Group 23 Fuel system Pre-heating 1982-1983 Preheating system 1982-1983 it Components 1 Battery 2 Ignition switch 8 Starter motor 11 Fusebox 29 Positive terminal 71 Start inhibitor switch (auto) 98 Indicator lamp, boost pressure gauge 104 Indicator lamp for glow current 130 Glow plug relay 195 Fuel valve (injection pump) 199 Temperature sensor 208 Giow plug 212 Service socket 233 Pressure sensor ¢ Avi Colour code for connectors Colour code fr witing diagram = without votape —— = oarvground Fuse No.8 Fre No, 10 é =~ sireitvolge Direction indicators Reversing lights === = voltage lower than circuit voltage estar current flow Engine running, charge pressure too high € Ignition ON (GLOW) Starter motor engaged (coolant temp, below 55° (131) 172Group 23 Fuel system Pre-heating system 1982-1983 Component location 1982-1983 models Av2 173Group 23 Fuel system Pre-heating system 1984 p73 BLA. Pre-heating syste Colour code for wiring diagram earthiground, = circuit voltage lgnition ON (GLOW) 174 Coolant temp + 50° (120°F) without current potential = voltage lower than circuit voltage m 1984 Avs Components 1 Battery 2 Ignition switch 9 Starter motor 11 Fuse box 71 Start inhibiter switch (automatic transmission) 98 Indicator lamp, boost pressure gauge 104 Indicator lamp, glow current 130 Glow plug relay 195 Fuel valve, injection pump 199 Temporature sensor 208 Glow plug 233 Pressure sensor 278 Aneroid switch 279 Solenoid valve, altitude compensation syster AA» Connector left side wiring harness (wheel ho B Connector, engine wire harness © Ground D Battery ground Colour cde fr connector ¢ bik over ame ved Soon eS See cre Nene osed vo wala Soa ruse. 10 Fuse No.1 é Comtinedinsrumoxt penal Dion indestore Reversing ght Gow plug ray ‘Starter motor engaged Engine running Charge pressure too highGroup 23 Fuel system Pre-heating system 1984 Component location 1984 e 175Group 23 Fuel system Pre-heating system 1985- AVS Pre-heating system 1985- ‘Components 2 Ignition 9 starter motor 11 Fuse box 71 Start inhibiter switch (automatic tranmission) 98 Indicator lamp, boost pressure gauge 104 Indicator lamp, glow current 130 Glow plug relay 195 Fusl valve, injection pump 199 Temperature sensor o) 208 Glow plug 223 Pressure sensor, turbo 278 Aneroid switch, altitude compensation 279 Solenoid, altitude adjustment AA” Connestr, lt side wiring harness (heel hog 8 Connector, engine wiring hamess C Ground D Ground E Battery ground 195 Fuse No. 12 a Backup light way pals (et | 2 ee S| Tpit Starter motor engayed —_Eagioo running: © Coolant temp. under 50°C (120°F) Charge pressure too highGroup <3 Fue! system Pre-heating system 1985- Wie US, CDN 7Group 23 Fuel system Pre-heating system, function AX. Preheating system, function To facilitate cold starting the swirl chambers are heated by glow plugs prior to start. The length of time the plugs, are engaged depends on coolant temperature. A variable resistor (sensor) sends information on coolant temperature to a control unit which regulates the engagement time of the plugs accordingly. When the ignition key is turned to position 2 the preheating system (glow plugs) is engaged and the dashboard indicator light comes on. Approximate engagement time at different coolant temperatures is as follows: -20°C (-4°F) prox 9 seconds °C (32°F) 1pprox 6 seconds 20°C (68°F) prox 4 seconds 40°C (104°F) = approx 3,5 seconds 50°C (122°F) jpprox 0 seconds After the indicator lamp goes out the plugs remain on for an additional 0-14 seconds, depending on tempera- ture, to allow sufficient time to start the engine. Once the starter motor is engaged, current flows to terminal 50 of the control unit to ensure that the glow plugs remain on and “new” air is heated up. When the engine starts and the key is released terminal 50 is de-energized and the glow plug is switched off. As a safety precaution, a cut-out device is incorporated in the control unit to cut off the current supplied to the glow plugs after a certain time irrespective of whether ‘or not the engine has started. If the plugs were left on too long they would melt, and damage the engine. If indicator lamp comes on (or is on) with warm engine AXI Disconnect wire from coolant temperature sensor and ground it. Turn key to position II (glow). Indicator lamp should not come on. Hfindicatorlamp does not come on: temperature sensor is probably defective and should be replaced. Hfindicator lamp lights: probably a breakin temperature sensor - control unit wire or defective control unit. Chee! Turn on ignition. Withdraw plug from control unit. Ifindicator lamp goes out: control unit is defective and should be replaced. If indicator lamp remains on: orange wire between in- dicator lamp and connector is shorted. g control unit 178 EndGroup 23 Fuel system Pre-heating system, checking Pre-heating system, checking Engine should be cold at start of test (coolant temperature below 40°C = 104°F). If pre-heating system disengages during check turn key to position 1 and then backto position 2 (glow position). 