HHhhhhmmmm - that doesn't look anything like the relay module that Rovers North sent me. The part number on the one from my 90 is YWB 10041 C and I can't find it on their site, any ideas where I might be able to find one?

Let me do some research.....BRB

That's the one that Rover's North sent me and is a standard looking relay, but the part that the manual page you sent has me pulling out is a black box with 2 wiring harness plugs that doesn't look a thing like the AFU part. In searching around a bit it appears the '97 D90s had a different relay module, but I can't find this part on the internet...

Hmmm... Can you take a picture of it and post it up here?

Is it inside the black box?

Part number is different but it sure looks like the right thing.... Of course it has to be twice as expensive as the older model relay! Thanks again for all the help and look forward to buying you a beer one of these days.

Cheers!

The only thing about all this, is that I'm not sure that this is the source of the problem. The car stalled randomly a couple of times (no sputtering, just died like it had been turned off) but restarted right away, and then one day it just wouldn't start. I have no fuel pressure so I figure it is either the relay or the pump... it seems a lot easier to replace the relay than replace the pump, so I have my fingers crossed.

Sounds accurate. Relay first, then pump if needed. How old is the pump?

As far as I know the pump is original - the worst part is while I was away a while ago my wife needed have the fuel filler hose replaced (was leaking) - she had to take it to a dealer since I wasn't around, and they would have dropped the tank to replace it.... now I may have to drop it again.... but I keep hoping it's the relay

Relay relay relay......

Well, if you need help with it, let me know.

Dan

It has been my experience that the fuel pump relays tend to last longer than fuel pumps. Since the truck runs, it doesn't seem like there could be a problem with the relay. I guess the relay itself could be sticky and work periodically, but that is much less likely than a fickle fuel pump.

Swapping the pump itself is an easy job. I'm not sure what the interior is like on the D90, but on a Disco all you have to do is pull the rear trim piece, lift the carpet to access the fuel pump. There is a small cover that has to be removed then the fuel pump itself is easy t pull. Disconnect the fuel lines and electrical connector, then remove the plastic ring that hold the pump in place. Pull the pump and reverse the process to install.

Have you ever measured the fuel pressure to see if the pump is weak? Assuming that the pump is the same as on the Discovery, the fuel pressure should be 34-37psi with the ignition on / engine off. When the engine is running it should be ~30psi.

Before you go changing parts, I'd confirm the fuel pressure specs for the Defender and check the fuel pressure and go from there.

You have to drop the tank on the Defender unfortunately...

The car stalled a couple of times and then it wouldn't start at all - no fuel pressure. I'm keeping my fingers crossed on it being the relay, but know I might be stuck having to change the pump. 2 rovers down, only one working.... gotta love 'em!