[TD5 will start intermittenly]

Hi. My flooded TD5 with a new (used) ECU took me 60 km out of town last Saturday with just one incident of dying on the hi-way but continued on since I was doing about 100 kph. When it was time to go home the engine would fire and after a couple of minutes die down. This happened about 5 times then the engine would just turn but not fire.

When the engine light and the glow plug light come on then the engine will fire. When the lights (engine and glow plug) don't come on the engine will just turn.

I checked the main and fuel pump relay and jingled the wires of the connector that attach to the ECU. Sometimes the lights would turn on most times I don't get anything. Sometimes I think I've solved it by changing the relays or crimping the connector leads but then the same thing. The engine will start then die again. Once I tried to jiggle the ECU box and the lights turned on after that I didn't get any reaction even when I jiggled everything inside the ECU box.

So, sometimes I think I should replace the ECU and sometimes I'm sure its just some corroded part that has a loose connection somewhere.

The following was suggested by the seller of the re-mapped ECU -

"its sounds like a bad earth on the transfer box, we had the same problem with one a few months back, what happens is when the glow plugs trigger it puts a high amperage load on the connections then looses connection through arcing out, the engine light and glow plug light then goes out.

The fuel pump and main relay do not get it's supply from the ecu its from the ignition barrel switch (check spade connectors on ignition switch) also the ignition switch can fail due to water damage (just bridge spade connections to bypass switch to try). One more thing we have found in the past is the spade connections on the relays near the ECU get hot and arc out, and make sure you are using the correct relay."

I was wondering if anyone had any suggestions.

Thanks,

TOny

[Engine light and heater light don't light-up]

Based on what I have in mine, (see picture,) I think you'll find the one on the right above the fuse box is for the glowplugs and the other (yellow) one is the "Main" relay switched from the ECU.

I dont think it matters what brand of relay is used so long as it has the same connector configuration and power rating, they all seem to be pretty standard nowdays.

Hi. Thanks for the photo. I think my compartment has about 5 relays instead of 2 that you have in your defender. It's good to know that I may have found the faulty connection in the main relay to the ECU. I will know tom.

[Engine light and heater light don't light-up]

Hi Andrew, yes I'm referring to the relays under the passenger seat near the ECU. As regards to the relay connected to the starter motor (second from left under the fuse box) mine is working fine. The relay to the right of it which is the power window relay is not working. I will try to remove the plastic cover and spray it with non conducting contact cleaner in case the parts are stuck.

I think the relay under the passenger seat that I'm talking about is somehow connected to the ECU because when I removed it the engine and the glow plug heater refused to light. I removed the plastic cover and sprayed it. I will re-install it in the morning and hopefully the car will start.

[Engine light and heater light don't light-up]

Hi. I complained recently about my engine suddenly dying or refusing to fire-up when starting. I think I found the problem. Under the passenger side where the ECU is located I found some relays but without any written notes as to what they are for. I started the engine this morning and it wouldn't fire-up and the engine light didn't turn-on at all.

This afternoon I tried to start the engine and it fired-up. I started checking the relays and found one to be warm to the touch. I turned-off the engine and removed the relay and tried to start the engine again. The engine light and heater light remained off and the engine just turned without firing.

Could anyone tell me what this relay is connected to? Also, the relay is a 40 amp Ford relay with 4 feet. Would this relay be the same as the Bosch 40 amp relay with 4 feet? I can't get Ford relays here in the Philippines but Bosch is available.

Thanks.

[TD5 Electric Windows]

Hi, I just finished repairing my 2 power windows on my 2004 TD5 defender also. In my case it was the relay under the fuse box under a/c that was the problem. I presume its not the relay in your case because your passenger side works. Most likely it would be the fuse. I think number 34 or number 35 if I remember correctly. However, it could be the switch because you say it didn't just stop working but rather intermittently worked and not worked until finally it stopped working altogether.

[Does the TD5 fuel pump have a relay?]

Thanks, sounds kind of the same. The first time it happened after replacing my drowned ECU with the second hand re-mapped ECU I got from eBay I was parked with the engine running and then the engine just died. I tried to turn the key to start but the engine would just turn but not fire. The engine light wouldn't light up at all. I tried to start for a couple of minutes then I stopped. The next day I tried to start the engine and it fired up and I kept it running for 30 minutes. Yesterday I started the engine. after about 5 minutes the engine died, I tried to restart and it started. I'm wishful thinking that when I get everything sorted out and start driving it around the problem will disappear.

