Puma Engine Cutout - Relay/wiring issue - URGENT

[tcf]

Defender 110 Puma 2.4L.

Have had engine cutout several times this morning and the battery and traction control lights come on, on the dash. There is a relay in my ex box which gets red hot every time this happened.

Problem is I don't know what the relay relates to. Please see the pics below and let me know what this relay belongs to...

I tested the relay and it seems ok, so I want to know a) what it belongs to and b) trace the connection/wiring through.

Thanks for your help

Tim

https://www.aulro.com/afvb/images/imported/2015/04/729.jpg (http://s1101.photobucket.com/user/tcf19/media/48748B19-1945-4E08-90C2-CD1058A943BA_zpsumotsav3.jpg.html)

Close up of relay

https://www.aulro.com/afvb/images/imported/2015/04/730.jpg (http://s1101.photobucket.com/user/tcf19/media/48A58E94-3165-4823-A175-47219FA11BC3_zpsys5esqjz.jpg.html)

[POD]

Having moved everything from it's original location doesn't help in identifying what's what, but there does not appear to be a corresponding relay (with that number and those wire colours) in my 130, so I suspect it is associated with either traction control or ABS (the 130 has neither).
A good way to identify a relay is to see what stops happening if you pull it out.

I wouldn't read too much into the battery and TC lights coming on when the engine stops, I think these are on any time the key is on with the engine not running.
Have you compared the temp of that relay when the engine is running normally?
What are the circumstances when your engine stalls, e.g. is it whilst driving, whilst idling when cold, etc.

[tcf]

Hi thanks for your reply.

Yes it is a pain that they have moved from the original position. And I have discovered several dodgy things completed by the previous owner - but there is not any indication that this issue is a cause of that.

If I pull the relay the engine shuts off - if I try to restart with it out, the engine will try to crank, but not fire. The relay seems to be warm most of the time and red hot when the engine cuts out. It has happened 5 times now. All times have been within the first ten minutes of driving and at relatively low speeds <60km/h.

[POD]

Okay, I'm not exactly sure what the relay powers but sounds like perhaps the fuel pump. Heat in electrical components is caused by resistance. I would suggest it's possible that the relay has worn contacts, causing the heat to build up, then conductivity across the contacts is lost. I'd start by replacing the relay. This does not explain the problem only occurring when the engine is cold though.

My 2008 130 (2.4 Puma motor) sometimes cuts out when cold- I usually let it idle for a few minutes in the morning before driving, occasionally it will run for a minute or so then stop as though switched off, always starts again without difficulty. Has recently started doing this again as the weather has cooled down. With the nanocom attached the other day, I noticed that the cutting out happens when the EGR valve opens, so I assume it is an EGR problem- the valve has also recently got noisy during the self-clean cycle after shut down.

[tcf]

I just replaced the relay and tightened the contacts on the holder.

On very close inspection there was a small groove on one of the relay spades which may have been causing the heat/trip in the relay.

I will keep an eye on it all. Hopefully the issue doesn't come back next week when I'm driving MEL to BNE and back.

Cheers.

[tcf]

Well the cutout while driving didn't happen all the way from Geelong to Fraser Island (and back). But oddly, after traversing an inland track across Fraser Island (read quite rough), upon stopping to air up, the car would not start again. I had full charge on both batteries (which are only 1 month old). Lights on the dash etc. The vehicle would not turn over, would not even make a click. After a few @#$%&*@#$%& moments, I got a guy to help me push start it and all was good, fired straight up.

I am no closer to solving this problem. :censored:

[alien]

Well the cutout while driving didn't happen all the way from Geelong to Fraser Island (and back). But oddly, after traversing an inland track across Fraser Island (read quite rough), upon stopping to air up, the car would not start again. I had full charge on both batteries (which are only 1 month old). Lights on the dash etc. The vehicle would not turn over, would not even make a click. After a few @#$%&*@#$%& moments, I got a guy to help me push start it and all was good, fired straight up.

I am no closer to solving this problem. :censored:
I may be missing something but I read this as problem solved due to it not cutting out.
The no start issue could be in no way related, wonder if the immobiliser timed in/out as you aired up?


Slip me some details on your rig's year and the colour of the wires to the suspect dodgy relay and I can try to find out from the wiring diagram on my Puma RAVE what it's for, if your interested.