Recap: When the 2 sets of wires that feed the glow plugs are disconnected, sparking stops?
When the battery cable is disconnected from the relay, sparking stops?
Should 2 more little wires running to the relay, when their unhooked, does the spark quit?
Does all of this happen with the key on or off? If it does it with the key off, relay is shot. If it does it with the key on, either the glow plugs or wires are shorting out, or the controller/timer is shot.

 

-Recap: When the 2 sets of wires that feed the glow plugs are disconnected, sparking stops? [answer] yes.
When the battery cable is disconnected from the relay, sparking stops? [answer] yes.
Should 2 more little wires running to the relay, when their unhooked, does the spark quit?
[answer] no.
Does all of this happen with the key on or off? [answer] With the key off.
The spark happens with the key on also. Tomarrow i will replace the relay and see what happens, I,ll post the results in the morning.

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Just replaced the glow plug relay the enginenspends stronger now but the batteries still drain down within 10 seconds of trying to start it. I'm still getting the heavy spark when trying to connect the batteries. thanks tony

 

Any Updates ?

 

So far no luck with getting it running. I did notice the engine harness was in BAD shape. I ordered a replacement engine harness along with the valve cover gasket harness. My plan is to replace the glow plugs also while i have it tore down this far. After tracing wires with a ohm meter the ssparking only stops when the glow plug harnesses are unpluged, if either side is plug in the sparking will be present when trying to connect the batteries. I have a feeling it could be the IDM [injector driver module] as well, reason i say this is, The passenger side gasket harness looked good [yet the sparking was present when plug in]. havent inspected the driver side yet, before i buy a IDM i'll send it to the dealership for dianostic. If you have any advice it 's appreciated... thanks tony

 

have you replaced the glow plug relay? if you havnt i would suggest replacing it.

as for buying an idm, buy one from beans diesel performance, there 300 with a $200 core charge, so for a $100 you get a new idm and a mod.


EDIT: i see that you have already replaced the relay, have you bought all new battery cables? its kinda $$$ but its a simple fix, sometimes its the simple things that go bad.

 

so far i have replaced all the battery dables except the main cable running to the starter, I cut 3" slite an checked it for corrosion did'nt see any so in did'nt replace it.

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by the way exactly where is the idm located??? I checked the bean diesel site for a idm but no luck finding one for pricing or viewing do i need to call them ?

 

the wires that are chafed are the ones under the valve cover? If so - you need to replace those harnesses..

 

No, the wires messed up are the ones running into the valve cover gasket harness. the engine harness is in bad shape!!!!! Yet i'm replacing both valve cover gasket harness,engine harness,and idm relay if i can find it. My cousin say driver side fender but no luck finding it... any help??? thanks tony

 

IDM is like $600. It's what tells the injectors what to do. Interlinks with the ECM.

 

it in the 94-97 psd under "chips" i would bean ans ask if they offer the idm mod for the newer 7.3