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The manual thing is pretty easy to do, if you understand basic electrical systems. HOWEVER, DON'T try to manually control the older 9G or 11G glow plugs, as the first time the button is held too long, the glow plugs will burn out, swell up, making removal difficult and/or break off and get imbedded in the piston tops! The glow plugs can draw as much as 120 Amps, so it's best to use a relay (solenoid), operated by the in-cab pushbutton. The '82 and '83 (or thereabouts) systems had a discrete relay mounted on the fender, with one side of it's coil connected to "IGN" power, as long as the key was "ON". Simply running a wire from the solenoid's other small terminal to a pushbutton that would ground it when pressed would give you manual glow plug control. Your's is likely the newer setup that combines the controller and solenoid in one unit, mounted in the center valley of the engine, near the rear of the LH cylinder head. To achieve manual control without HEAVY wiring into the cab, it's necessary to add a solenoid to that system. That being said, it's EASY to update the system you have to a BETTER automatic system. The guys at TheDieselPage.com came up with a "mod" to extend COLD glow time, for better starts, when 60G glow plugs are used. Lots of folks posting over there have done the "mods", with good results, and I have personally changed over close to a dozen of these old trucks, with GREAT results. The 60G's and the extended glow time make cold starting MUCH better, without the need for a manual system, that is confusing if a friend or "significant other" needs to jump in the truck, and start it, without an operating lesson. The system works just like the factory system, only better, retaining the dash-mounted "WAIT" light. Also, we eliminate the "glow plug inhibit" sensor, making the glow plugs made a short cycle, even when the engine is WARM. This makes for MUCH better warm starts, especially with high-miles engines, and LESS smoke at startup. The 60G's tolerate this very well. The 1994 and up trucks with the glowplugs under the control of the PCM were set up to cycle the glowplugs in this manner, from the factory. BOSCH makes a dual-coil glow plug, also, that is pretty much comparable to the 60G's. Email me, if you'd like more information. bigcoulee@hotmail.com
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