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AndyT66



Member Since: 19 Sep 2016
Location: Bedford
Posts: 148

England 2004 Defender 90 2.5 TD XS CSW Zambezi Silver
TD5 2003 Defender intermittent non starter
Hello All,
After many years of saving I am now the proud owner of a 2003 Defender with, as I am fast discovering, all the usual things sent to test us including three fuel pressure regulators (2 after market and 1 OEM which solved the leak). My latest problem is an intermittent starting fault which occurs randomly and unexpectedly, the last event was at the petrol station (good timing I must say).
On a good start when turning the ignition the engine management light, coil light etc illuminate and the fuel pump whirs in the back – bingo off we go.


Click image to enlarge


The Non start event includes no engine light, no coil light and temperature gauge that goes to the red ,despite a cold engine. The fuel pump remains silent, the engines turns but fails to spring into life.


Click image to enlarge


Just to note a couple of months ago I had the injector harness replaced after she went into safe mode, i subsequently found oil in the red ECU plug (oh joy) - it's still as dry as a bone today? A few previous posts i have read mention an ignition relay as a possible cause?

Any possible suggestions as to the cause would be gratefully received. Bow down I can cope with rotting doors etc but engine electrics are a dark science i'm afraid. Sad

thanks in advance all Andy
Post #575683 5th Nov 2016 8:11pm
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gazman



Member Since: 17 Aug 2015
Location: Liverpool
Posts: 652

United Kingdom 2003 Defender 90 Td5 HT Alpine White
check the main relay under the drivers seat next time it does it. Give it a shak/tap and if it clicks and everything goes back to normal check the contacts.
If not its a earth issue 2014 - current ..... 2003 defender td5 90 (my car)
2009 - current .... 2005 zx10r
Post #575695 5th Nov 2016 8:49pm
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AndyT66



Member Since: 19 Sep 2016
Location: Bedford
Posts: 148

England 2004 Defender 90 2.5 TD XS CSW Zambezi Silver
Many thanks for the reply, I'll give that a go and let you know
Post #575702 5th Nov 2016 9:07pm
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4RF RDS



Member Since: 19 Jul 2015
Location: Ottawa
Posts: 890

Canada 2000 Defender 110 Td5 XS CSW Epsom Green
Could be time to pull the starter and rebuild the starter motor contacts. Do a search on this site for what to do, easy to complete by yourself for about £20 quid and a half hour work. 2010 Range Rover MkIII Autobiography Super Charged (Idris)
2003 Range Rover Mk III (Desmond FitzWilliam)
2000 Defender 110 CSW TD5 (CTX)
1992 Range Rover Classic (Lizzy)
1972 Series III 300 Tdi (Stanwood)
1967 MGB GT

Every normal man must be tempted at times to spit on his hands, hoist the black flag, and begin to slit throats.
H. L. Mencken (1880 - 1956)
Post #575738 6th Nov 2016 1:44am
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pj2106



Member Since: 20 Dec 2012
Location: Huntingdon AKA The Shire
Posts: 1500

United Kingdom 2008 Defender 110 Puma 2.4 USW Stornoway Grey
Firstly try cleaning up the live/neg cable connectors on the starter motor they get full of crap had this on mine also check starter relay and crank sensor had both these too 2008 110 2.4 XS Utility (Hagrid)
2002 90 TD5 Hardtop (Sully) Sold
1998 300TDi D1 (Billy) Sold
Post #575756 6th Nov 2016 8:27am
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miker



Member Since: 13 Sep 2015
Location: Surrey
Posts: 1758

United Kingdom 1999 Defender 110 Td5 CSW Rioja Red
4RF RDS wrote:
Could be time to pull the starter and rebuild the starter motor contacts. Do a search on this site for what to do, easy to complete by yourself for about £20 quid and a half hour work.


If it's turning but not firing then won't be starter.

