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Glow plug relay -- '83 300D

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Robby Ackerman's picture
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I have a problem with the points in my glow plug relay. One set has worn down such that when they close, one set closes and one remains open. Is it safe to adjust the tab and close the gap on the points a smidgen or is it time to fork over $160 - $200 for a new relay.

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1960 190 SL
1983 300 D (WVO)
1984 190E 2.3-16 / Mosselman Turbo System & Dinan suspension
1984 190E 2.3-16 / Delsing Motorsport suspension
1992 500SL


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Robby Ackerman's picture
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Re: Glow plug relay -- '83 300D

The points are an obvious problem. I cleaned them up and will adjust them. Thanks for the tip on soldering new tips. I mentioned this to a neighbor who is an LTL trucker and he suggested if all else failed powering the relay via a good quality push button starter switch.

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1960 190 SL
1983 300 D (WVO)
1984 190E 2.3-16 / Mosselman Turbo System & Dinan suspension
1984 190E 2.3-16 / Delsing Motorsport suspension
1992 500SL


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Re: Glow plug relay -- '83 300D -- Wastegate

In the meantime ... this past week I made the 400 mile RT to Rockville, MD on three 5-gallon containers of WVO in the 300D. Before leaving on the trip while I was messing with the preglow relay, I took the occasion to replace a broken air filter mount. When I removed the air filter I found the hose from the turbo to the wastegate had blown off the turbo.

I wonder how many miles, months or years that has been loose and what sort of reduction in boost pressures this resulted in, if any? On the other hand, it may have just prevented the wastegate from properly opening if pressure got too high? I do recall hearing a faint whistling sound. I should have paid more attention to the whistling.

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1960 190 SL
1983 300 D (WVO)
1984 190E 2.3-16 / Mosselman Turbo System & Dinan suspension
1984 190E 2.3-16 / Delsing Motorsport suspension
1992 500SL


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winmutt's picture
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Re: Glow plug relay -- '83 300D

Junkyards are cheap and it would take a matter of minutes to pull a relay.

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Robby Ackerman's picture
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Re: Glow plug relay -- '83 300D

Thanks for the reminder. Nearest one is 90 minutes round trip, which makes it borderline convenient. Unfortunately the relays are different between the '83 and my '84 parts car.

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1960 190 SL
1983 300 D (WVO)
1984 190E 2.3-16 / Mosselman Turbo System & Dinan suspension
1984 190E 2.3-16 / Delsing Motorsport suspension
1992 500SL


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Re: Glow plug relay -- '83 300D

Robby Ackerman;150082 wrote:
Thanks for the reminder. Nearest one is 90 minutes round trip, which makes it borderline convenient. Unfortunately the relays are different between the '83 and my '84 parts car.

No they are not. 1982 to 1985 all took the same relay. Part number 001 545 98 32.

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Re: Glow plug relay -- '83 300D

Interesting.

The one that came off my '84 is part number 002 545 06 32 and when I opened it up, inside it is built different than the '83 which is the 001 545 98 32. The external connections are the same on both.

I installed the 002 545 06 32 and when I switched it on, ouch, wierd stuff happened with the dash lights and buzzers and the horn started sounding.

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1960 190 SL
1983 300 D (WVO)
1984 190E 2.3-16 / Mosselman Turbo System & Dinan suspension
1984 190E 2.3-16 / Delsing Motorsport suspension
1992 500SL


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Re: Glow plug relay -- '83 300D

002-545-06-32 is the old number

Ken

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Re: Glow plug relay -- '83 300D

Okay -- well, I've got two bad one's. One obviously much worse than the other. I'll toss them before I or someone else tries using them again. Thanks again for the information.

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1960 190 SL
1983 300 D (WVO)
1984 190E 2.3-16 / Mosselman Turbo System & Dinan suspension
1984 190E 2.3-16 / Delsing Motorsport suspension
1992 500SL


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Re: Glow plug relay -- '83 300D

I wouldn't bother driving 90 minutes for a JY relay. Perversely, the relay's die much faster when not in use. A fresh new relay from the dealer or Rusty really is the right way to go, and then you won't have to worry about that again for another 20 years...

