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BaronDefenders

Member Since: 28 Jun 2019
Location: London/Cotswolds
Posts: 917

2004 Defender 90 Td5 CSW Santorini Black

geobloke wrote:
At the very least it is worth opening up the cover just to see where the singeing originated. I had to replace all the yellow relays in Miffy. The contacts within the relays had badly eroded over time. Caused the overheating and blackening, plus some irritating running issues.

I did pull it apart, but there wasn’t anything too obvious. Perhaps a little bit of discolouration from heat.

I’ve replaced the battery as well, as it had completely died. It wasn’t holding its charge for long at all. Possibly a contributing factor.

Camelman, no oil in the plugs. However, I have changed the harness in the last couple of years as a service item. A very easy job indeed! I know there’s now an aftermarket harness on the market that is supposedly a fit and forget item. Charlie

1949 Series 1 80 (SOLD)
2002 Td5 90 (SOLD)
2008 Freelander 2 (SOLD)

1958 Series 2 88 Pastel Green (2019 LR Legends Best Restored)
1983 V8 110 Limestone (Previously owned by Tom Sheppard MBE)
2004 Td5 90 Santorini Black (Td5INSIDE Powered & Rebuilt by CSK)
2012 Puma 110 Zermatt Silver (Overlanding Build)

Instagram: @BaronDefenders

30th Nov 2022 5:43pm

Procta

Member Since: 04 Dec 2016
Location: Sunderland
Posts: 5274

I am starting to suspect my in tank pump is failing, After todays test. Would yours not pick up after 40 mph? mine will not go over 40 mph, its starts to struggle, and wants me to change down, and starts to idle a little rough. Defender TD5 90 ---/--- Peugeot 306 HDI hatch back

In the words of my Good Friend, Gary Forrest 1980 -2025
" we will work something out"

12th Dec 2022 9:09pm

BaronDefenders

Member Since: 28 Jun 2019
Location: London/Cotswolds
Posts: 917

Mine was fine to 2,500rpm and then spluttered. Now that the relay has been replaced, the pump makes a strong noise and performance is fine. Charlie

1949 Series 1 80 (SOLD)
2002 Td5 90 (SOLD)
2008 Freelander 2 (SOLD)

1958 Series 2 88 Pastel Green (2019 LR Legends Best Restored)
1983 V8 110 Limestone (Previously owned by Tom Sheppard MBE)
2004 Td5 90 Santorini Black (Td5INSIDE Powered & Rebuilt by CSK)
2012 Puma 110 Zermatt Silver (Overlanding Build)

Instagram: @BaronDefenders

12th Dec 2022 9:59pm

Procta

Member Since: 04 Dec 2016
Location: Sunderland
Posts: 5274

where is the fuel relay located? something i can check tomorrow.

Defender TD5 90 ---/--- Peugeot 306 HDI hatch back

In the words of my Good Friend, Gary Forrest 1980 -2025
" we will work something out"

12th Dec 2022 10:06pm

htb2

Member Since: 02 Nov 2018
Location: Carmarthenshire
Posts: 546

Under the drivers seat, nearest the transmission at the rear are two yellow relays, one of them is the fuel pump relay. On mine its the rearmost one,

12th Dec 2022 10:17pm

Procta

Member Since: 04 Dec 2016
Location: Sunderland
Posts: 5274

Defender TD5 90 ---/--- Peugeot 306 HDI hatch back

In the words of my Good Friend, Gary Forrest 1980 -2025
" we will work something out"

12th Dec 2022 10:37pm

BaronDefenders

Member Since: 28 Jun 2019
Location: London/Cotswolds
Posts: 917

If you count 1 to 3, 1 being towards the rear - that’s the fuel pump relay. Charlie

1949 Series 1 80 (SOLD)
2002 Td5 90 (SOLD)
2008 Freelander 2 (SOLD)

1958 Series 2 88 Pastel Green (2019 LR Legends Best Restored)
1983 V8 110 Limestone (Previously owned by Tom Sheppard MBE)
2004 Td5 90 Santorini Black (Td5INSIDE Powered & Rebuilt by CSK)
2012 Puma 110 Zermatt Silver (Overlanding Build)

Instagram: @BaronDefenders

12th Dec 2022 11:13pm

Procta

Member Since: 04 Dec 2016
Location: Sunderland
Posts: 5274

i will also check the crank sensor connector and sensor tomorrow too, in case that's causing trouble too. Defender TD5 90 ---/--- Peugeot 306 HDI hatch back

In the words of my Good Friend, Gary Forrest 1980 -2025
" we will work something out"

13th Dec 2022 1:00am

andy2111

Member Since: 17 Oct 2021
Location: Kent
Posts: 368

You need to be careful because with old trucks it is quite possible that the relays have been moved about and are not in the correct position.

Had that problem on my truck and I read similar on here too.... TD5 hardtop to Puma inspired Poptop - my build thread

2002 110 TD5 Hardtop ¦ Full Puma interior ¦ Carpathian grey / Santorini black ¦ X-Vision-X poptop

13th Dec 2022 9:23am

Martin
Site Admin

Member Since: 02 Apr 2007
Location: Hook Norton
Posts: 6662

2015 Defender 90 Puma 2.2 XS CSW Montalcino Red

Best to ID the Td5 fuel pump relay from the wire colours:

White/Purple
Purple/White
Brown/Orange
Blue/Purple

In descending wire size order.

1988 90 Td5 NAS soft top

2015 D90 XS SW

13th Dec 2022 1:02pm

TexasRover

Member Since: 24 Nov 2022
Location: Paris
Posts: 1233

2002 Defender 110 Td5 DCPU Chawton White

Fuel pump relay must the weakest point in any car. I have had Volvo's, Mercedes, BMW, Porche, etc all suffer from burned out relays, typically at a parking lot. They obviously carry a lot of load, but you would think they could make them solid state! At least the Td5 it is just an ordinary relay so cheap to replace even preventative, say every few years.

However looking at your socket, you might want to gently remove the terminals one by one (battery disconnected of course) and clean them up and tighten them up a little. Then the new relay will seat properly and you don't start building up heat and burning up the new relay with a poor connection.

You should also watch a few of these Vice Grip Garage Video's, its amazing what can be fixed on the side of the road. It ain't dead till you tried everything. I have dismantled carburetors on the side of the road. The only time I called in the tow truck what when the clutch (hard pipe) failed on my S3, I could have driven it home without a clutch, but it was not worth damaging the gearbox (and the recovery was free..)

13th Dec 2022 2:22pm

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