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Cactus79

Member Since: 09 Jan 2017
Location: Cheshire
Posts: 51

New Owner and first breakdown :D

New here so howdy

Have come across from the Disco 3 as the wife always wanted a Defender

Recently bought a 03 HT TD5 with low miles. Drove it all the way home from Scotland 2 weeks ago and it never missed a beat.

Got the dreaded call today from the wife to say plumes of smoke coming from the exhaust. Went and picked her up as she was just down the road.

Engine miss firing, stinging eyes smoke, turbo sounds alright. Have removed red plug and quite abit of oil (should have removed the plug when i checked it over at the weekend but hey ho) bother on the ECU and plug.

Did try cleaning up with brake cleaner and starting car again but it continued to miss. Have pulled the ECU and it's on the radiator upside down to drain.

When replacing the injector harness do they replace the engine loom (red plug) as well? is the fault / miss caused by the injector loom or oil on the contacts at the ecu end?

Replacing the engine loom easy enough job? Injector loom looks easy enough and if i'm doing that i'll do the injector seals at the same time.

Thanks

20th Jan 2017 7:26pm

grafty99

Member Since: 15 Aug 2012
Location: North Devon
Posts: 4788

Welcome

Have you checked all of the fluid levels?

Is the coolant still at the mark?

Has the oil level risen?

These should help diagnose but changing the injector harness and seals is a good thing to do regardless if the vehicle is new to you

2002 90 Td5 Station Wagon
1990 Vogue SE
Triumph Tiger Explorer 1200
Td5 90 Thread http://www.defender2.net/forum/topic50767.html
Tdi 110 Thread https://www.defender2.net/forum/topic69562.html
RRC Thread http://www.defender2.net/forum/topic54492.html
Instagram http://www.instagram.com/george_grafton

20th Jan 2017 7:34pm

mini Anaconda

Member Since: 23 Aug 2016
Location: Thames Valley
Posts: 794

Welcome!

If it makes you feel any better, I also broke down today!

20th Jan 2017 7:39pm

Mdm

Member Since: 11 Sep 2013
Location: Sunny Lancashire
Posts: 1631

new realtionships are often tricky if there is an old landrover involved.

i wouldnt bother swaping the loom until you have found the main fault.

take it to a good 4x4 independant garage for diagnosis. they can guide you to any secondary jobs such as the loom and proactive servicing.

20th Jan 2017 7:58pm

lightning

Member Since: 23 Apr 2009
Location: High Peak, Derbyshire
Posts: 2880

If there's oil at the ECU then you can change the injector harness, it's an easy job that can be done in half an hour. After you do that it might be OK.

Our 2003 90 started misfiring and changing the harness cured it. No white smoke though.

After you change the harness, it will take a while for the oil to stop coming through to the ECU. Remove the rubber seal from the red plug so the oil drips out rather than seeping into the ECU.

Check the coolant level and oil level. Although being a 2003 l think the head gasket is less likely to fail.

20th Jan 2017 11:47pm

Vogler

Member Since: 02 Nov 2014
Location: Brussels
Posts: 309

Here's an excellent guide to replacing the loom:
http://www.discovery2.co.uk/Injector_harness.html

It's actually only the part in the engine that needs replacing, the rest remains untouched. So after you have done this, you'll need to clean the plug a couple of times until most of the oil that remained in the rest of the loom, has disappeared. In severe cases the oil found its way onto the circuit board and into the ecu housing. You can unscrew the lid and check the inside.

There likely are other possible causes too..

Greetings,

Joris

21st Jan 2017 3:10am

Cactus79

Member Since: 09 Jan 2017
Location: Cheshire
Posts: 51

Morning,

Oil levels seem to be all over the place. Checked this morning and level is slightly higher than last night and probably does have a wiff of diesel.

Anyone have an Injector removal tool near Cheshire?

21st Jan 2017 8:37am

rallysteve

Member Since: 10 Feb 2014
Location: Cumbria
Posts: 2237

2002 Defender 110 Td5 DCPU Keswick Green

Dont need the tool. A longish 5mm allen key or small heel bar does the job perfectly with no damage. Have done it on 20 injectors and has worked perfectly

Steve 02' 110 TD5 Double Cab Rebuild Thread

21st Jan 2017 8:50am

grafty99

Member Since: 15 Aug 2012
Location: North Devon
Posts: 4788

Any rise in oil level is likley to be injector seals or worse the dreaded cracked head (usually around injector one)

Another "tool" that works well is half a pair of plummers grips

Get genuine injector seals and a loom (do sent need to be gen). Have a look before removing your rocker cover as it may be worth changing the rocker cover gasket whilst you're in there

21st Jan 2017 10:31am

Cactus79

Member Since: 09 Jan 2017
Location: Cheshire
Posts: 51

Managed to get the injectors up with a long 5mm allen key, works very well actually.

Thought we had found the fault after pulling the first injector

Click image to enlarge

New LR seals in, new loom, new rocker cover gasket and still the same unfortunately.

So onto FPR, or dead injector? Probably need Nanocom or Hawkeye to progress.

Anyone any other thoughts?

Thanks

21st Jan 2017 4:33pm

Cactus79

Member Since: 09 Jan 2017
Location: Cheshire
Posts: 51

Checked this morning the turbo, MAF sensor (smoke's worse)

Thought i'd include a video to show how bad it is

If i remove one of the plugs off the injector would that stop injecting the fuel and therefore isolating the smoke?

22nd Jan 2017 10:13am

mk1collector

Member Since: 17 Sep 2009
Location: West Yorkshire
Posts: 6769

Head gasket? Ray
My build thread
http://www.defender2.net/forum/topic17615.html

22nd Jan 2017 1:31pm

Cactus79

Member Since: 09 Jan 2017
Location: Cheshire
Posts: 51

So i chopped one of the plugs off the old harness and put it onto each of the injectors in turn, taped up the live end and turned the car over.

Isolating number 1 the car would start and behave the same. Isolating any of the others and the car wouldn't start as it was down to 3 cylinders. So we know we've got a problem somewhere with cylinder 1.

So had the number 1 injector out again, and there doesn't appear to be any cracks in the walls from visual inspection, still doesn't rule out a cracked head mind.

Also checked continuity of injector feed and a visual inspection of the loom as far as possible. Seems fine despite more oil coming out the red plug again.

Could still be

Dodgy Injector
Head Gasket
Piston Rings
Cracked Head
Fuel pump - making some wining noise probably needs purging
Fuel filter

FPR is leaking a little and will need to be sorted sooner rather than later.
Can't see the crank position sensor, will be a right pain to replace.

So going to order a Nanocom and Spare green injector and some more seals.

22nd Jan 2017 1:53pm

Cactus79

Member Since: 09 Jan 2017
Location: Cheshire
Posts: 51

Feels like Christmas with all the parts arriving this week.

So plugged the car into Nanocom, which showed loads of errors logged but more importantly injector 1 balance is miles off running +30.

Spare secondhand injector also arrived so will be swapping it over tomorrow and hopefully we should be back up and working.

26th Jan 2017 7:49pm

miker

Member Since: 13 Sep 2015
Location: Surrey
Posts: 1767

Remember you will need to read the code off the new injector and use the nanocom to code it in.

26th Jan 2017 9:36pm

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