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Green Machine

Member Since: 19 Nov 2010
Location: North Yorkshire
Posts: 1226

2005 Td5 Intermittent starting issue (suspect electrical)

Hi all,

Having been almost completely reliable for the 13 years I've owned it, my Td5 90 has just begun to not start. First did it one morning a few days ago - turned the key, waited for glow plug lamp to go out, turned to starting position and instead of just catching immediately (which it always has) it cranked several times and then started.

It then started perfectly normally for a few days (started immediately - no hesitation). Then a couple of days ago did the same thing again where it cranked a few times before starting, and then the next start following this it just wouldn't start - just cranking continuously with no attempt to start. Tried 3 or 4 times in fairly quick succession (left it a minute or two in between attempts) but just did the same thing - cracking but no attempt to start.

So called out the AA, waited 2 hrs for them to arrive. The lad jumped out of his van, into the Land Rover and it started on the button (of course!). He suggested putting a new fuel filter on it.

So took it to my local mechanic, who thought it didn't sound like a fuel issue (running absolutely perfectly once started - no hesitation / coughing etc.) but took the fuel filter off and said it was clean - no water or gunk / dirt. Put a new filter on anyway as I had one in stock. He started it up a few times and it started perfectly each time. Also checked the wiring loom at the ECU end which was totally clean and dry - no signs of oil.

Just been to collect it from his place and it wouldn't start again when I got in it. What I have noticed is that on the occasions it won't start, the 'engine management' (yellow engine block) light doesn't illuminate on first ignition, which I guess indicates some sort of electrical / relay issue? Also seems that the glow plug lamp doesn't illuminate (although not certain on that as could be already at temperature).

So does anyone have any suggestions before I call out an auto electrician / diagnostics expert? Can someone point me in the direction of the relay(s) involved in starting?

Many thanks in advance,

Tris. 2005 Td5 | 90 Station Wagon | Tonga Green

2nd Jul 2023 12:07pm

TexasRover

Member Since: 24 Nov 2022
Location: Paris
Posts: 1034

2002 Defender 110 Td5 DCPU Chawton White

Or the relay powering the ECU? Is there not one for that?

2nd Jul 2023 12:52pm

Linds Hanson

Member Since: 16 Jan 2021
Location: Cornwall
Posts: 484

Thats your ECU load relay its under the drivers seat makes sure the connector block isnt corroaded and all the female spade connectors in the block are a tight fit on the relay. Swap the relay with one of the other less essential relays.

2nd Jul 2023 2:02pm

Green Machine

Member Since: 19 Nov 2010
Location: North Yorkshire
Posts: 1226

So the problem has now evolved ... it is now starting OK (fire's up immediately once glow plug lamp has extinguished, as normal) but then coughs or cuts out. I noticed that when it coughs / stutters, the yellow 'engine management' light flashes up. It has once coughed and then continued running as normal, next start-up it actually cut out and had to be restarted.

I'm guessing that the coughing / cutting out is fuel starvation?

I'm also guessing that as it starts and runs it's not the ECU (as presumably if the ECU was dead, it just wouldn't run). 2005 Td5 | 90 Station Wagon | Tonga Green

13th Jul 2023 12:32pm

Green Machine

Member Since: 19 Nov 2010
Location: North Yorkshire
Posts: 1226

Just by way of conclusion to this - I contacted the local LR specialist where I used to live in North Yorkshire (DPG Defenders in Kirkbymoorside), who I had previously used for all servicing etc. for several years. He advised that the relays under the driver's seat were the most likely culprit, and it sounded like the main relay.

I purchase a set of 3 new relays online (thought I might as well just swap all of them for new) so that's the main relay, fuel pump relay and glow plugs relay, which seems to have solved the problem. I have run it now for a couple of weeks since swapping the relays and have had no further issues with starting / cutting out.

When I took the old relays out, I prized the plastic covers off and had a look inside. Sure enough, there was significant wear / pitting to the contacts on all of them and one in particular (which I suspect was the main relay - I should have kept better track of which one was which!).

Anyway, if anyone has a similar issue, replacing the relays appears to have worked for me. Dunstan at DPG said that the relays on Td5s should really be considered a service item - they usually need replacing after 10 years and will eventually cause issues. 2005 Td5 | 90 Station Wagon | Tonga Green

18th Aug 2023 9:31am

geobloke

Member Since: 06 Nov 2012
Location: Nottinghamshire
Posts: 4410

Excellent

Sorry I did not see your original post I probably could have saved you much effort as I have documented the degraded relay issue in the Workshop adventures of Miffy thread.

Hope you have many more happy miles

18th Aug 2023 10:20am

Green Machine

Member Since: 19 Nov 2010
Location: North Yorkshire
Posts: 1226

@geobloke - thanks, I actually found your thread during my research and found it very useful - it confirmed what the LR Specialist was advising and also gave me some images to understand / compare against. My relays were in a very similar state! 2005 Td5 | 90 Station Wagon | Tonga Green

18th Aug 2023 10:24am

geobloke

Member Since: 06 Nov 2012
Location: Nottinghamshire
Posts: 4410

Marvellous

That is the whole point of documenting the maintenance process

18th Aug 2023 10:29am

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