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Re: Glow plug relay -- '83 300D

Maxbumpo;150132 wrote:
I wouldn't bother driving 90 minutes for a JY relay. Perversely, the relay's die much faster when not in use. A fresh new relay from the dealer or Rusty really is the right way to go, and then you won't have to worry about that again for another 20 years...

Don't forget to check on the 240D "relay upgrade kit," a relay with four glow plugs for about $10 more than just the relay. May not be a dealer part, but it is Bosch.

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James Marriott 1987 300SDL (155k, mein Auto, 100% homebio 3 years) 1983 300D (221k, frau Auto, 100% homebio 3 years) 1997 Suburban (149k, gas/4WD towmaster 6000) www.engineeringworks.biz 1982 300SD junker, 265k

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Back to the beginning

I was having problems with my relay and Don told me how to repair it. At the same time I checked all the glow plugs and #2 was defective so I replaced it, repaired my old relay and still had problems starting the car so I figured something was wrong with the relay other than the points -- though with the cover off and power applied, points snapped closed -- points visibly were not closing before.

So I purchased a new relay and installed it and still had problems starting the car. Checked all the glow plugs again and #4 had gone bad. It tested fine before, really. So I now have a car that starts fine and I've got two perfectly good relays; one old and one new.

I know the old adage to replace all the glow plugs at the same time, but that applies more when someone else is doing the work because you don't want to keep taking it back, and less when it's a DYI job because I can easily swap'm when one fails, or so I thought, ha.

Boise - Thanks for the tip about the 240D upgrade.

P.S MAX Never heard anything from Anthony S, though I dropped him a couple emails. Will be heading to Kiawah Thursday. Cheers.

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1960 190 SL
1983 300 D (WVO)
1984 190E 2.3-16 / Mosselman Turbo System & Dinan suspension
1984 190E 2.3-16 / Delsing Motorsport suspension
1992 500SL


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Hyperactive GP circuit--1984 300D

My problem is a little different: My glow plug circuit erratically (not always, but frequently) seems to cycle on and off while driving. When it acts up, the glow plug light and accompanying buzzer come on for about 6 seconds, then turn off for about 4 seconds, then on again, etc. Sometimes, if I come to a stop and idle, the problem seems to go away, but as soon as I start to accelerate it comes back.

Does this sound like a relay going into action when it shouldn't, or something else? Would a new relay resolve the issue?

By way of background, I recently bought the car used (124,000 miles), and it would not start without a shot of starting fluid into the air intake. I replaced all 5 glow plugs, and now it starts fine, but has the condition I described above. I am concerned that if the relay is cycling on and off continuously, it will fry my new plugs, and I suspect that might be the reason they were not working in the first place.

Any thoughts?

Thanks.

Jim Norman

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Re: Glow plug relay -- '83 300D

I think you are correct that the problem is with the relay. I'd replace it.

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1960 190 SL
1983 300 D (WVO)
1984 190E 2.3-16 / Mosselman Turbo System & Dinan suspension
1984 190E 2.3-16 / Delsing Motorsport suspension
1992 500SL


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Re: Glow plug relay -- '83 300D

Thanks, Robby, I'll do it this week and report back.

By the way, something I forgot to mention: this problem had not initially appeared (coincidence?) until a mechanic friend of mine advised me to replace the ignition switch barrel because he said the difficulty I was having turning the key would eventually result in a more serious problem requiring the switch to be drilled out.

Now, of course, the new switch and key work smoothly. But that's when the GP problem first surfaced (during my ownership, anyway--as I mentioned earlier, I suspect that this might have been the cause of my non-funtioning glow plugs). So he suggested replacing the circular contact module behind the switch, and he did that for me. After he did that, the problem seemed to go away, again, perhaps coincidentally.

