We converted our Defender TD5 to a camper when in the USA. We shipped her from Florida over to the UK and immediately had starting and misfire problems. We replaced the battery but still the misfire continued and then we diagnosed diesel bug. After treatment and changing the fuel filter, she seemed OK and drove her to Portugal and three months later, back through Spain where the misfire disabled us. We added more treatment, changed the fuel pump and the filter and continued without a problem. We then parked her for two months in Greece, while we took care of an island while waiting out the winter but after the first month, we drove her and she shuddered and we added more diesel bug treatment and left her for another month. After a month, we left the island and she wouldn't even climb up a hill. We changed the air bleed valve, gave her a service and filled the fuel filter with injector cleaner. By the end of that day and a 500km drive later, she was running perfectly. We then stopped in Thessaloniki for 4 days and the misfire returned. We drove her into Turkey, filled up with good fuel then drove her South. One cold morning she refused to start but eventually did, we then drove as far South as we could before she gave up in a town called Burhaniye. We found a campsite, diagnosed the problems as best as we could and ordered some parts. It has been twenty days in this camp, so far we have changed the Crankshaft position sensor, the fuel pressure regulator, the injector loom, two fuel filters, cleaned and checked the pump, clean and checked all wiring, cleaned and freed the turbo wastegate, checked the earth, repaired a crimped section of fuel line, checked the turbo hoses, checked the ECU wiring, checked the battery and have 2 mechanics come to camp to help us but the problem remains. Some days she starts well, other days she refuses to start . After changing the fuel filter, she will drive great but the next day will be terrible. When she is going well, the problems manifests in 5th gear with a slight stutter, when she is going badly, she stutters on 3rd to 5th and stalls on the side of the road. Some days she's great, some days she's terrible. Our next job is to change the injector seals and washers and we noticed a slightly chaffed wire in the ECU which happens to be the wire to the CPS. We don't have diesel in the oil and the oil level doesn't change and the fault is intermittent, so, any recommendations would be great.
