Club 80-90 Forums

Hi, need help with a hot starting problem on my aaz engine, starts fine and will start again after a short run, but after a long run will not restart and will not start again until the glow plug light comes back on , believe its a problem linked to the sensors??? any advice would be appreciated ,Thanks Dave

It's a very common problem. Put a 470 or 600 ohm 1 watt resistor in series with the glowplug relay temperature sender. This will give a short glow even when the engine is hot. I can post full details of how to do this tomorrow if you want, it's past my bedtime now.

Any old 600 ohm (or thereabouts) resistor will be OK.
I used 560 ohm because that's near enough the right value. It really doesn't matter. I used 1 watt because they are a decent size and robust enough for what we want. They are only a few pence each.

1. Snip the leads down to about 1 inch long each.
2. Get some insulated wire (stripped out of a bit of old flex will do). Cut two 6 inch lengths, and strip the ends. Arrange the wires passing over the resistor body, and twist the bare ends tightly around the leads of the resistor. Solder the wires to the leads.
3. Wrap the whole lot in self-almalgamating rubber tape to make a really robust waterproof blob with a wire sticking out of each end.
4. Attach an insulated female 1/4 inch spade to one end and a male 1/4 inch spade to the other.
5. Pull the female spade off the glowplug temperature sender at the rear (front of the van) end of the cylinder head, and connect it to the male spade on your blob. Push the female spade of your blob onto the temperature sender.
6. Tie the blob to the wiring harness with a Zip tie.
7. Check that you get about 10-15 seconds glow with a cold engine, and just a few seconds with a hot engine.
Job done

Here's a pic


Mods, could this be put in the Wiki, as I get quite a few enquiries about this?