TD5 cutting out

I have aproblem with td5 defender
It will run perfect ( sometimes for weeks)
then cuts out
Turns over and wont restart even with towing

Leave it till next day and it starts and runs perfectly until does it again
So far have
Changed ECU
Seals in injectors
Fuel pump and filters
Checked wiring lom over gearbox
changed Injector loom

If put on autologic doesnt show any faults up that will stop it running

Any ideas am at wits end

what faults have shown up,? ive had a similar thing one was poor connections at pump intermittenly can you hear pump running normally or sound like air in it when fault occurs ,,and one with poor battery and loose clamp it would allways turn over but not allways start presumably unconstant voltage was giving fault,are you running on clean disel ,loose wiring connectors etc

Diesel fine and pump connection ok aand ive changed pump

Im convinced it is electrical but am really baffled since changed ecu and fuel pump
Its baffling as it always resatarts next day / after a few hours

id say crank position sensor if it just dies, but think that would show in fault codes

Simular issue with my bosses old Td5 - turned out to be the yellow relays under the drivers seat.

Would drive fine for ages then would just spin over but not fire and temp gauge would shoot to red.

Just had to move the yellow relay a little and it would fire up again - although he was too tight to replace them!!

HTH

thanks for the replies i will try the crankshaft sensor does anyone know what it should meter at ?

ive tried wiggling yellow relay but might swap it just in case

Sounds like dodgy electrical connector to me. Fuses and relays are prone to rattling loose or getting slightly corroded and also the earth under the drivers seat box is prone to coming loose and/or corroding.

I had a similar problem, my engine just died and wouldn't restart. Turned out to be one of the cables to the ECU had worn through on a sharp corner thus shorting out on the bodywork.

update have run it agan till it cut out
changed crankshaft sensor no differant
cleaned lugs on head and ecu no differant

really at wits end now as cant see what can make these stop running

One thing strange when it stops seems no fuel at regulator however ith then pumps through and pressures up but still wont start
can fyel pressure reg fail intermitantly ( it isnt leaking )
Am loatherd to take to dealer again as all they do is clear faults and charge £80 but not sort problem

i had a similar problem on a merc sprinter,it would cut out without warning, wouldnt restart for could be minutes, sometimes hours, fault code showed fuel sensor fault, it went numerous garages including merc themselves, all changed parts but fault kept returning, finally as a last option i booked it in with a good auto electrician, who ran the vehicle until fault appeared, whilst reading live data, it turned out to be a pin on the ecu connecter that was breaking contact intermittently, dont know if that points you in the right direction

Exactly what happened to myn it ended up being the yellow relays under seat clean and crimp them up tighter.

Im thinking it could be loom / plug fault
have checked filter behind pressure reg and thats ok so am ruling fuel out

I have got a new Loom form ECU to engine so am going to try fitting that as running out of ideas rapidly
problemm with live fault reading is it can go days sometimes without cutting out

just check your relays, they are cheep enough to do and also do yourself a favour and wire in a thin earth wire derectly from the batt to one of the nuts that holds your ecu in place, then see if theres a differance. had one do the same and changed relays around, their pins also work out and become loose, my earth wire (original tested continuous with meter but afrer i wired in a new one the issue went away cost about 1pound compared to all the stuff you have done) JUST TRY IT

Rean said:

just check your relays, they are cheep enough to do and also do yourself a favour and wire in a thin earth wire derectly from the batt to one of the nuts that holds your ecu in place, then see if theres a differance. had one do the same and changed relays around, their pins also work out and become loose, my earth wire (original tested continuous with meter but afrer i wired in a new one the issue went away cost about 1pound compared to all the stuff you have done) JUST TRY IT

Click to expand...

LEAD A HORSE TO WATER! :doh:

ive tried Relays and re earthed everything

TOok to a Garage they managed to stop it runnuing alltogether !!
they checked all sensors and say allright

Put original ECU on

now started changing Sensors and trying as im really lost for what to do and what baffles me is garages spend thousands on testers and still cant diagonose

im now thinking if a sensor is faulty its pulling down the 5v from ecu and then cutting ecu out thats why im swapping sensors

Hi
EXACTLY the same problem on my Disco TD5 (2003)
with the addition of the temperature gauge reading maximum and the temp warning light
coming on(even when stone cold)

It was the top earth point by the ECU loose. Tighten this and away you go.

Just added this for the next person searching for a solution.

Steve