1. Checking glow plug control unit and dashboard indicator lamp. AX3 Connect a test lamp between glow plug wire and ground AXA Turn key to position II. ‘Test lamp and indicator lamp should come on No lamps on See page 181 {)_eperaton Axe Only dashboard ‘See page 182 lamp on operation AX11 Only test See page 183 lighy on b operation AX13 Both lamps light: Continue check on next page. 179Group 23 Fuel system Pre-heating system, checking 2 10 +40 +80 #04 4122 Fz tee: Engagement time AXS Checking engagement time of plugs Connect a test lamp between ground and glow plug wire. Turn key to zero and then to position I. Check how Iong lamp is on ‘When indicator lamp goes out, test lamp should remain on 0-14 seconds depending on coolant temperature. See graph. Hf engagement time is too short: Test circuit with a new control unit. If this does not help, replace coolant temperature sensor. Hf engagement time is correct: Continue with next operation. AX6 Checking glow current when starter motor is switched on Connect test lamp between ground and glow plug wire. ‘Turn key to position ll when indicator lamp and testlight go out, turn key to switch starter motor on. Test light comes on: OK. Continue check on next page. Test light doos not come on: Test for voltage at terminal 50 (blue-green wire at con- nector) on control unit. When starter motor is switched on test light should come on. Voltage: Control u No voltage: Blue-green wire to control unit is probably shorted (refer to wiring diagram). is defective and should be replaced. 180Group 23 Fuel system Pre-heating system, checking Checking glow plugs Turn key to zero. Disconnect ground strips between glow plugs. Connect a tet light between battery (+) and each glow plug. Light does not come on: replace glow plug. Light comes on: OK Refit ground strips. AX8 Checking control unit cut-out circuit Disconnect wire from temperature sensor at rear of engine. (Make sure that itis not grounded). Connect a test light between glow plug and ground. Turn on ignition. Deshboard indicator lamp and test light should go out after approx. 25 seconds. End Checking control unit (continued) Hf none of the lamps come on... Turn key to position I! Check for voltage at terminal 15 (blue wire) on control unit. Use a test light. Light should come on. Test light off: Open circuit in wire or connector between central electrical unit and control unit. (refer wiring diagram). Light comes on: OK. Continue to next page. 181Group 23 Fuel system Pre-heating system, checkinG AX10 Check control unit ground connection Connect a test lamp between terminal 31 (black wire) on control unit and battery (+). Light should come on. Test light off: Control unit not grounded. Test light on: Ground connection OK, but not control unit. Replace control unit. End ve Checking control unit (continued) AXIT H only indicator lamp comes on. ‘Check for voltage at terminal 30 (red wire) on control unit. Use a test light. No vottag Open circuit in wire between battery and control unit. Volta, OK. Proce with checking. AXI2 Checkfor voltage at terminal Goncontrol unit(redwire) ) when key is turned to position Il and indicator lamp is on, Voltage: Control unit OK. Check wire between control unit and slow plugs. No voltage: Check control unit fuse. If fuse is OK, replace control unit. End 182.Group 23 Fuel system Pre-heating system, checking Checking control unit (continued) AX13 Only test light o Disconnect connector from control unit. Ground orange wire. Turn key to position Il. Indicator lamp comes on, test light comes on Indicator lamp OK, control ut lefective. Indicator lamp does not come or Lamp defective or wire def Check lamp If lamp is OK, check orange wire and connector on Acpillar. End 183