Starting problem when engine is cold (2.5tdi)

Is cranking speed slow? Do a voltage drop test on battery cables.and a high output amp meter to test starter draw. normal ampere draw should be 250-350 amps cold and 300-375 amps hot as engine turns these readings should drop to 200-250 amps if not bad starter.

The solenoid click sounds very strong, implying that you have a charged battery and the ignition circuit is functioning out to the solenoid. Suspect an issue with the starter motor. Is the starter motor installed and connected properly?

the heading is diesel glow plug relay and then you go on about a choke and petrol inplug holes
what have you got a diesel engine or a petrol engine

There is a safety switch on top of the brake pedal lever or clutch lever which is suppose to prevent lurching on start-ups. It is suppose to insure that the Brake pedal is pushed OR the clutch is down before the engine will crank.

The Ignition switch is interrupted by the above cutout switches. But when Ignition is turned on, the Glow plug timer should click and cycle if Power Relay is giving it juice. So if you do not hear that type of clicking, the glow plugs will stay cold.

I would check to see if power is going to the Power Relay above the glow plug timer, and if it is getting power, does the Power Relay send it to the Timer? The starting circuit is more involved in a Diesel because the fuel must be atomized by heating it for initial starts. But you must be getting this process if jumping the solenoid results in the engine starting.

Therefore the big test is whether the small wire to the starter solenoid is dead when a foot is pressing the Brake or clutch pedal when the Ignition key is in the STARTER position.

So either your Ignition switch is bad at the STARTER terminal position or the signal is interrupted by the anti-lurch Interlock switch. It is quite common for problems with this switch being hit and broken or displaced by the Drivers' feet.

There was also no indication of whether you jumped the solenoid on a warm engine which could atomize the fuel by compression or a very cold engine which needed the glow plugs to work.

Please comment on my info and report your success.

im assuming this is the diesal 6.0, and your using the heated plug for over night. in this case check the battery,starter, and altinator. sounds like the oil is warm and starts easily, and oil is cold and has hard time turning the engine over due to the cold (thicker) oil. or the starter just may not be getting the full amount of amps it needs to turn it over, I would start there and if this works, then try a thinner oil in the cold weather, then thicker for summer.

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

pumping the throttle does not help just hold it wide open ,firstly check the preheaters ,and if they all work make another posting and we go from their ,,to check glow plugs remove the cable that connects then alkl together and then test with a cable from the + battery terminal and see if it sparks when you touch each heater plug in turn ,and renew the defective ones or go the whole hog and just change them .

1. check your battery.
2. check your connection to the starter
3. check your ignition key.
4. check your relay, etc

if you need connectors and terminals for the glow plug connections under the valve cover, Ford sells then so you don't need a whole $600 harness.

info for your use

Section 03-07B: Glow Plug System 1996 F-250, F-350, F-Super Duty Equipped with 7.3L Diesel Engines Workshop Manual
DESCRIPTION AND OPERATION Glow Plug System The 7.3L diesel engine uses a glow plug system which preheats air in the combustion chamber to improve cold engine starting. The system consists of eight glow plugs, the glow plug control module (12B533), powertrain control module (PCM) (12A650), engine oil temperature (EOT) sensor and barometric pressure sensor (BARO sensor) (12A644). The glow plug system is electronically controlled by the powertrain control module. The powertrain control module energizes the glow plugs immediately after the key is placed in the ON position and then determines how long the glow plugs will be on according to the engine oil temperature and the barometric pressure. The required time for the glow plugs to be energized decreases as the engine oil temperature and barometric pressure increase. The glow plugs are self-regulating, and the powertrain control module controls relay ON time. The powertrain control module protects the glow plugs by energizing them for short durations if the battery voltage is abnormally high.

Possible Causes: Insufficient glow plug ON time will not allow enough heat to accumulate in the combustion chamber to easily facilitate starting. If the glow plug system ON time does not meet any of the specifications in the accompanying chart the problem is most likely a faulty wire harness connection, ground connections or glow plug relay.

