200tdi cutting out randomly - Defender Source
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  #1  
Old July 22nd, 2014, 10:23 PM
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Brandon
200TDI in a RHD 1986 D90
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200tdi cutting out randomly

Currently have a 200tdi defender motor installed in my 84’ 90, once every 100 miles or so the engine will shut off while driving as if you turned the key to the accessory position with the key remaining in the on position. The battery warning light will come on and the engine shuts off. In the past 500 miles since I have put the engine in it has occurred 6 times. All I have to do is turn the key from the on position to the accessory position back to the on position and the engine starts running again instantly without cranking as long as you are moving. It occurs in many different circumstances but in most cases it is cruising on the highway. I would assume the power to the stop solenoid is being lost and by resetting the key power is restored.
The motor has recently be put in and the fuel line, lift pump and fuel filter are all new. I have no symptoms of air getting on or hard starting. It seems as the problem is purely electrical. To strengthen this suspicion the same problem occurred with the discovery 200 I used to have in the truck which leads me to believe that it could have to do with the ignition switch. I have checked the connections which seem to be good but I was wondering if it could be internally damaged and this would cause the fault.
I have nothing on my keychain and if I jiggle the key around it does not cause the problem.
Has anyone had this issue before?
Could there be another source for the problem or am I looking in the right place?
Can I just change the switch or should I change the whole barrel?
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  #2  
Old July 22nd, 2014, 10:34 PM
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Jeff Labbé
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Happened with mine, the switch had loosen on the three retainers. I tried to fix it but it still cuts while test driving it. End up buying a new switch and problem solved.

Different parts different quality, check and make sure you get a descent replacement!
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  #3  
Old July 22nd, 2014, 10:38 PM
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John B.
1991 Defender 90, 200TDI
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Sounds like a faulty ignition switch to me since the charge light is coming on. They do die. You can swap over the key barrel.

Get a genuine one as the aftermarket ones are crap.
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  #4  
Old July 22nd, 2014, 10:40 PM
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Brandon
200TDI in a RHD 1986 D90
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thanks guys
that is what i thought
will get a new switch and will get back to you with the results
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  #5  
Old July 22nd, 2014, 10:53 PM
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Doug Crowther
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My brother set his solenoid up on a toggle when this happened with his. Been running like that for a year
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  #6  
Old September 2nd, 2014, 02:06 PM
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Brandon
200TDI in a RHD 1986 D90
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Hey guys i ended up replacing the switch and have not had the problem for a month

so i think it was deff the switch
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