[Does the TD5 fuel pump have a relay?]

Thank you Les and than you crwoody. Td5 is TD5

I'm sorry to hear that its most likely the ECU. I will drive it around once I have the wipers fixed. I'll have to be on my toes I guess while checking out the engine cut-off problem. But in the meantime I guess I'll have to foot the bill for a brand ECU.

crwoody, was your problem the same? Everything is running fine and then all of a sudden the engine just dies and then when you turn the key it will start again?

[Does the TD5 fuel pump have a relay?]

Hi, I installed a re-mapped ECU to my TD5 and my engine started. The thing is, every now and then, the engine will just suddenly die. I have not really taken it around driving because I'm still sorting out power windows, locks and wiper but I do start the engine and its happened twice that the engine will just die. I'm worried about this problem because I can imagine overtaking and then suddenly having the engine die on me. I hope its not the ECU and I was thinking that I should check the fuel pump relay (flooded defender) if indeed the TD5 has one. Thanks.

[TD5 power window won't work]

Thanks for the tip. I checked the wires and they were good but its good to file that tip for future reference. I found the relay in the fusebox underneath the a/c. I tried switching relays around and the lines came alive and power windows worked. Although after I switched the relays around the engine refused to respond. Replaced the relay to where it came from and the engine started. The code for the relay is SM. Does that mean starter motor? If so, that would explain why the engine would't turn.

[TD5 power window won't work]

Hi, I already checked and cleaned the power window motor and when attaching direct to the battery the motor will work both ways. I checked the fuses and they're intact. I connected a tester to the power window wires attached to the switch and they don't receive any power from the switch. I checked the switch and I get a continuity from wires 1 and 4 going up and 1 and 3 going down. There are six prongs in the switch and 5 wires but the others don't get any continuity readings. Is there something I'm not checking like relays or something else? Thanks.

[Drowned TD5, He's ALIVE!!!]

Hi, I removed my power window motor assembly as per your instructions. Tested the line from the switch and power is supplied. Brought motor to repair shop for testing and repair. Also removed CDL pump and the line also has power. Will look for alternative pumps to replace the broken ones. I was also able to remove wiper motor and brought to the shop. Wiper motor worked in the shop so I'm hoping it had just gotten stuck-up. Will re-install tom.

[Help with removal of Defender TD5 wiper motor]

Thanks. I opened up the gear cover and I took out the circlip from the lever that controls the wiper cable. I also removed the part that's attached to the gear body to free the motor and gear assembly from the wiper cable. I brought the wiper motor to the repair shop and when they tested it the motor actually worked. Either the gears or motor was stuck or there's something wrong with the electrical line.

I will re-install tomorrow. Hopefully it works installed.

[Help with removal of Defender TD5 wiper motor]

Hi, my wipers don't work and I need to remove the windshield wiper motor. I've removed the dash and exposed the wiper motor. I've removed the two phillips screws that attach the motor and tried to turn the nut that attaches the motor to the rod that operates the wipers. The rod won't let go. Could anyone help me out on how to remove the motor so I can have it checked? Thanks.

[New Limited Edition Defender Models - Fire & Ice]

There's a limited edition Defender in the showroom here in the Philippines but it's not called Fire or Ice, it goes by the name of SVX, Black body and black roof with the crystal lights and Recaro seats. Retails for 51,700 pounds.

[TD5 engine suddenly died]

You're right, it's plastic. According to my mechanic he siphoned out some fuel from the tank. Now he says there wasn't much water in the tank. I tried running the engine today for about 30 minutes parked and there were no issues. Since the problem is intermittent I'll just observe first and hope the problem doesn't come back. Will work on the power windows and the central locks this weekend.

Thanks.

[TD5 engine suddenly died]

Is that the case? The mechanic that initially cleaned the vehicle claimed that he was able to drain about a gallon of diesel that dripped water initially?! Does that mean I'll have to drop the tank in order to get the diesel out?

[TD5 engine suddenly died]

Thanks Andrew and Les and BogM. I do hear the fuel pump running but then the car has started running again. I was wondering. It might be a little water in the fuel system. I drained the fuel initially but only let about a gallon of diesel come out. There might still be some water in the fuel lines which causes the engine to die every now and then. I guess I'll try to drain the tank completely and refill with diesel.

