Td5 engine stops at 2500 + - 100 revs

Hello,
I have (from new) a Defender 110 td5 2004 with 122000 km on the clock. In Saturday morning I did drive on the road from the front yard and the engine did stop with engine light turned on. Turned back the key to off and the engine did start as usual.
The next day I did try to recreate the problem and the engine does die at aprox 2500 revs (measured with the Nanocom) every time. Then I put the negative earth terminal on the battery and pull out of the ECU the red and black connectors. Everything OK, they look like new - no oil or any other stuff. Put them back on and did connect the negative earth back to the battery. The engine started with no problem and did run even over 2500 revs with no issues. Then I did stop the engine and start it back on. The problem is here again.

The Nanocom shows no faults in the error log.

Then I did connect other tester (Launch) and it did show the following errors:
Aircon Fan Drive Open Load Fault. Logged. <-- this one is always there
Fuel Pump Drive Open Load Fault. Logged
Gearbox/ABS Output Drive Open Load Fault. Logged
Aircon clutch drive open load fault. Logged
MIL Lamp Drive open load Fault. Logged
GlowPlug Lamp Drive open load Fault. Logged
Injector 2 peak charge short. Logged
Injector 3 peak charge short. Logged

I did checked the fuel filter (changed), the fuel pump is operating normal (when the ECU was reset (as described above), the engine did run great).Tthe ground (negative earth) is good (measured the resistance and the multi meter shows 0.1 to 1.0 ohms) in every way - engine to chassy, chassy to ECU, gearbox to chassy, gearbox to ECU, and then also all of the segments (chassy, gearbox, ECU, engine) to negative terminal on the battery. So the ground pole is good in any direction against the negative terminal on the battery.

I have the feeling that the ECU should be replaced or repaired (if that is possible) The ECU is upgraded to "Stage 1 Defender TD5" by the JE Engineering (JE MotorWorks). The ECU was upgraded from new (three moths after the vehicle was bought). No problems at all with this Defender till now.

Please help.
Thank you in advance for any idea how to resolve the issue.
Regards,
Mirko from Slovenia

Pull the connector on the front of the engine. Just because the red plug is clean it doesn’t mean the loom hasn’t failed, the oil may not have made it that far yet.

Hi, did you measure the fuel pressure as to be certain that the pump is delivering HP too? they can run only on LP and the only way to rule this out is to check the pressure with a gauge in the FT sensor's port of the FPR, on LP the engine can start and run up to a certai rpm then die, that's common... if nanocom shows no faults that's it, the OBD2 scanners can usually show false codes so forgat about that launch thing

Check the MAP Sensor. Had a similar issue.

Hello lads,

Now the engine does not even start any more.
Just before this, the engine produced a heavy black smoke, and now even black smoke does not come from the exhaust pipe.
The fuel pump is running - at least it sounds so.
The connector (where the wires goes into the cyl head) on front of the engine is clean and dry.
So, AdamD1 and sierrafery, you think that this is the fuel pump issue ... ?

merzelmm said:

sierrafery, you think that this is the fuel pump issue ...

Click to expand...

I can't be sure as long as you didnt measure the pressure as i explained once

And I wouldn’t know sorry, much of my knowledge has come from @sierraferry & co. I’m still a bit of a D2 noob.

Hello,

To update the situation:
- the fuel pressure checked on the inlet pipe of the FPR, which comes to the FPR from the back of the wehicle, and the gauge showed 4.2 bars or 60 PSI
- checked and cleaned the EGR valve - everything OK
- the CKP (crankshaft position) sensor measured and it shows 1367 Ohms - the output voltage should be 2-3 volts when cranking the engine - I have to measure this yet (there is very little space there to do it)
The MIL light does not come up, the engine does not start. It looks like the injectors would not open the fuel to enter the combustion chamber. More and more, I have the feeling, that the ECU is dead.
Tomorrow, I'll get another ECU and will try to start the engine up. I am aware, the ECU have to learn the security code from the AS10 before starting the engine.

Will let you know the results.
Thank you in advance for any comments or advises.

Hello,

To update the situation:
- measured the CKP sensor output during cranking --> 2.4 volts
- checked the fuel on the pipe, which goes into the fuel cooler and the fuel is coming out, so the cylinder head is filled with fuel and the FPR is doing it's job
- installed another ECU and did teach it the security code --> the engine started like a thunder.
So, the ECU is a problem.
I did open an ECU with no problems (the cover should be sealed to the body of the ECU), and did find a piece of none insulated wire in it jumping around. One of the transistor coolers was bent away. The ECU was not sealed as it should be. This ECU was purchased from JE Engineering about 14 years ago. Yes, it did work for the past 14 years with no issues and every ECU may fail to work anytime --> I do understand this perfectly. But the fact, I did find a peace of a non insulated wire (about 3/4 of an inch long) inside the ECU and twisted transistor cooler ... This is not it ... I do believe, they are better now.

Thank you very much to all of you for your suggestions and advises.