Land Rover2001–2007

Defender 2.5 TD5: Common faults & known problems

Common faults & known problems

14 known faults documented in workshop bulletins. Of these, four concern the engine and fuel system and four the brakes. Symptoms, causes, repair steps and part numbers are shown where supplied.

Updated Technical specifications

Engine & fuel system

4 documented faults — symptoms, causes and workshop fixes.

Loss of engine power

Affects Defender, →VIN 2A 622424.Fit new part

Symptoms

Black smoke from exhaust.

Cause

Turbocharger (TC) to intercooler hose separated internally causing a blockage.

Turbocharger (TC) to intercooler hose split.

Repair

  1. Fit new turbocharger (TC) to intercooler hose.
Parts2 parts
Parts listed in the bulletin
PartPart numberQty
Hose - DefenderPNH1020701
Hose - DiscoveryPNH1021001

Data: Motorwise Workshop. Bulletin 1.

Engine malfunction indicator lamp (MIL) illuminated

Affects All models.

Symptoms

Accelerator pedal operation may be reinstated when ignition is turned OFF and ON. Engine stays at idle. No response from accelerator pedal.

Cause

Wiring harness multi-plug not correctly latched to accelerator pedal position (APP) sensor.

Repair

  1. Ensure that wiring harness multi-plug is fully engaged and latched to APP sensor.

Data: Motorwise Workshop. Bulletin 2.

Lack of power

Exhaust gas recirculation (EGR) solenoid filter blocked.

Overview

Affects
All models.

Symptoms

Black smoke from exhaust.

Repair steps

  1. Defender: Disconnect filter from EGR solenoid.
  2. Discovery: Disconnect filter from EGR solenoid.
  3. If condition is rectified, replace filter.

Parts

Parts listed in the bulletin
PartPart numberQty
FilterESR43231

Data: Motorwise Workshop. Bulletin 3.

Water-in-fuel warning lamp illuminates when driving

Water-in-fuel sensor is oversensitive. Fix: fit a modified part.

Overview

Affects
Defender: VIN XA 159810-1A 199999/VIN 1A 600000-1A 610263.
Remedy
Fit modified part

Repair steps

  1. Clean area around water-in-fuel sensor.
  2. Drain fuel filter.
  3. Clean new sensor electrodes, seal and mating surface.
  4. Ensure no fingerprints are present on these areas.
  5. Fit modified sensor.

Parts

Parts listed in the bulletin
PartPart numberQty
Water-in-fuel sensor - DefenderWKW0000301
Water-in-fuel sensor - DiscoveryWKW0000201

Data: Motorwise Workshop. Bulletin 4.

Brakes

4 documented faults — symptoms, causes and workshop fixes.

ABS warning lamp illuminates permanently or intermittently

Poor routing of ABS wheel speed sensor wiring harness around front flexible brake hose. Fix: fit a new part.

Overview

Affects
All models with ABS, VIN XA 159810-2A 62899.
Remedy
Fit new part

Repair steps

  1. Release brake system fluid pressure.
  2. Remove brake hose and pipe from hub mounting bracket.
  3. Fit new hub mounting bracket.
  4. Fit brake pipe, brake hose and ABS wheel speed sensor wiring harness to hub mounting bracket.
  5. Bleed brake system.

Parts

Parts listed in the bulletin
PartPart numberQty
Front ABS wheel speed sensorSSW1000502
Front ABS wheel speed sensor clip bracket, rightRGY0000201
Front ABS wheel speed sensor clip bracket, leftRGY0000301
ABS harness clipDYC1014102
Clip - brake hose to ABS harnessNTC82422

Data: Motorwise Workshop. Bulletin 8.

ABS warning lamp illuminates permanently or intermittently

Poor routing of ABS wheel speed sensor wiring harness around the rear axle.

Overview

Affects
All models with ABS.

Repair steps

  1. Fit cable tie and clip around axle tube.
  2. Ensure the cable tie is outboard of the shock absorber with the clip on top of the axle tube.
  3. Fit ABS wheel speed sensor wiring harness to clip.
  4. Repeat procedure for opposite side.

Parts

Parts listed in the bulletin
PartPart numberQty
ABS wheel speed sensor assembly - rearSSW1000601
Accelerator cableRGY5000102

Data: Motorwise Workshop. Bulletin 9.

Stop lamps not working

Affects All models.Fit new part

Cause

Brake pedal position (BPP) switch faulty.

Repair

  1. Fit new BPP switch.

Data: Motorwise Workshop. Bulletin 11.

Squeal from rear brakes when braking lightly at 30-50mph (48-80kph)

Affects All models with rear disc brakes, 2005→.Fit modified part

Cause

Rear brakes vibrating when brakes applied.

Repair

  1. Fit modified rear brake pads. Note: When fitting brake pads ensure large chamfer is facing downwards.
Parts1 part
Parts listed in the bulletin
PartPart numberQty
Rear brake pad kitLR0329541

Data: Motorwise Workshop. Bulletin 12.

Suspension & drivetrain

1 documented fault — symptoms, causes and workshop fixes.

Vibration above 50mph, 2900-3400rpm

Affects All models, 110/130, →VIN 3A 647098.Fit modified part

Cause

Transfer box shock absorber.

Repair

  1. Fit modified shock absorber.
Parts1 part
Parts listed in the bulletin
PartPart numberQty
Shock absorberIAI1000311

Data: Motorwise Workshop. Bulletin 5.

Clutch & gearbox

1 documented fault — symptoms, causes and workshop fixes.

