Perfectly normal to feel dread passing through K-town, happens to us all.
Out of curiosity, was the HZJ turbo & would that make a difference? I've never noticed an increase in smoke crossing the mountains (1HZ turbo, 1HD-FT, TD42 turbo) but never had an NA diesel.
Remove the overhead console where the sunroof switches and sub tank gauge is, should have good access to the motor from there.
Lots of good info here:
https://forum.ih8mud.com/threads/how-to-sun-roof-repair.260221/
Could get new seals:
https://rubbersealsaustralia.com/product/sliding-cargo-window-rubber-seal-kit-toyota-fj60/
Could spend a little more on one of these:
https://thecruisercompany.com.au/toyota-landcruiser-60-series-lift-up-window/
Any photo's of how bad they are? An aggresive brush and...
I think + power goes from the bar to the timer rather than timer to bar. Bar gets it's power from the relays, timer needs to sense what voltage the bar is receving.
Hopefully the timer sorts it out, but if it doesn't here's what I'd look for:
A bad relay can still 'click'. Did you test them...
Just a thought, but there's a small round grey single wire plug on the passenger side wheel arch, pretty sure it's from relay to resistor. Mine had come loose and gave me glow issues until I noticed it. Slim chance, but possible.
Good info in these threads:
https://forum.ih8mud.com/threads/no-after-glow-resistor-issue-1hz-24-volt.1267365/
https://forum.ih8mud.com/threads/super-glow-explained.597560/
Seems like the resistor wouldn't be causing a hard start condition, but worth checking anyway.
Timer controls the dash...
There are two relays. The one in the fender is the glow sub-relay, glow main is on the inner fender arch.
Unplug the connector to the relay that has the smaller wires. Apply 12v+ to the plug and ground the remaining pin, listen/feel for a click.
Easy test is to get someone else to turn the key...
The timer box is relatively easy to open up and check for any damaged circuitry. Other than that you can bench test both relays, also if your charge warning light doesn't work you won't get glow.
I don't remember having that fusible link in my HZJ harness, can check tomorrow. Check for continuity between the bus bar and that black/yellow wire from the preheat timer (behind) glove box.
Check the back of the cluster, make sure all the circuits on that blue paper are in tact and that all necessary bolts are in place.
Out of curisity, does it have factory cruise control and if so, does it still work?
I only used them to test drive while I was building the car, ended up fixing the electric seats (rare and "cool" over here) and put them back in.
That said, I spent a lot of time in those seats in a commodore and never had an issue, always comfy, supportive under spirited driving conditions...