Do you have a copy of the electrical schematics? May be helpful to start tracing wires.
Post #575807 6th Nov 2016 1:32pm
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4RF RDS



Member Since: 19 Jul 2015
Location: Ottawa
Posts: 890

Canada 2000 Defender 110 Td5 XS CSW Epsom Green
Thumbs Up 2010 Range Rover MkIII Autobiography Super Charged (Idris)
2003 Range Rover Mk III (Desmond FitzWilliam)
2000 Defender 110 CSW TD5 (CTX)
1992 Range Rover Classic (Lizzy)
1972 Series III 300 Tdi (Stanwood)
1967 MGB GT

Every normal man must be tempted at times to spit on his hands, hoist the black flag, and begin to slit throats.
H. L. Mencken (1880 - 1956)
Post #575850 6th Nov 2016 4:45pm
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dorsetsmith



Member Since: 30 Oct 2011
Location: South West
Posts: 4554

Crankshaft position sensor can cores non starter as the ecu has no information of engine rpm

check wiring to it and the plug driver side engine flywheel end also remover it clean of swart as it has magnetic core

https://www.lrdirect.com/NSC100790-Sensor/


Last edited by dorsetsmith on 29th Apr 2019 6:44am. Edited 3 times in total
Post #575857 6th Nov 2016 5:10pm
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gazman



Member Since: 17 Aug 2015
Location: Liverpool
Posts: 652

United Kingdom 2003 Defender 90 Td5 HT Alpine White
their is something wrong of the temperature guage is in the red. I had a issue with mine a few months back and it would cut out intermittently, everytime it did the water guage went into the red like the one in this post. Knocking the main relay got it running again. I cleaned and tightened the contacts and it was fine afterwards 2014 - current ..... 2003 defender td5 90 (my car)
2009 - current .... 2005 zx10r
Post #575880 6th Nov 2016 6:10pm
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AndyT66



Member Since: 19 Sep 2016
Location: Bedford
Posts: 148

England 2004 Defender 90 2.5 TD XS CSW Zambezi Silver
Thanks all for the info for above, much appreciated. I'm going to start with the main relay, possible the easiest option ! Looking at the schematics it appears the main relay, fuel pump and glow plugs are interconnected? She's been OK today as luck would have it, though I am now actively listening for a relay click under the seat as I turn the ignition on. Unfortunately it will be next weekend before I can delve into this. Thanks again , Andy
Post #575928 6th Nov 2016 9:03pm
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resnonverba



Member Since: 08 Aug 2015
Location: Lisboa
Posts: 4

Portugal 2005 Defender 90 Td5 ST Tonga Green
I had this symptoms too. It was the Main relay loose on the rack.

It was hard to reproduce. I had to pull out completely the relay rack and shake it outside with the engine running to reproduce the failure.

I tightened the contacts a bit with the tip of a screwdriver and no more failures!
Post #576894 10th Nov 2016 6:35pm
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AndyT66



Member Since: 19 Sep 2016
Location: Bedford
Posts: 148

England 2004 Defender 90 2.5 TD XS CSW Zambezi Silver
Many thanks Resnonverba I'm definitely heading to that relay first at the weekend. Ps I had a great holiday this year in Lisboa, lots of well looked after defenders as well Very Happy
Post #576947 10th Nov 2016 8:34pm
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resnonverba



Member Since: 08 Aug 2015
Location: Lisboa
Posts: 4

Portugal 2005 Defender 90 Td5 ST Tonga Green
...see also the condition of ECU ground ring terminal. Try to clean it with a contact cleaner. Because the temperature gauge behavior is not main relay related, it's a earth issue.


Glad you liked Lisboa. We have some dedicated fans here. Thumbs Up
Post #577172 11th Nov 2016 6:41pm
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AndyT66



Member Since: 19 Sep 2016
Location: Bedford
Posts: 148

England 2004 Defender 90 2.5 TD XS CSW Zambezi Silver
A rather belated update, the starting problem did stem from the main relay, a quick flick of the relay with my finger activated the fuel pump and coil light. Thanks all. Picture of offending relay under screwdriver. Very Happy

Click image to enlarge
Post #584208 11th Dec 2016 7:36pm
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jst



Member Since: 14 Jan 2008
Location: Taunton
Posts: 7664

2011 Defender 110 Puma 2.4 USW Stornoway Grey
great its sorted and even better you responded to say what the issue was, top man. Cheers

James
110 XS Utility
130 Puma Station wagon/camper (in the making)
90 Puma Hardtop
Post #584209 11th Dec 2016 7:45pm
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