Heavy clutch pedal action

Overview

Affects
All models with manual transmission, 1999→.
Remedy
Fit modified part
Parts
4 parts

Cause

Clutch pedal return spring weak.

Repair

  1. Remove and discard clutch pedal return spring.
  2. Fit modified clutch pedal return spring and bushes.
Parts4 parts
Parts listed in the bulletin
PartPart numberQty
Clutch pedal return springEDP7510L1
BushDCP3212L2
BushCLP31801
GasketANR63321

Data: Motorwise Workshop. Bulletin 13.

Air conditioning & heating

1 documented fault — symptoms, causes and workshop fixes.

Heater unable to demist front screen

Overview

Affects
All models.

Symptoms

Sound of water moving in heater.

Cause

Heater air intake drain valve sticking or blocked.

Water trapped in heater ducting.

Repair

  1. Ensure air intake drain valve operates correctly.
  2. Ensure air intake drain tube is not blocked.

Data: Motorwise Workshop. Bulletin 6.

Body & trim

1 documented fault — symptoms, causes and workshop fixes.

Excessive movement between exterior door handle and door

Overview

Affects
All models, 2006→.
Remedy
Fit modified part
Parts
2 parts

Cause

Exterior door handle retaining bolts loose.

Repair

  1. Fit modified exterior door handle retaining bolts and washers: Remove door trim panel. Fit modified retaining bolts and washers. Tightening torque: 2.5 Nm. Note: Only remove/replace bolts one at a time. Refit door trim panel.
  2. Repeat procedure for opposite side.
Parts2 parts
Parts listed in the bulletin
PartPart numberQty
Retaining boltLR024165As required
WasherWC105002As required

Data: Motorwise Workshop. Bulletin 14.

Wipers & visibility

1 documented fault — symptoms, causes and workshop fixes.

Erratic front wiper operation

Front wiper arm loose, allowing wiper spindle to rotate without moving wiper arm. Fix: adjust and tighten.

Overview

Affects
90/110/130/Defender, 1995-09: VIN 600000→.
Remedy
Adjust & tighten

Symptoms

Front wipers not working.

Repair steps

  1. Remove wiper arm nut protective cover and remove nut.
  2. If wiper arm has come loose from spindle inspect affected components for damage. Replace components as necessary.
  3. Ensure wiper motor is in park position.
  4. Fit front wiper arm. Tighten wiper arm nut as follows:.
  5. Freelander (97-06): 18 Nm.
  6. Freelander 2 (06-): 25 Nm.
  7. 90/110/130/Defender: 17 Nm.
  8. Discovery 3 (04-): 18 Nm.
  9. Range Rover (02-): 18 Nm.
  10. Range Rover Sport: 34 Nm.

Data: Motorwise Workshop. Bulletin 10.

Other

1 documented fault — symptoms, causes and workshop fixes.

Alloy wheels difficult to remove

Overview

Affects
All models with alloy wheels, →03/01.
Remedy
Clean & lubricate
Parts
1 part

Cause

Corrosion between hub spigot and wheel centre.

Repair

  1. Clean corrosion from wheel contact surfaces.
  2. Apply anti-seize grease to wheel contact surfaces.
Parts1 part
Parts listed in the bulletin
PartPart numberQty
Anti-seize greaseRYL105020L1

Data: Motorwise Workshop. Bulletin 7.

Glossary

Technical terms used in this guide.

VIN
Vehicle identification number — 17 characters, found at the base of the windscreen and on the V5C logbook
Nm
Newton-metres — the standard unit for how tightly a bolt is done up
ABS
Anti-lock braking system — stops the wheels locking under hard braking
EGR
Exhaust gas recirculation — feeds some exhaust gas back into the intake to cut emissions
BPP Switch
Brake pedal position switch — behind the pedal, it triggers the brake lights
BPP
Brake pedal position — the switch behind the pedal that triggers the brake lights
TC
Turbocharger — the exhaust-driven compressor that boosts engine power
Accelerator Pedal Position
The sensor that tells the engine control module how far the accelerator is pressed
Anti-Seize
Grease that stops mating parts (like a wheel on a hub) from corroding together
EGR Solenoid
The electrically operated valve that controls exhaust-gas recirculation
Hub Spigot
The raised centre of the hub that locates the wheel
Multi-Plug
A multi-pin electrical connector on a wiring harness
Solenoid
An electrically operated valve or actuator
Transfer Box
The gearbox that splits drive between the front and rear axles, and selects high/low range
Water-in-Fuel
Water contamination in diesel, collected in the fuel filter
Wheel Speed Sensor
A sensor at each wheel used by ABS and stability control
Wiring Harness
The bundled cables that carry power and signals around the vehicle
Bushes
Rubber mountings that let a suspension or body joint move without metal-to-metal contact
Intercooler Hose
The pipe that carries pressurised air between the turbocharger, intercooler and engine
Recirculation
Air-conditioning mode that recirculates cabin air instead of drawing in outside air

Frequently asked questions

What are the common faults with the Land Rover Defender 2.5 TD5?

This guide contains 14 workshop bulletins for the Land Rover Defender 2.5 TD5. Of these, four concern the engine and fuel system and four the brakes. Symptoms, causes, repair steps and part numbers are shown where supplied.

Does every Land Rover Defender 2.5 TD5 have these faults?

No. These are patterns documented across the model by workshops, not predictions for an individual vehicle. Where a fault applies only to certain vehicles or VIN ranges, that is listed with the fault.

Can I check for Land Rover Defender 2.5 TD5 faults myself?

Many of them. The documented symptoms can be seen, heard or felt during a test drive.

Related guides

Glossary term

See in the glossary →