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Cooperracer05



Member Since: 07 Nov 2020
Location: Sussex
Posts: 90

2003 Defender 110 2.5 TD SW Java Black
true...the issue with hypothesising and not just getting greasy!

Can't hurt to take it off, clean it, inspect and purge as it is a 'freebee'...before I spend on new housing, new MAF (which I need anyway), new seals (which I hopefully dont need but might have to bite the bullet...

Ill clean the contacts on the relays too....
Post #974434 12th Dec 2022 5:33pm
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geobloke



Member Since: 06 Nov 2012
Location: Nottinghamshire
Posts: 4392

United Kingdom 
Perfectly happy to hypothsise Thumbs Up It is how we figure out these little irksome problems after all...

When you buy your MAF do not buy anything other than a VDO unit. It is not worth the effort with any other brands. BAS is a good place to get them at sensible money or Eurocarparts if they have an offer on.
Post #974439 12th Dec 2022 5:46pm
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Cooperracer05



Member Since: 07 Nov 2020
Location: Sussex
Posts: 90

2003 Defender 110 2.5 TD SW Java Black
yeh at this point the money hole is so deep that any non OEM spec bits would be unkind!

Thanks for the help indeed - I guess if I spend too long thinking about it I can go round in circles, better at some point to just get into it and try and sort....going to also charge the battery with a mains charger and then see
Post #974440 12th Dec 2022 5:48pm
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geobloke



Member Since: 06 Nov 2012
Location: Nottinghamshire
Posts: 4392

United Kingdom 
It just occurred to me whilst sipping my coffee (still too hot)... I never asked, how fast is the engine turning over?

As fast as in August? Just wondering whether it is worth sticking the battery on charge overnight then trying it in the morning. Or stick some jump leads on to another vehicle and see if that helps. Could be as silly as just not enough CCA in the battery to spin the engine fast enough. New battery or not, they hate the cold.
Post #974504 13th Dec 2022 10:12am
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Cooperracer05



Member Since: 07 Nov 2020
Location: Sussex
Posts: 90

2003 Defender 110 2.5 TD SW Java Black
I did think of this and I also out a new (big) battery in the car recently... although it could be down to earth strap, bad starter, or volts dropping slightly....I will pop it on charge over night just to be sure. It seems to be cranking fine / fast....just taking longer and longer to start

I cleaned all the relays, they all look good. Looked at all the wires into the relay blocks too...
Post #974505 13th Dec 2022 10:22am
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geobloke



Member Since: 06 Nov 2012
Location: Nottinghamshire
Posts: 4392

United Kingdom 
Great, keep ticking off the potentials and it is inevitable you will find the cause sooner or later Thumbs Up
Post #974507 13th Dec 2022 10:33am
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Cooperracer05



Member Since: 07 Nov 2020
Location: Sussex
Posts: 90

2003 Defender 110 2.5 TD SW Java Black
Just went back out and had a peak at the fuel filter housing and noticed definitely some diesel leaking....i thought I'd sorted it and actually the car started better yesterday after being left for 6+ hours. After a full night and more like 16 hours it was a pig to start....what is odd is the purge sequence hasn't in the past made any difference which is odd...but I have read it can need 6x cycles to clear the air. Maybe I just hadnt done enough to actually clear the air out so was getting a false negative.

Anyway, I'll strip the filter head off and clean it all and inspect and if it looks past it I'll get the GORE one.
Post #974521 13th Dec 2022 11:24am
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geobloke



Member Since: 06 Nov 2012
Location: Nottinghamshire
Posts: 4392

United Kingdom 
If the filter head looks in serviceable condition may I suggest that when fitting the brass outlet/inlet ports you assemble with the copper washers, but also a slight smear of gasket sealer on the washers as a belts and braces approach. It will effectively mimic a dowty washer - like this - https://uk.rs-online.com/web/p/washers/068...lsrc=aw.ds
Post #974524 13th Dec 2022 11:31am
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Cooperracer05



