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Grannville

Member Since: 12 Nov 2016
Location: Isle of Skye
Posts: 28

TD5 Cuts out, long story warning.

Hi Guys

I'll cut to the chase.

I have 2006 TD5 110

I use it quite alot but not everyday to set the scene.

I was returning from a job - engine cold but not stone cold and while driving I felt the engine misfire, it repeated this a couple of times and then ran fine. I made it home 30 miles or so.

The next day I went to set out and after 5 mins of driving (engine warmed up for 10 minutes before leaving) it cut out and restarted on the key, cut again and I turned back home. Drained the fuel tap from the filter - some water nothing crazy - im on the isle of skye so.... all buckled back up pump prime sequence, engine started and backfired once and then ran fine for 2 hours of driving, I did some work for a few hours, cold engine started fine, drove back home.

The day after it was snowing so I though oh no! (brilliant) jumped in Django and set off, got about 20 mins in and the engine strutter and a started to lose power until it finally cut out again, quick road side fuel filter drain and pump priming sequence, retarted and i finished my journey.

Changed the fuel filter and cut the old one up - not too bad. now the engine will only backfire on starting i.e its injecting at the round time sort of sound diesel snapping. if the pump is primed once or twice the engine runs ok occasionally giving a little backfire but more often than not runs ok when warmed up. certainly will not entertain running cold.

I have so far changed the

fuel filter (twice - genuine)
filter housing as the air bleed valve was blocked
regulator assembly on the head including cleaning the last chance filter - running at 4.5 bar before and 4 bar now
all injectors - recoded correctly using test book
I have inspected the quality of the fuel to the rail using an optical block. No air after running and no huge amount of air just before misfire etc.
Tank pump sounds fine and is delivering good pressure despite being alittle loud now the regulator is reduction the free pressure.
The ecu is not long back from a ECU testing repair job - none start no fuel pump prime issue
Ive change the fuel rail wiring harness in the head,
no oil in sockets etc.

getting a bit sick of it now as you might imagine.

I have some fault codes which clear down fine and reappear with a backfire stall of the engine here they are:

FAULT 27-04 injector 4 peak charge long (CURRENT)

FAULT 27-05 injector 5 peak charge long (CURRENT)

FAULT 28-01 injector 1 peak charge short (CURRENT)

FAULT 28-02 injector 2 peak charge short (CURRENT)

FAULT 28-03 injector 3 peak charge short (CURRENT)

FAULT 28-04 injector 4 peak charge short (CURRENT)

FAULT 28-05 injector 5 peak charge short (CURRENT)

FAULT 31-01 injector 1 open circuit (CURRENT)

FAULT 31-02 injector 2 open circuit (CURRENT)

FAULT 31-03 injector 3 open circuit (CURRENT)

FAULT 31-04 injector 4 open circuit (CURRENT)

FAULT 31-05 injector 5 open circuit (CURRENT)

BOTTOMSIDE CURRENT TRIP LOGGED - Cannot find any info on this one

Any ideas before I dig a hole a bury it?

Suspect ECU however very strange it seems to run ok when warm, ive given the wiring harness a good pull tug and havent discovered anything as of yet.

All opinions welcomed!

15th Mar 2020 1:10pm

dorsetsmith

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

1. you say that your ecu back for repair have you check injector code on each injector matches the codes in the ecu program ?

Click image to enlarge

2.check all long your engine loom from ECU to injectors for damaged i.e. rubbing against metal work also open cct wiring in same loom

Click image to enlarge

Last edited by dorsetsmith on 15th Mar 2020 4:00pm. Edited 2 times in total

15th Mar 2020 3:22pm

Adammacky

Member Since: 28 Dec 2019
Location: West Midlands
Posts: 309

This sounds very similar to what happened to me last week, it was the crankshaft position sensor and also the harness too, garage replaced them both and the problem is fixed now, but similar symptoms, engine stuttering and then losing power before eventually cutting out.

Good luck anyway

15th Mar 2020 3:44pm

lightning

Member Since: 23 Apr 2009
Location: High Peak, Derbyshire
Posts: 2225

I was going to say crankshaft position sensor as well.
Try a new one.

