Glow controller upgrade...

[Jgreemo]

Hi all, after dealing with the 83-84 controller long enough, I am aiming to upgrade my system to the 85-93 system. I am trying to get the part number for the harness, or a vendor that sells them. Neither GM or Napa carries them. If anyone should know a place to get it, I would appreciate it.

Thanks for the help.
Jon

[BobND]

I bought the controller, and ordered a replacement connector from GM, which comes with 8" or 10" leads.

I made a simple bracket to mount the new controller to the LH FENDER, where the original RELAY was. By mounting it to the fender, the glow plugs will come on at warmer engine temperatures than with it in it's intended location on the engine, which really helps with warm starts. I also added a resistor in series with the "feedback" lead, as suggested by Dr. Lee. I have actually converted 3 vehicles in this manner, and with the 60G's, the longer glow time, and cycling at warmer engine temperatures has caused NO problems with the GP's. (I had noticed that with the '94 and up computer-controlled units, the GP's cycle once, even on a WARM startup, also, so this conversion is bringing the old units up to date with the newer models, for better starts with less smoke.) Mounting the new controller there also eliminates have to re-work the high-current glow plug wires.

Wiring is simple... (I have a diagram at the shop with the hookup, this is just an overview.)

1- wire from controller to switched 12 Volt "Ignition On" source.

1- wire from controller to engine block ground.

1- wire from controller to starter solenoid feed... (purple wire, easily accessed in harness near brake booster.)

1- wire from controller to glow plug harness... (feedback... used to connect to the old controller.)

That's it... fabricate bracket, hook old power wires to new contoller, run 4- 14 or 16 gauge wires, and you're done!

However, you MUST be SURE to use this ONLY with 60G's or equivalent glow plugs that can take the longer glow cycle and operation at warmer engine temps. The conversions I have done are on high-mileage vehicles, and it has really made an improvement in starting, and less smoke.

I will post back in a little while with a picture of the controller.

If interested, I can respond tomorrow with a diagram, and part numbers.

[john8662]

Another souce for the harness connector and leads can be found at a salvage yard or close by. The harness used on the 83+ in the 80's trucks, cars, suburbans cruise control servo is the same connector. I'm using one for my glow conversion too, just thought I'd throw that in just in case you already had one and didn't know it or want to find one for near nuthin.

[Jgreemo]

Thanks Bob and John. I didn't realize that the connector was the same as that for the cruise control. That should make it much easier to find. I had also planned to park the controller on the fender in order to get the quick pulse with a warm engine. Many thanks for the connections though.

I have Kennedy Quick Heats installed as of two months ago. Also changing out the starter and cables. It starts fine in warm weather, but is a bear in colder temps. The current controller is less than a year old and it's already starting to act up and I am not going to spend the $140-$180 to replace it.

Thanks again you guys.
Jon

[FWBennett]

I think I bought my new controller and harness from Kennedy - they were pretty quick on the shipping. There used to be an articke in the member's area on installing the new controller - someplace around here I've got directions on how to put he old relay to use as a glow plug controller override switch - basically I have a momentary button on my lower dash that I can push the button - the glow plugs stay on as long as I hold the button in - it's saved my cheeks MANY times. Maybe someone recalls this article and has a better filing system than I??? :confused:

[Jgreemo]

Looks like the pigtail harness is a discontinued GM product for both the controller and cruise control. I checked with Napa and they don't have one either. This looks like a junk yard job or maybe one of the vintage parts places might have one.

Thanks for the help.
Jon

[BobND]

Here's a picture of the controller install:

http://ndtc3500.stellarnet.com/~blweltin/bob/diesel.jpg

Here's where it lives, in it's native habitat:

http://ndtc3500.stellarnet.com/~blweltin/bob/burb2.jpg

(I didn't grab the number for the replacement connector when I was at the shop today. I suppose it's the same # you guys found that has been discontinued, but it may be worth checking out. I'll post it tomorrow.)

[Jgreemo]

Well it looks like the connector is the hard to find part. Called Gomer's and they don't have it. I believe Dr. Lee used them to source the part when he did the original upgrade. So GM, Napa and Gomer's don't have it. Looks like a trip to the junk yard is in order. As my cruise control has never worked, I am also going to look at just carrying that connector over.

Just curious though, for the guys who have made the upgrade in the past, where did you find the connector?