[TD5 engine suddenly died]

Hi guys, thanks for your suggestions. When I got back this afternoon and tried to start the engine it started then after a few seconds it died again. I opened the fuse box underneath the a/c and pushed in all the relays and fuses. Turned the key and the engine fired up again. I took him for a spin and after about a hundred meters the engine stalled for a split second and engine light lit=up and then the engine kicked-in again. Ran for another couple of hundred meters and I parked the vehicle afraid it might die on me in the middle of the street. I'm hoping its not the ECU that I bought but I guess the old axiom "buyer beware" holds true for this purchase. Wrote to the seller a week ago and haven't received a reply yet. It's just that I was enjoying the great acceleration from my re-mapped ECU and if I had to buy a brand new one I'd have the old setting again.

I will check all fuses again tomorrow morning and try to look at all electrical connections related to the engine.

I guess it will take sometime before my Defender is in tip-top shape but what's important is that it's running. (Thanks to you guys)

[TD5 engine suddenly died]

Hi, my TD5 is the defender that drowned in the flood. I fitted a reconditioned ECU and 10AS my vehicle and I was able to use the vehicle for a couple of days. I decided to drive my TD5 out of town today and when I started the vehicle this morning it started then after about 10 seconds the engine just cut off and died. I tried re-starting but the engine just turns without firing. I'm thinking that maybe the ECU i bought is defective.

I noticed that the engine light and the heater (glow) light don't light up anymore when I switch the starter on. The oil and battery lights still light-up. Now I'm thinking that it could be the engine fuse. Would a blown fuse prevent the engine and heater lights from lighting-up and I guess from also prevent the ECU from getting power?

Many thanks!

[Drowned TD5, He's ALIVE!!!]

Hi Andrew, thanks a lot for the comprehensive instructions. I will need to wait for the weekend to work on the power windows so I can devote a lot of time to it. Have never worked on a power window before so I will follow your instructions and do it slowly. If I do need parts then I will need to get from Richard of Nam Seng. Just having my TD5 up and running again bring tears of joy to my eyes

At least my Puma does not have power windows or central locking. Just hope that ECUs will come soon enough.

Will update you on my progress.

Thanks.

[Drowned TD5, He's ALIVE!!!]

Inspected starter today but at first it wouldn't function. When we tested the armature it turned, when we tested the solenoid it pushed out but the starter wouldn't push out and turn at the same time. I noticed that the rod with the copper washer that makes contact when pushed out was sticking and not moving out smoothly. The flood waters and the 40 day inactivity made the parts rust and stick. I cleaned it with DW-40 and activated the rod with my hand until it was moving smoothly. Re-installed the starter and switched the ignition key and the engine fired-up.

Initial findings are: power windows don't work, central locks don't work and front windshield wipers don't work. I was wondering if anyone could tell me if any of these 3 functions are connected to the ECU?

Also, I think my newly installed ECU is programmed without activating the alarm. (I think this might be a good thing) When I press the lock button on the remote and then try to start the engine the engine starts.

I also replaced the ATF in the power steering system. The clutch and brake systems seemed untouched by the flood waters.

[Drowned TD5, He's ALIVE!!!]

As soon as I get the starter fixed I'll bring him straight to the shop for all the fluid changes. But that's right, I do have to have the wheel hubs repacked. Thanks for the suggestion.

[Drowned TD5, He's ALIVE!!!]

Hi, yes immediately after the flood I drained the engine oil and replaced oil and filter. Also replaced diff oil, fuel filter and air filter. Removed intercooler and turbo and drained water out.

[Drowned TD5, He's ALIVE!!!]

Hi! I just wanted to report that I received by post the used ECUs I got on eBay for my drowned TD5 and installed them this afternoon. The engine still wouldn't turn but I could hear the starter solenoid activating. Power windows wouldn't work, central locking wouldn't activate but I could hear something switching in the 10AS. On a hunch I had my staff pushstart the vehicle and on the second try he sputtered and the beautiful sound of my TD5's engine running reached my ears.

What a great feeling!

Airconditioner works just fine, no power windows, no central lock but all the lights work. He spat out muddy water from the tailpipe for a few seconds but other than that the engine is running smoothly. 10 hours underwater and now my TD5 is running. Thank you for all the info offered during my time of distress.

Now for the Puma, unfortunately the ECUs won't get in until December.

[Temp Gauge and Speedometer failing]

Hi, I had to bring my 110 to the shop due to an engine oil leak from the camshaft seals. I had them check on the grounding of my gauges but they couldn't find anything wrong. When they checked on my rear wiper motor they fopund out it wasn't working. They suspect that there might be a short in the motor and disconnected the connection. Gauges are working now so I hope htey are fixed.