage going to 2 of the terminals of the "smaller plug" - I think this brings power from the ignition switch.

The plot thickens as I took the GP relay apart & found that the O ring on the cover was broken & there was water in the relay- about 1/4 inch worth. I'm currently drying out the relay & will reinstall it tomorrow- hopefully my problem will be gone. I also lightly sanded a pair of points in the relay that looked pretty corroded.

If this doesn't solve my problem, where do I look next? Also, which fuse in the fuse box is responsible for the GP relay?

Sorry for the long-winded & vague terminology - my service manual hasn't arrived yet.

Aivars

Ps I scanned the archives & with that info. I got this far.

I will probably get in a lot of trouble for what I am about to say.... but what the heck,, we have a delete feature on this forum....LOL....
Has anyone considered simplyfying the glow plug system ? I mean hooking up wires to the battery, a normally off, push on switch, a horn relay, and directly to the glow plugs... just bypass all this timing etc stuff?
Anyone old enough to remember when cars had MANUAL chokes? You just pull it when you want to start the car,,,, and push it off after the car is warmed up a little... then they put in bimetallic springs which were supposed to do that same job... but they would slowly become less effective and you had wasted all sorts of gas before you actually noticed that it was not completely opening the choke even after then engine was hot.
On old cars I do not see anything wrong with simplyfying the mechanism. Can you (generic) hold your finger on the button for 15 to 60 seconds, then try the starter... ? why would we need a timer for these just to potentially give us problems at a time we don't need it....braced for the reaction.... Greg

Greg, prior to buying my 240d, I looked at another 240d that had glow system problems & had been butchered big time by the PO.

Your suggest is exactly what I was going to do if I bought the car. ( but the deal fell through) Get a Ford starter solenoid relay - hook it up to the glow plugs & have a little push button on the dash that I would hold for 15-20 seconds.

As far as I'm concerned, the simpler the better!!

Aivars

Amen, I have just had too many cool, but unnecessary things go wrong mechanically in my life...as long as it works... fine,, but when it starts messing up... I say settle for less fancy and more reliable....Greg