If the glow plug resistance to ground is high, the most likely causes are an open UVC (under valve cover) harness or open glow plug.
--------------------------------------------------------
Relay Operation
Install a DVOM on the glow plug feed side of the glow plug relay (large stud with two wires connected). Turn the ignition key to the ON position but do not attempt to start. Note the time in seconds from when the key is turned on and the glow plug relay energizes until the glow plug relay de-energizes. The glow plug relay makes a loud click noise which is easily heard when it energizes and de-energizes. The dome light will dim and the dash voltmeter will dip when the glow plugs are drawing current from the battery. Compare the times measured to the table (time will be affected by engine temperature, battery condition and vehicle altitude). The voltage at the glow plug feed terminal may vary from 9 to 12 volts depending upon battery condition.
--------------------------------------

-----
If battery voltage not present check for B+ at power supply terminal (terminal with single large wire). Power for glow plug power supply is supplied from starter relay through two fusible links at solenoid.
Glow Plug Operation
Disconnect all of the glow plug/injector harness connectors from the valve cover gaskets. With the pigtail installed, measure glow plug resistance to ground (preferably B-). A resistance measurement of .1 to 6 ohms indicates a good glow plug.



Glow Plug Harness Continuity
Measure for continuity from the connector harness to the glow plug feed terminal on the glow plug relay. Resistance should be less than 5 ohms.
Incorrect measurements will result if all glow plug/injector connectors to valve cover are not disconnected.

---------------------------------------------------
Glow Plug Relay The glow plug relay (12A343) has a plastic base and two mounting bolts. It is operated by the powertrain control module (PCM) (12A650) which senses engine oil temperature, PCM voltage and barometric pressure. When the engine oil temperature or the barometric pressure is low, the PCM activates the glow plug relay and the glow plugs. If the PCM voltage is too high, the powertrain control module deactivates the glow plug relay and the glow plugs immediately energize for a shorter duration, decreasing the modulation of the duty cycle.
-----------------------------------------------
Glow Plug Removal

1. WARNING: THE RED-STRIPED WIRING HARNESS CARRIES 115V DC. SEVERE ELECTRICAL SHOCK MAY BE RECEIVED. DO NOT PIERCE.
   Remove valve cover (6582). Refer to Section 03-01D .
   

1. Disconnect glow plug electrical connector using a pair of pliers.
   

1. Remove glow plug using 10mm socket.
   

1. Clean and inspect glow plug tip for damage. Replace if damaged.
   

Installation

1. Install glow plug and tighten to 19 Nm (14 lb-ft).
   

1. Connect glow plug electrical connector. Make sure glow plug wiring is routed to avoid moving parts.
   

--------------------------------------------------------------
Glow Plug Control Glow plugs are used to warm the cylinders to improve cold-engine starting. The PCM uses the engine oil temperature (EOT) sensor and barometric pressure (BARO) sensor to determine how long the glow plugs will be on. The PCM energizes the glow plugs longer if the engine is very cold or if the barometric pressure is low at high altitudes.
The PCM controls the relay that supplies power to the glow plugs with the glow plug control (GPC) signal. When the GPC signal is grounded by the PCM the relay closes, turning the glow plugs on.
The glow plugs are controlled by the following sequence:

1. PCM energizes the glow plugs.

1. The PCM energizes the glow plugs immediately after the ignition is placed in the ON position.

1. The PCM then determines how long glow plugs will be on based on EOT sensor and the BARO sensor. The required time to warm up the cylinder decreases the engine oil temperature and barometric pressure increases at low altitudes.

Glow Plug Lamp Control The glow plug lamp (GPL) signal controls the WAIT TO START light located on the instrument panel. This light is used to indicate when to start the engine. The cylinders are being warmed by the glow plugs during and after this light is lit. The PCM energizes the glow plug lamp longer if the engine is very cold or if the barometric pressure is low.
When the GPL signal is brought low, the "Wait to Start" lamp is turned on.
The glow plug lamp is controlled by the following sequence:

1. PCM lights the WAIT TO START light after a key on reset occurs.

The PCM determines the glow plug lamp activation time based on engine oil temperature, barometric pressure and battery voltage.

1. PCM turns off the WAIT TO START light.

The glow plug lamp is turned off when the timer counts to the number of seconds specified by the PCM. The glow plugs will normally remain on longer than the "Wait to Start" lamp.
-----------------------------------

it might be the starter or ignition