At the same time, I was having problems with the instrument cluster: speedomenter pegged at the max, jumpy temp gauge, fuel gauge never reading more or less than half-full. I had a line on a cheap used cluster with everything functiong, so I swapped it out, and now all those things work fine, but the GP issue is back.

As you can see, there are a lot of variables happening here. Anyway, I'll report back after the relay is in place.

Thanks again.

Jim

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Just say NO to ether was[Re: Hyperactive GP circuit--1984 300D]

JimNorman;152165 wrote:
My problem is a little different: My glow plug circuit erratically (not always, but frequently) seems to cycle on and off while driving. When it acts up, the glow plug light and accompanying buzzer come on for about 6 seconds, then turn off for about 4 seconds, then on again, etc. Sometimes, if I come to a stop and idle, the problem seems to go away, but as soon as I start to accelerate it comes back.

Does this sound like a relay going into action when it shouldn't, or something else? Would a new relay resolve the issue?

By way of background, I recently bought the car used (124,000 miles), and it would not start without a shot of starting fluid into the air intake. I replaced all 5 glow plugs, and now it starts fine, but has the condition I described above. I am concerned that if the relay is cycling on and off continuously, it will fry my new plugs, and I suspect that might be the reason they were not working in the first place.

Any thoughts?

Thanks.

Jim Norman

Jim,

If your 617 still runs, I'd suggest NEVER EVER EVER NEVER again :mad: using ether to start it. The prechambers are tough in normal use but under the violent action of ether will crack/shatter, shed parts, break pistons, etc. :eek: If the car goes down remotely you can drag start it to get it running; it will continue to restart with no plugs as long as the engine is still "warm."

A 617 will easily start with no plugs down to about 60 dF ambient if the valves are properly adjusted. Check those, too; probably get a new gasket for $8 before beginning the project.

The relay on the later cars (like ours) has a built-in temp sensor. The relay gets a "start" signal from the ignition, sniffs the ambient (NOT engine) temp, and powers the plugs for up to 60 seconds. Random odd notes and factoids: the light goes out before power is removed from the plugs (my light goes out in about six seconds if it's 20 dF, but you won't hear the relay cut out for about 30 seconds); the plugs can still be powered even though the light does not illuminate (say, a fault in two plugs, the remaining three will still get juiced allowing a start but the light's failure is your indication of trouble).

The PDF you need is w126CD1\program\Engine\617\15-705.pdf (glow), which is too big to attach here.

Best,
James

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James Marriott 1987 300SDL (155k, mein Auto, 100% homebio 3 years) 1983 300D (221k, frau Auto, 100% homebio 3 years) 1997 Suburban (149k, gas/4WD towmaster 6000) www.engineeringworks.biz 1982 300SD junker, 265k

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Re: Glow plug relay -- '83 300D

James:

Thanks, and I have just thrown away the can of starter fluid! The car is still running quite nicely, but I don't want to take any chances.

The PDF link does not seem to work. Can you check it for me? Do I need to precede it with anything?

Thanks.

Jim Norman

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Re: Glow plug relay -- '83 300D

JimNorman;152243 wrote:
James:
The PDF link does not seem to work. Can you check it for me? Do I need to precede it with anything?

Ahh. I thought you had a service CD and I was pointing to the correct file. You'll soon be purchasing a CD, no? DO NOT get an ebay one--they are typically pirated and usually don't work/well. Ask me how I know . . .

I put your file on my web site at http://www.engineeringworks.biz/15-705.pdf and I'll leave it there for a few days.

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James Marriott 1987 300SDL (155k, mein Auto, 100% homebio 3 years) 1983 300D (221k, frau Auto, 100% homebio 3 years) 1997 Suburban (149k, gas/4WD towmaster 6000) www.engineeringworks.biz 1982 300SD junker, 265k

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Re: Glow plug relay -- '83 300D

Thanks, James, got it.

Now, about that service CD... Can you point me to a reliable source? I see plenty of them on eBay, and they are dirt cheap, but you have warned me.

Thanks.

Jim Norman

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Re: Glow plug relay -- '83 300D

I bought all 3 of my cd's from mercedes.

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