1990 Syncro Diesel Blows the BIG fuse in the Black Box!

[Team WorldTour]

So, I've had some work done lately. I had the Dealership swap out the cylinder head. This morning was a little cold, so I decided to drive the van.
No start.
Pulled the choke. No start.
Popped the hatch, had a look around, Found the burnt fuse.
Come home from work, armed with FOUR 80A fuses. Used two of them to figure out it must be something with the glow plugs. When I hit the key, EVERYTHING goes black, I hear a very loud BZZAP!, and everything lights up again.
No start.
As soon as I can get someone on the phone at VW (they seem a little busy lately for some reason....), I will get them to do something about it.
I want to understand what is going on first though.
If you have any idea, or can offer any advice, I'm all ears.
As far as checking with the Bible (Chapter 97, Verse 42), I was able to determine it is on the circuit for the glow plugs.
And it should be a 50A.
Thanks!
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1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

[?Waldo?]

Yes, 50A not 80A. Stop using fuses as diagnostic tools.

I'm just going from memory, but I believe one side of that 50A fuse receives power from the starter. Power then goes through in one big lug of the glow plug relay and out the other on to the buss bar at the 4 glow plugs. I would look for a short to ground at the glow plugs. I would then disconnect at the wire at the buss bar and insulate it from ground. I would remove the 50A fuse. Then check to see if there is continuity between the glow plug side of the fuse holder and ground. If so, pull the relay. Test at the relay big lugs for continuity to ground. If there is not with it unplugged, replace the relay. If there is, then track it down.

[MsTaboo]

The glow plug bus bar is a strip of exposed copper running across all four glow plugs. Easy to short out with something. Check to be sure nothing is resting on it.
Here is a great upgrade for the glow plug system. The pictures are for a Golf or something but the concept is the same for Vanagon. I did this to my '89 Traistar that has an 1.9 TD AAZ conversion from JX and it works really well. Much faster starts. It's a fairly quick and easy upgrade, the only hard part is getting at the glow plug behind the injection pump.
http://vincewaldon.com/index.php?option=com_content&task=view&id=30&Itemid=28

Check out his other How-To tips!

You didn't say which diesel you have, but here is a wiring diagram for the glow plugs/relay '82-'92 Td.
http://syncrosport.com/info/wiring/VW_Transporter_80-92_TD_coolantpump.pdf
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Currently:
'90 Syncro Westy 3 knob w/Zetec

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X2 Vince Walden pimp upgrade made easy
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'84 Transporter 16" CLK's/LED's/ AT's/Mansi injectors
'86 Wolfey Weekender Westfalia AT's/otherwise stock
Sold-'82 TinTop Diesel

[Team WorldTour]

MsTaboo- I have the EXACT same set up as you, JX to AAZ.
Andy, not what I was trying, just how it worked out. I still have two left, and I plan on keeping them whole.
I did do the simple checks, like grounding on the bus bar, broken wires, things touching where they shouldn't......
I brought the issue here because I ran out of easy checks.
I am still trying to reach VW and let THEM figure it out (It worked just fine when I drove it into their shop!).
That GP upgrade looks awesome. I will get on that as soon as I can!
Thanks again for the advice!
_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!