89 Ford E350 Diesel - two problems 1) no power to instrument cluster, 2) diesel will not fire off without starter fluid...but the glow plug solenoid does click and wait light goes off

10 amp fuse labeled instrument cluster also protects idle sensor on diesel models

Your diesel requires the glow-plugs to heat up to start when cold. This is why the truck smoked excessively when you pull it to start the motor. Siince you are not having the glow-plugs warm up via the "Timer" for them and you are getting intermittent Solenoid response from the tickler wires on the Solenoid, there is one common point.

The Ignition switch is the common point. You should also observe if your "Start" light is getting the feedback from the glow plug "Timer". Replace the Ignition switch and see if you hear the "Timer" clicking before a cold start. You can also take a 12 volt test-light or gauge and check the wires to the glow-plugs when cold. The glowplugs should be getting power from the until the glow-plugs heat up.

Remove and check the glow-plugs. A good way is to remove all of them, and take some jumper cables to each briefly. BE careful as they can melt and you can ruin the threads with the jumpers. Comparison is the best way to describe testing them. They should heat up the same for all. The glow-plugs that stay dark the longest are bad.

Ask the auto parts place if they show an Ignition relay for your Diesel. This would cover the poor starts when warm. Also tell them it is a Diesel when getting the Ignition switch.

Hi,
I would recommend disconnecting your glow plug relay if you are going to use starting fluid.
With starting fluid in the engine and the glow plugs turn on it may explode the fluid and do head damage. Starting fluid and any kind of ignition source ( hot glow plug ) is like a bomb.
Wayne

Glow plugs create enough heat to fire the diesel fuel - could be some are defective..Saw an individual start a diesel by spraying either into intake. He said his glow plugs needed replaced. It started right up.

Normally, only 2 things stop a diesel from firing:
1. no fuel
2. not enough compression

No fuel can be caused by (obviously no fuel) or a failed fuel pump. To test, have someone turn the engine over and then sniff at the exhaust - does it smell of unburned diesel? (If you've run out of diesel recently, you may have an airlock in the system, this needs bleeding out.)

Not enough compression needs specialised equipment to test - that's a garage job.

Ok well the glow plugs on a diesel have nothing to do with the engine firing. All the glow plugs do is heat up the combusion chamber on cold starts. Diesel engines fire using high compression. An oxygen sensor won't cause the vehicle to not start and your diesel doesn't have one of those anyways. It could be a fuel related issue. (pump, line, pressure etc.) Have you it scanned for engine DTC's? But based on your knowledge of your diesel vehicle i'm going to suggest you take it to a shop.

The glow plug on key on,connects the glow plugs to the battery positive,and allows the glow plug to GLOW,and ignite the cylinder,for combustion.

only 2 things can maake a diesel run rough at start up ,,1--- air in the system 2----- 1 or more of the glow plugs not working. this sounds like the latter ,if you have a couple of glow plugs not working ,it will miss on those cylinders until it warms up ,and the smoke is mostll exesive fuel when it does fire . recommend you check the glow plugs

It has to have 2 batteries because it is a diesel engine. Diesels use compression to fire the combustion mixture instead of a spark plug as a gasoline engine does. It has glow plugs that heat the mixture up before starting to help promote this and it has probably twice the compression ratio,therefore it takes alot of amps to start it and that is why you have 2 batteries. No it still only has one solenoid for the starter but it has to use a gear reduction starter instead of a conventional one.

it should be number 42


MKIV FUSE LIST
1. Washer nozzle heaters, glove compartment light, memory seat control module (10A).
2. Turn signal lights (10A).
3. Fog light relay, instrument panel light dimmer switch (5A).
4. License plate light (5A).
5. Comfort system, cruise control, Climatronic, A/C, heated seat control modules, automatic day/night interior mirror, control module for multi-function steering wheel, control unit in steering wheel (7.5A).
6. Central locking system (5A).
7. Back-up lights, speedometer vehicle speed sensor (VSS) (10A).
8. Open
9. Anti-lock brake system (ABS) (5A).
10. Engine control module (ECM): gasoline engine (10A); diesel engine, Model Year 2000 > (5A).
11. Instrument cluster, shift lock solenoid (5A).
12. Data Link Connector (DLC) power supply (7.5A).
13. Brake tail lights (10A).
14. Interior lights, central locking system (10A).
15. Instrument cluster, transmission control module (TCM) (5A).
16. A/C clutch, after-run coolant pump (10A).
17. Open.
18. Headlight high beam, right (10A).
19. Headlight high beam, left (10A).
20. Headlight low beam, right (15A).
21. Headlight low beam, left (15A).
22. Parking lights right, side marker right (5A).
23. Parking lights left, side marker left (5A).
24. Windshield and rear window washer pump, windshield wiper motor (20A).
25. Fresh air blower, Climatronic, A/C (25A).
26. Rear window defogger (25A).
27. Motor for rear windshield wiper (15A).
28. Fuel pump (FP) (15A).
29. Engine control module (ECM) gasoline engine (15A); diesel engine (10A).
30. Power sunroof control module (20A).
31. Transmission control module (TCM) (20A).
32. Injectors: gasoline engine (10A); diesel engine (15A).
33. Headlight washer system (20A).
34. Engine control elements (10A).
35. 12 V power outlet (in luggage compartment) (30A).
36. Fog lights (15A).
37. Terminal (86S) on radio, Instrument cluster (10A).
38. Central locking system (with power windows), luggage compartment light, remote/fuel tank door, motor to unlock rear lid (15A).
39. Emergency flashers (15A).
40. Dual tone horn (20A).
41. Cigarette lighter (15A).
42. Radio (25A).
43. Engine control elements (10A).
44. Heated seats (15A).
Fuse arangements in fuse bracket/battery:
S162. Glow plugs (coolant) (50A).
S163. Fuel pump (FP) relay/glow plug relay (50A).
S164. Coolant fan control (FC) control module/coolant fan (40A).
S176. Relays panel interior (110A).
S177. Generator (GEN) (90 Amp.) (110A).
Generator (GEN) (120 Amp.) (150A).
S178. ABS (hydraulic pump) (30A).
S179. ABS (30A).
S180. Coolant fan (30A).