We have had the trusty 2005 2.8 CRD KJ for just over a year now and it has thrown up another problem.
In the last two weeks the warning lights on the dash board have been flickering on / off oil light, fuel light on fuel gauge reading empty or partial measurement, WIF light, red led under fuel gauge comes on I no idea what that is) check engine light, depending which light comes on and they don't all come on at the same time, so you get a nice variety, you also get the warning ping, this is in conjunction with the speedo and tacho bouncing around randomly or not working.
Plus occasionally it would cut out at tick over.
On the whole the problem is getting worse now which could a good thing to help diagnose the fault.

However now .....
It constantly shows empty fuel with the light on, the cutting out is getting worse as are all the other symptoms.

So after reading many a forum I have replaced the rear abs/speed sensor and replaced a large portion of the abs/speed sensor loom, wiggled the remainder of the loom to see if I could generate the fault
Replaced the CPS
Checked the battery at rest first thing on a frosty morning, this shows 12.4V
Alternator is charging in excess of 14V
Checked the connections on the rear of the instrument cluster and re soldered the connector on the pcb, give it a bash / wiggle just in case
Replaced the fuel filter head with latest GEN 2
A colleague on a UK forum had an issue with wring under the air box so I have checked for chaffing etc in this area couldn't see anything obvious


Now I have seen this as an issue a few times on here reading through the last 30 pages or so in the tech section but there doesn't seem to be a definitive resolution other than an alternator failure.

At this point I am open to any suggestion ....... as the next stop to get the tent out, get some steaks, a match and use it as kindling

I had similar issues with my 2002 CRD...turned out to be multiple wiring issues.

First thing is to check your battery connections are good as well as connections of earthing strap to chassis is good.

Your ignition switch may be packing as well as the actuator that operates the switch may be on point of breaking.

I would suggest you plug your voltmeter into the front cigar lighter/aux power point and watch the voltage while driving...you may find that turning something on while driving causes the voltage to rise suddenly or drop suddenly.In my case this happened when I turned on front wipers or turned on air-con.
The voltage would rise to about 17 volts, "Ping", gauges go crazy and sometimes engine would stall with CEL light on. Restart the engine and voltage is fine.

Try the monitoring of the voltage from inside the cabin while driving and get back to us here if there is an issue.

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2002 Export CRD 2.5 Sport

Thanks for your suggestion.

Update .............

So after reading through numerous pages of electrical issues on here in the tech section.
I have slowly worked through all he suggestions.
Main additional ones, even though the battery was 12.4 V on a chilly frosty morning I replaced it for what was a new one of my XJ checked the connections etc ...... no difference.
Checked the relays in the PDC and connections underneath, while I was in the area all seemed ok swapped the relays around just in case ........ no difference.
I recalled there is a module down on the left side chassis rail I read about in a previous thread about, checking the connectors / connections hadn't corroded etc worth an unplug and plug back in !! and I saw the air con pipes did seem too close to the wiring coming out from the connection at the front side of the module.
At this point it was where the air con pipes change from rubber flex hose to the large "crimp" like connection for the beginning of the metal pipe. As I pushed them forward I could see that the pipes had worn through the insulation on 4-6 wires and shorting out a mixture of cables as it saw fit.
I have pushed a piece of rubber in between, to space the wires from the pipe and problem fixed.
Just need to effect a proper repair at the weekend

I hope this helps someone in the future

Great...glad you fixed it

This sort of frayed wire problem often happens but usually in some hidden place that is difficult to see!

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2002 Export CRD 2.5 Sport

A picture would be great too!

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05CRD: GDE Hot ECU & TCM tunes, Provent, Cat filter, Facet lift pump, TransGo kit, Florida TC, Samcos, stainless brake lines, HDS thermostat, Renegade light bar,
Bilstein adjustables, Al's Gen 4.5 Arms, 235/85-16 Duratracs, DTT rear, Elocker front, EVIC+TPMS, Turbo timer, McNally pillar gauges, Weeks Stage II kit.