2000 chevy 1 ton van. no start today in 25* weather, so i went and towed it in. after lunch i got a chance to look at it. glow plug controller seems to be cyling the plugs for very short bursts. racked it up, and ohmed the glow plugs, 3 dead, so i replaced all 8 upon replacing, 2 welded the connectors to the plugs, so i cut them off and crimped on heat shrink spade terminals after gettign all the glow plugs out(2 fought the whole way out with carbon buildup) i installed them, and went to test for power at each one. 2 and 3 cylinder back op nthe passanger side bank did not have power(they do not share the same loom right by the head) felt the wire, and it had "melted back" like fusible link wire would, leaving 1" of empty insulation between the wire and connector. are these fusible links wire, or did it just overheat? traced the wire back some, and spliced id and reran it down to the glow plugs on those 2. relaying staying on to long causing the burnout? as these where not on the dead GP cylinders. havent pulled the engine cover off yet due to it being so full of junk and you have to pull a seat out to get it out(cage). backed it out for now, and will try starting it first thing monday morning when cold.
Is it possible the one or more of the dead plugs shorted to ground? I don't believe that the wire is a fusible link, or at least have never read that anywhere. The GP relays on the 6.5 are subject to premature failure, so perhaps the the relay stuck closed at some point, keeping the GP's energized way too long, melting the wires and burning out the GP's.