15th Mar 2020 7:19pm

HansT

Member Since: 25 Dec 2012
Location: Mariefred
Posts: 173

I had a similar problem several years ago. Ended up to be the ECU. These were the fault codes.

(10,1) AIR CONDITIONING FAN DRIVE OPEN LOAD, (LOGGED)
(10,4) GEARBOX / ABS DRIVE OPEN LOAD, (LOGGED).
(10,5) AIR CONDITIONING CLUTCH DRIVE OPEN LOA D, (LOGGED).
(14,1) AIR CONDITIONING FAN DRIVE OPEN LOAD, (CURRENT)
(14,4) GEARBOX / ABS DRIVE OPEN LOAD, (CURRENT).
(14,5) AIR CONDITIONING CLUTCH DRIVE OPEN LOAD, (CURRENT).
(15,2) HIGH SPEED CRANK (LOGGED).
(27,1) INJECTOR 1 PEAK CHARGE LONG, (LOGGED).
(27,2) INJECTOR 2 PEAK CHARGE LONG, (LOGGED).
(27,3) INJECTOR 3 PEAK CHARGE LONG, (LOGGED).
(27,4) INJECTOR 4 PEAK CHARGE LONG, (LOGGED).
(27,5) INJECTOR 5 PEAK CHARGE LONG, (LOGGED).
(28,7) TOPSIDE SWITCH FAILED PRE INJECTION, (LOGGED).
(31,1) INJECTOR 1 OPEN CIRCUIT DETECTED, (LOGGED).
(31,2) INJECTOR 2 OPEN CIRCUIT DETECTED, (LOGGED).
(31,3) INJECTOR 3 OPEN CIRCUIT DETECTED, (LOGGED).
(31,4) INJECTOR 4 OPEN CIRCUIT DETECTED, (LOGGED).
(31,5) INJECTOR 5 OPEN CIRCUIT DETECTED, (LOGGED).

Full story at
https://www.defender2.net/forum/topic22280-105.html

Good luck! /Hans

16th Mar 2020 10:19pm

MadTom

Member Since: 10 Sep 2013
Location: Olomouc
Posts: 572

(28,7) TOPSIDE SWITCH FAILED PRE INJECTION, (LOGGED) - this is problem

(15,2) HIGH SPEED CRANK (LOGGED).
(27,1) INJECTOR 1 PEAK CHARGE LONG, (LOGGED).
(27,2) INJECTOR 2 PEAK CHARGE LONG, (LOGGED).
(27,3) INJECTOR 3 PEAK CHARGE LONG, (LOGGED).
(27,4) INJECTOR 4 PEAK CHARGE LONG, (LOGGED).
(27,5) INJECTOR 5 PEAK CHARGE LONG, (LOGGED). - this are results of the first problem

(31,1) INJECTOR 1 OPEN CIRCUIT DETECTED, (LOGGED).
(31,2) INJECTOR 2 OPEN CIRCUIT DETECTED, (LOGGED).
(31,3) INJECTOR 3 OPEN CIRCUIT DETECTED, (LOGGED).
(31,4) INJECTOR 4 OPEN CIRCUIT DETECTED, (LOGGED).
(31,5) INJECTOR 5 OPEN CIRCUIT DETECTED, (LOGGED). - not a big problem, typically after starting engine with disconnected injectors or injectors loom

(10,1) AIR CONDITIONING FAN DRIVE OPEN LOAD, (LOGGED)
(10,4) GEARBOX / ABS DRIVE OPEN LOAD, (LOGGED).
(10,5) AIR CONDITIONING CLUTCH DRIVE OPEN LOA D, (LOGGED).
(14,1) AIR CONDITIONING FAN DRIVE OPEN LOAD, (CURRENT)
(14,4) GEARBOX / ABS DRIVE OPEN LOAD, (CURRENT).
(14,5) AIR CONDITIONING CLUTCH DRIVE OPEN LOAD, (CURRENT). - just some non-existing things in car (A/C, ABS, electric fan) "Drobek" = The Small One - Discovery 2, "Blufínek" = The Blue Thing - Defender 130, and for me at least Ford Mondeo

17th Mar 2020 10:14am

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