Thanks,
Jon

[BobND]

Originally posted by FWBennett:
I think I bought my new controller and harness from Kennedy - they were pretty quick on the shipping. There used to be an articke in the member's area on installing the new controller - someplace around here I've got directions on how to put he old relay to use as a glow plug controller override switch - basically I have a momentary button on my lower dash that I can push the button - the glow plugs stay on as long as I hold the button in - it's saved my cheeks MANY times. Maybe someone recalls this article and has a better filing system than I??? :confused: With the new-style controller, moved to the fender, with Dr. Lee's "extended glow" mod, I've never needed the manual option. It is simply amazing how well the system works with the 60G's, the extended glow time, and the cooler mounting location on the fender, that allows operation before a warm start.

[Jgreemo]

Oh, I forgot to add that Kennedy didn't have the connectors as well. Everyone has the controller, but they keep referring me to GM for the connector. I can get a complete engine harness from them for $1300. No thanks.

Looks like I will need to do something sooner than later. My year old GM 82-84 controller is on the fritz. Sometimes it works right, sometimes not so right. After tearing apart the old one after it failed, I noticed the unit had been leaking, with some of the wiring corroded. Solid state, here I come.

Jon

One last thing, if anyone has a part number for the connector, I would love to have it.

[BobND]

I finally checked out the connector information I have. The part # I have is GM 12101871.

I just talked to my favorite GM parts guy, and he says this is shown as a good number, with a LIST price of $42.91.

His information lists this as a 4-wire connector with leads, cruise control, and glow plug controller.

Would you like me to post a simple wiring diagram?

[Jgreemo]

Thanks Bob, I appreciate the part number. I was on the phone with GM for nearly an hour last week and all he could come up with is either a full harness or calling a vintage parts shop.

I have the reprint with the original article, but if you can put up a diagram, I am sure it would be helpful.

Thanks again,
Jon

[BobND]

Let me know what you find out with that part number. The GM partsman was sure he could still get it, and wanted to order it for me, but I have no more conversions lined up at the moment, so I didn't order it... probably should have to have around, for later use.

I'll put up a simple diagram tonight or tomorrow.

[Jgreemo]

Hi Bob, the local GM dealer had the connector in stock for $37. GMpartsdirect had it for $19. Also going to hit radio shack to pick up some resistors.

Not too happy with the customer service at GM. People are great, ability to find parts without a part number is not.

Looking forward to seeing the diagram. Thanks for the help.
Jon

[Chad 2001]

When I changed the controller on my 82 I could not find a connector. I purchased 4 small electrical connectors from the local parts store that fit the pins on the new controller and made my own connector. Cost was very little. I have had no problem with my new controller.

[Jgreemo]

The part number Bob provided is correct and stocked by GM. The charts and diagrams GM parts has do not apparently have this connector listed so they were unable to pull it by description alone. I picked mine up on Tuesday for $37 along with the new controller. Now off to radioshack for the resistors and I should be in business this weekend. Hopefully get the new starter (28MT) in as well!

Regards,
Jon

[BobND]

Be sure the get the GM #2350 2557 starter brace to match the new gear-reduction starter.

I will still post my diagram for the GP controller changeover, and the value of the resistor I used, to see how that compares to your information. I've been on a "paper chase" the last week, and haven't had time to stop by the shop long enough to dig it out of the files, but I'll get to it in the next day or so.

I'm curious to see how this works out for you, it certainly has made a world of difference on the vehicles I've changed over.

[More Power]

The 1985-93 glow controller part numbers, photos of the parts, electrical diagram and operational description have always been in chapter 13 of the online troubleshooting guide.

http://www.thedieselpage.com/members/guide13.htm

MP

[spitfirenut]

What is the value of the resistor and the wattage? Does it go in the line from the glow plug post to pin c? Looking at the diagram that makes sense. Kind of in the same location as the inhibit switch? Thanks,

[Doug Towne]

My 83 controller just gave up the ghost once again. I rigged a manual system with a push button momentary switch and a ford type relay as a temporary fix.

Today, I went to my favorite self serv auto recycler and lo and behold, 3 6.2 trucks. I was able to get the newer style wire connector for $3.50. I also saw the cruise control connector on several mid 80's GM cars.

I noticed on the 85 relay connector/harness, a larger gauge wire is used on pin D. Is this not required on the upgrade?

[spitfirenut]

resistor value and pin location on the newer controller? what are they for the extended glow mod? I plan to check in the boneyard for the newer controller soon and would like to have my 60g's glow long enough. Thanks.

[Jgreemo]

I am going with ~9 ohms 2W on the C terminal. I wound up with a 2.2 ohm and a 7 ohm resistor soldered together. Built the pigtail Sunday and shrink tubed the connections. My meter showed 9 ohms with the other wires at 1 so it looks good.

Will install controller and harness this weekend and update on how it goes. Good luck.

[spitfirenut]

Thanks, that was what I was looking for. mainly which terminal to use and a ballpark on the resistor. Keep me posted on how it goes.