Howdy,

On my 82 240D, it has been starting harder lately with temps in the high 50's in the morning . . .

Usually the glow plug light does not come on, so I still leave it in that position while I hook up my seatbelt, then I crank it, for 3-5 sec it will start but run rough, and in about 5-8 sec the last cyl starts firing, and will smooth out, cloud of smoke out the back . . .

I went to Diesel Giant website, and followed his tutorial (well almost! [I did not remove the plugs]) I have 13.7v engine running, 12.8 engine off.
Battery voltage on both sides of fuse strip.
Cyl 1,2,3 good continuity(.001), #4 bad (doesn't move needle!) [I just tested between the wire conn on plug to ground]
I tested the relay . . .I get power to all five pins, and in about 20 sec shuts off.
When I tested the wires it appears that the front three are hooked together! For instance with a lead on #4 glow plug, and I probe #4 socket in the relay harness, that is the only one that will work! BUT if I move to glow plug #3, #2, or #1 I can probe either #1,#2, or #3 socket in the relay harness and get a reading. What is going on?

I know I need a new plug for #4 (I'll buy four new new ones, and keep the old 3 for emergency!) But what else is going on? Maybe only 5% of the time will the glow plug light come on, and only stays on for maybe 5 sec, and still starts hard. Could it be the fuse?

It also appears that maybe somebody at some time replaced a relay from a 617?





Edit to add: All of the wires had full continuity from relay plug harness to glow plugs.

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82 240D Manual 277K and still rolling!
02 Volvo S60 AWD For Sale