Member Since: 07 Nov 2020
Location: Sussex
Posts: 90

2003 Defender 110 2.5 TD SW Java Black
Nice idea, yep I have some of this liquid gasket stuff already....

So today I removed the fuel filter and the connectors and put it all back together but same issue....seems I have 2x leaks, 1x from the connectors, and 1x from the plastic screw on plug on the bottom of the filter....
Post #974579 13th Dec 2022 7:10pm
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rallysteve



Member Since: 10 Feb 2014
Location: Cumbria
Posts: 2196

United Kingdom 2002 Defender 110 Td5 DCPU Keswick Green
Just bear in mind with the Gore one (which is a great quality product which i also have) that it doesnt come with the copper washers or pipe unions. Not an issue if your old fittings are in good condition but can be expensive if you have to replace all of them.

I recall it is cheaper to buy 4x of the 'air bleed' fittings and just remove the insert from three of them to use.

Cheers
Steve 02' 110 TD5 Double Cab Rebuild Thread
84' 90 3.9 V8 Caged Pickup Build Thread - Now For Sale


Mobile Diesel Heater Build Thread
Post #974582 13th Dec 2022 7:54pm
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Cooperracer05



Member Since: 07 Nov 2020
Location: Sussex
Posts: 90

2003 Defender 110 2.5 TD SW Java Black
OK...so making some progress...

I took the filter housing off along with all the connectors and gave it all a good clean up with degreaser.

I also very gently (on a flat surface) rubbed the housing mating surfaces up against some 400 grit.

What I can now see (due to a very shiny metal surface) is the housing is getting extremely thin and in some places looks to have corroded away almost, where the face would meet the copper washer....preventing a good seal.

I tried to buy the GORE housing however it is out of stock so I may go for the old pig iron one. My car is a bit of a princess and I can cover it in protective lanoguard grease to extend its life, so I am sure will give me plenty of value, however before I buy that, is there an alternative provider of these upgrade housings?

I did email GORE and ask when they are coming back in...no reply yet.
Post #974652 14th Dec 2022 3:22pm
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Cooperracer05



Member Since: 07 Nov 2020
Location: Sussex
Posts: 90

2003 Defender 110 2.5 TD SW Java Black
Woohoo GORE had them in stock:

https://goreproducts.com/products/td5-fuel-filter-housing

Planning on using the existing connectors,.new washers, new filter and new water sensor plug

I'm in pretty deep now:

£48 air bleed valve
£115 fuel filter housing
£40 new filter and plug
£100 new battery

Really hoping this sorts it as the wife had 'the chat' with me today and said she really thinks I should sell it and get a boring functioning German euro box like a Golf...pray for me!
Post #974685 14th Dec 2022 8:49pm
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markb110



Member Since: 22 May 2010
Location: Guildford
Posts: 2520

England 2002 Defender 90 Td5 HT Epsom Green
Well done. I fitted the Gore housing last year.

Only shame is that it’s a piece of art that’s hidden away. Very Happy
Post #974726 15th Dec 2022 10:12am
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TexasRover



Member Since: 24 Nov 2022
Location: Paris
Posts: 790

France 2002 Defender 110 Td5 DCPU Chawton White
The wife needs to understand that a Eurobox:

-is not free of maintenance cost, with some being expensive and frankly annoying (tire pressure monitoring etc)
-Suffers catastrophic depreciation
-Turns her husband into a sulking mister invisible at the Tesco Parking

I live in France: the misery of the French and their cars is something to behold.
Post #974754 15th Dec 2022 1:51pm
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Cooperracer05



Member Since: 07 Nov 2020
Location: Sussex
Posts: 90

2003 Defender 110 2.5 TD SW Java Black
markb110 wrote:
Well done. I fitted the Gore housing last year.

Only shame is that it’s a piece of art that’s hidden away. Very Happy


It is a bit like lingerie....as long as we know it is under there, that is enough!
Post #974835 16th Dec 2022 10:28am
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