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steve_c3



Member Since: 30 Apr 2015
Location: Hants
Posts: 171

United Kingdom 2002 Defender 110 Td5 SW Epsom Green
Another Engine Cutting Out!
Hi All,

I'm having a few issues with my 110 and I'm hoping someone may be able to offer some advice to help cure it - or if my hopeful cures work then it may help someone else so I'll keep you updated with progress.

The problem:
The engine will fire up from cold after its initial purge cycle.
I can then drive it until it gets hot and for no apparent reason - in the space of about 60 seconds - it will begin to lose power until there is nothing left and then all goes calmly silent leaving me coasting down the road (or motorway) with which can be a little hairy! I can sometimes keep it running a little longer by pushing the accelerator down further but if it happens coming down to a junction then its game over and won't pick back up again.
After doing a few purges and a lot of cranking it will eventually fire back up again, drives for another 10mins and does the same again.

Having done some checks, there was the dreaded oil in the red plug - I changed this a few years back but has done the same again. The injector loom has now been changed and the ECU checked for oil ingress and all clear.

Its had a Stage 1 remap on it for years and has been fine until recently.
The fuel pump is noisy and has been getting worse (whines...a lot) so the injectors are my next port of call followed by the pump itself.
Having done some research on the forum, I'm also going to change the Yellow Fuel relay.
Fingers crossed one of these cures it.

I've had the ECU fault codes read and its thrown up the following codes so if anyone has any other ideas...all thoughts would be greatly appreciated!


Click image to enlarge
 2002 Defender 110 CSW TD5
Post #961133 9th Aug 2022 3:00pm
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geobloke



Member Since: 06 Nov 2012
Location: Nottinghamshire
Posts: 4350

United Kingdom 
99% your ECU has come to the end of its life I am afraid. The only solution is a second hand item or send yours away to be reconditioned.

However... Before you do that it would be a good idea to go around the entire vehicle, clean up the earth points and keep your fingers crossed. It is unlikely to be that, but you never know.

The underboost is because your injectors are not firing so ignore that one and if you have a defender you do not have a waste gate modulator.

Hope that helps.
Post #961141 9th Aug 2022 4:11pm
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Mdm



Member Since: 11 Sep 2013
Location: Sunny Lancashire
Posts: 1509

United Kingdom 
as above failing ecu most likely but check for wiring issues 1st and pedal to ecu wiring..

you can get the ecu repaired or get a disco td5 one reprogrammed to defender spec.
Post #961177 9th Aug 2022 8:10pm
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andylee



Member Since: 29 Jun 2016
Location: South East
Posts: 78

United Kingdom 
Things also worth checking,
- Intercooler boost hoses for splits and cracks
- Fuel filter - Just replace in case blocked or faulty. this has happened to me and caused engine stuttering and loss of power due to using poor quality diesel.
- Fuel pressure regulator for leaks and fuel pressure
- Fuel pump could be on its way out. Mine got very noisy before stopping completely.

Hopefully not your ECU but you could send it to someone like Alive Tuning and they could definitively answer that for you.

Good luck
Post #961366 11th Aug 2022 6:33pm
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andy2111



Member Since: 17 Oct 2021
Location: Kent
Posts: 365

United Kingdom 2002 Defender 110 Td5 HT Bonatti Grey
I'm currently on holiday in the Pyrenees and have the dreaded fuel pump/relay/ECU problem which has plagued me intermittently for a couple of years.

New fuel pump fitted 2 weeks ago before we left, new fuel pump relay fitted and earth's checked. No obvious issues or fault codes in the ECU.

In the last week I've already had several instances of the fuel pump not running when switching the ignition on, either from cold or hot after stopping at services. I also occasionally suffer from the power loss above 2000 rpm where you can keep driving but you just limp along.

The fix is always to stop, get into the seat box, push on the relay (even though I've ensured it is secure a hundred times) and then it almost always fires up the fuel pump and off I go. Until yesterday...

Went to leave the campsite, pump didn't fire up with the ignition so I did my relay push ritual but it didn't work. Refitted the relay, tried a spare, checked the wiring to the relay, but no joy.

Got to the point of thinking I'd have to use my breakdown insurance and decided to check the fuses (MY 2002 so fuses in seat box). Third fuse from the top (30A) is one of a couple that have an engine symbol next to it.. I removed it and it was fine and as soon as I pushed it back in I heard the fuel pump fire!

Never had to do this before... and now I have one more variable to confuse me in figuring out how to fix this permanently.... Any thoughts or suggestions?

Might be helpful to others to try the fuse if you ever get stranded with no other options!
Post #961505 13th Aug 2022 8:50am
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Screbble



Member Since: 26 Apr 2015
Location: Lancashire
Posts: 1994

United Kingdom 2004 Defender 90 Td5 XS CSW Zambezi Silver
Good to know and glad you’re back up and running.

I had an unrelated issue with relays and fuses and found that giving all connections a squirt of switch cleaner and cable-tying the relays into their bases cured it.

I’ve just realised that by talking/writing about it I’ve now probably jinxed it! Rolling with laughter
Post #961558 13th Aug 2022 5:34pm
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lightning



Member Since: 23 Apr 2009
Location: High Peak, Derbyshire
Posts: 2159

United Kingdom 
l had a similar issue and it was the earth to the seat box. My local
LR specialist told me to drill a hole in the lower outer corner of the seat box and insert a self tapping screw in the hole.

This seemed a bit absurd but the fault never recurred. I've since run an earth strap to the seat box but it took me a few months to get around to doing it, because the fault had disappeared.



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Post #961690 15th Aug 2022 9:16am
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steve_c3



Member Since: 30 Apr 2015
Location: Hants
Posts: 171

United Kingdom 2002 Defender 110 Td5 SW Epsom Green
UPDATE: Success!
Fingers crossed she is now running like a dream again. I've yet to do some repeated long runs but a 30mile shakedown and a few local trips and all looks well. She starts instantly again, pulls well and crucially keeps running. It took some trial and error but one or all of the following solved it - I'm thinking it was was either the Injector seals or fuel pump that were the root cause but its all preventative for any future issues anyway:

New injector harness
Cleaned Red Plug
Checked ECU for oil ingress (none present)
New crank position sensor
New Fuel pump (this was whining terribly)
New injector seals
Swapped fuel relay with a known working one.

Thanks to all for your help on this...the wiring in the engine bay was also checked and nothing was found but whether it was disturbed while fitting the new parts which is what has temporarily solved it is yet to be seen! I did also read an article about a chap that found part of the wiring loom had rubbed through somewhere near the bulkhead so for anyone still having issues - its worth checking this too! 2002 Defender 110 CSW TD5
Post #962601 23rd Aug 2022 9:06am
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Screbble



Member Since: 26 Apr 2015
Location: Lancashire
Posts: 1994

United Kingdom 2004 Defender 90 Td5 XS CSW Zambezi Silver
Good news Thumbs Up
Post #962738 24th Aug 2022 11:47am
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