Filbee

Thanks for taking the time to check. Only 3 amps though. Mine is more like 13 amps! No smoke though, just a hot relay! Are you sure it's only 3 amps? The manual says maximum 15 amps. That's quite a difference. Got me more worried than I was before now....

First thing I did was swap the relay for a new one. When that made no difference I cut back the two main wires by about an inch and crimped and soldered two new female spade connectors to make sure there were no issues with the external connections.

Thank you for the advice, much appreciated. I'll check the voltages across the relay but I don't think I'll be able to check the pump terminals! I measured the resistance across the power feed wire from the fuel pump plug to the relay socket when I changed the pump and it was zero. I guess I should mention that as far as I can tell the overheating seems to be local to the relay. The wires are only warm for an inch or so from the relay socket, if that.

Again, forgive me if this is another silly question, but is there anything I can usefully and relatively easily measure to tell me if I do have a problem and if so, which part of the circuit/loom it might be?

The connections at the pump appeared to be in good order. No sign of them turning that lovely shade of green, the female sockets in the plug looked nice and clean and the plug was a nice snug fit without being too tight, if you know what I mean.

That's what I'm worried about. It's one thing having an overheating relay but another altogether worse situation if the insulation starts melting! How can you tell if there's a poor connection? Can that cause an increase in current draw? Apologies if that's a dumb question... I did notice that the connector plug on top of the fuel pump had lost one of the clippy bits that lock it in position but the other one was fine and the plug fitted very snuggly to the corresponding socket on the pump. I'm afraid the dark art of electrickery isn't my strong suit. Give me something I can put a spanner on any day! If you do manage to measure the current on the D2 when you do the pump it would be much appreciated.

I have a problem with an over heating fuel pump relay on my 2006 110. I'm assuming that the overheating is due to excessive current draw so can anyone tell me what is considered to be "normal" current draw at idle whilst stationary please? I know the LR workshop manual says up to a maximum of 15 amps, but I'd like to know if anyone has or could measure the actual current draw on their Defender. I used a little DC clamp meter on mine and it was quick and easy to do. I'm trying a different approach to my original thread as I've had no replies so far...

I'm hoping someone can shed some light on this... The fuel pump relay on my recently acquired 110 TD5 hardtop (ex utility) is getting very hot. The original yellow relay was playing up by occasionally not operating, so I pulled it out and noticed it had brown burn marks on the casing next to the terminals attached to the main pump feed wires (white/purple). I changed the relay for a new pattern one of the same spec. Made no difference, still getting really hot. Next I replaced the spade connectors with proper uninsulated crimped ones and even ran some solder into the connections to make sure there was a good connection. Made no difference, still getting really hot. So next I firted a new fuel pump (VDO), along with a new genuine LR filter head and filter. Made no difference, relay still getting hot... I bought myself a little AC/DC clamp meter to measure the current going through the white/purple wires from fusebox to relay and relay to pump. It's telling me it ranges between 13 amps when cold to 14 amps when up to temp (stationary, not under load). I've no idea if this is about right or not but I read somewhere that the factory workshop manual says it should draw a maximum current of 15 amps. So I'm a bit stumped really. I'll probably do the injector seals and FPR as a bit of preventive maintenance and see if that makes any difference. The truck runs fine. She starts first flick of the key, idles smoothly and pulls nicely. The only thing I have noticed is that the exhaust smells a bit strong. Has anyone come across similar issues or have any idea what might be causing my over heating relay? Thanks in advance