Relay clicking, engine stuttering.... help! - Defender Source
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  #1  
Old December 3rd, 2007, 07:45 PM
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Steve Maietta
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Relay clicking, engine stuttering.... help!

94, 3.9l 1?? K miles.

Hey folks.... I've had issues with stuttering engine, major loss of power, and heavy gasoline smell before, and its come and gone. Just the past two or three months I've noticed a relay clicking every time the engine sputters, and today it was very bad happening twice on my way in to work and many many times on my way back. Usually if the engine goes into its no power, heavy gas smell mode, if I turn it off and on again it will fire up and all is well.. But just 10 minutes ago, (almost home) it wouldn't restart.. it would rev for quarter of a sec and then die. Eventually after trying 5-6 times it lit up and I was able to make it home to the garage!!

The clicking sound (relays?) are in the passenger footwell.. I see what looks like an empty socket and then two moetal Bosch relays down there. They were both hot to the touch. Hopefully its just my relay(s) going bad..? Does one control the spark while one controls the gas pump? Is one for the left bank of cylinders while the other is for the right bank? Becaus esome times I just end up with half power and a heavy gas smell, while other times the engine fully dies.


Thanks for any ideas on this guys!

~Steve
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  #2  
Old December 3rd, 2007, 10:22 PM
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Charles Galpin
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Steve, my money is on the fuel pump relay. It is under the passenger footwell - the one with the blue socket. Replace it and I'll bet the problem goes away. This happened to me recently, only it took me *way* too long to believe it was the fuel pump relay

charles
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  #3  
Old December 3rd, 2007, 10:26 PM
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Steve Maietta
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thanks Charles.! ill try and find onw tomorrow..

should these relays be running warm/hot? could my fuel pump be drawing too much current and thus causing the relay to run warm, killing the relay in the process?

if the filter's clogged or there is some other restriction perhaps the pump is drawing excess current.. ?

anyway ill fit a new relay tomorrow!

any other thoughts on the situation guys?

thanks again
~Steve
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Old December 3rd, 2007, 10:31 PM
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Charles Galpin
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I honestly don't know how hot is too hot, but they will heat up some. I think they just go bad over time - like any moving part.

charles
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  #5  
Old December 3rd, 2007, 10:43 PM
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make sure you replace it with the genuine bosch.

i found that with a little prodding you can get one from carquest for under 10$ i think.
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  #6  
Old December 4th, 2007, 06:17 AM
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Issues we've found to cause these symtoms

Poor signal / loss of signal to ECU

Water contaminated ECU

Bad ground to main relay

Bad main relay
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  #7  
Old December 4th, 2007, 05:35 PM
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Steve Maietta
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Thanks Matt.. got a relay coming tomorrow, tonight I'll check some of these things if possible..

~Steve

ill report back with what I figure out.
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  #8  
Old December 4th, 2007, 06:18 PM
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Replace both silver relays. Consider them a wear item.
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  #9  
Old December 6th, 2007, 08:03 PM
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Steve Maietta
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Okay. Problem GONE. (for today at least)
didn't drive the rover yesterday while I waited for the relay... it sat in the 40degree garage.

today I drove it to work (40 mins) and back with no stutters or stalling or loss of power at all! Two days prior to this it had been the worst its ever been...

What I did was clean (scrape off corrosion) the ring terminals of all the wires connected to the coil, and then reseat the air flow sensor electrical connector a few times.

Still have the same relays in place, they gave me no problems today.

So either....
1- me pulling the one relay and then reinstalling it cleaned its conatcs.. OR
2- the corrosion that I scraped form the coils 2 lugs and associated wires was causing intermittent signals to the ECU/air flow sensor (or something else, wish I had a decipherable 94 NAS wiring diagram...), causing the issue. OR
3- me reseating the big connector on the front of the air flow sensor a few times cleaned it a bit for true running. (although I've started my engine with that connector unplugged and the engine did start and run /idle) OR
4- spending 18$ and an hour in the freezing weather at night under my hood cleaning electrical contacts and fumbling with 8mm nuts and numb fingers was enough to appease old man Lucas, and so he'll give me a good week of running.
-hope its not #4..

At least now I have a new relay incase I need it sometime.

thanks for the tips guys
~Steve
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  #10  
Old December 6th, 2007, 08:23 PM
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Charles Galpin
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Good to hear!

charles
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