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What brand and part# plugs are you using? The wellmans shouldnt swell that bad, I have seen the AC13's swell up really bad. The resistor only drops the voltage to 12v, not 2.8v. The glow plug IS a resistor, thats how they get hot, by creating a restriction in the path to ground for the current...

It means that they "shouldn't" overheat, if you leave them on for minutes at a time they still will but a few seconds over will not harm them.

the only civilian plug that should be used in a cucv (only if you have converted the plugs to 12v) is the AC-60G (self-limiting).

NO, DO NOT ELEMINATE THE RELAY. A lot of current flows through the glow plugs when they are on, you dont want to have that flowing inside your cab. The relay makes it so you dont need to have a 50amp rated switch with heavy guage wiring under your dash.

They are NOT the humvee plugs, hmmwv's run a straight 24volt system for everything. The CUCV only runs 24v for the starter, the glow plugs are run through a dropping resistor that is feed from the 24v buss bar. The dropping resistor lowers the voltage to ~14volts as soon as a load is placed on...

they use the standard spade connector (slightly larger than the connectors on the cucv wiring harness.) and can be purchased with a set of the waterproof connectors from http://www.indusadist.com/web_site_new_2008_005.htm

The glow plugs are NOT 24v, only the starter is. So swapping the engine in, is painless (as far as the electrical goes).

There is no reason to get your panties in a bunch. :roll: Usually when you start talking about a vehicle, it is assumed it is in the stock configuration, unless you explain what you did to it. [thumbzup] Take it down a notch or two ;)

For the Wellmen plugs They dont swell, they are self-regulating. When they do burn out, you just pull them out and put new ones in (always replace as a set of course) Why does your m715 have glow plugs?

Just to Clarify this, the relay is fed 12v to one small terminal, the other small terminal is the light blue wire, and is connected to ground via a switch (or controller in the stock setup) grounding it activates the relay, which then feeds current through to the glow plugs.

look at M1075's post a bit further up and you will see the pic of the controller. The card is inside the black plastic box. Pull it out and look for burnt marks or leaking capacitors.

Yes

Locate the glow plug controller under the dash, its a black box with about 10wires going into it (located near the steering column) the light blue wire is a ground, its completes the circuit on the relay that energizes it and makes the connection between the top and bottom terminals (thus...