Defender TD5 Cutting Out

[Chas Dean]

.Recently my TD5 is cutting out esp after first 20km.

Engine cuts sometimes W dash light/s Orange etc

sometimes without.

After a few minutes and/or sometimes lightly pressing 2 underseat

 rear relays ( Fuel & glow plugs ?) the engine starts and runs again for up

to 20km or so before cutting.

The relays get hot ... too hot to keep finger pressed on them. 

I believe relays overworking is symptom & not cause of deeper 

underlying problem. 

I’ve changed relays , crank angle sensor and earthing 

and checked for harness oil etc ... but not , recently, Fuel Pressure Regulator

or injectors or their seating etc.

Any ideas or leads ?

[SB backup]

I’d take a guess that it could be the fuel pump on its way out

Sent from my iPhone

On 20 Apr 2023, at 17:35, Chas Dean <ed...@telkomsa.net> wrote:

.Recently my TD5 is cutting out esp after first 20km.

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[Bertus Bekker]

Check if those relays have the same pin-out as the orifginals.

There are two versions of DIN-cube relays, and you could be feeding with the low-current coil side rather than the battery side

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[Chas Dean]

L-Wx have cleaned tank & put new pump

& checking out the problem ... 

... but it’s intermittent/erratic so tricky to nail !

Will look into variation in relay pins layout.

[Chas Dean]

So today changed the little  1-way valve in the return feed pipe 

at/from the fuel filter back to the in-tank pump...

so far vehicle now starting and  running much better 

... without cutting out...

Time will tell , but I’m hopeful.

[Chas Dean]

... these little goodies ...