LAND ROVER ACCESSORY FITTING INSTRUCTIONS

VEHICLE :
PART NO :
KEYWORD :

LAND ROVER

DEFENDER

WINCH MOUNTING KIT

VPLEP0427 / VPLEP0490 / VPLEP0428 / VPLEB0437 / LR137889 / VPLEP0431 / VPLEB0443 / LR129440

FITTING INSTRUCTION

WARNING
  • Accessories which are not correctly installed can be dangerous. Read the instructions carefully prior to installation. Comply with instructions at all times. If in doubt, contact your nearest approved retailer.
CAUTION
  • Installation of winch mounting kit to Plug-in Hybrid Electric Vehicle (PHEV) vehicles will require the sounder link harness which is only available as part of 'Remote Electric Winch Kit' - VPLEP0426.
  • The 'Remote Electric Winch Kit' - VPLEP0426 is not part of the 'Winch Mounting Kit' - VPLEP0427 / VPLEP0490. This part must be ordered separately.
NOTE
  • The 'Winch Mounting Kit' can be ordered with either VPLEP0427 or VPLEP0490.
  • For winch Operational Manuals, Instructions, Quick Start Guide, Synthetic Rope Installation Guide etc, go to https://international.warn.com and navigate to 'Zeon 10-S Platinum Winch' where the documentation can be found under the ‘Manuals and Literature’ section.
Accessories Part Number Superseded By
Winch Mounting Kit - 1st Release version VPLEP0427 VPLEP0490
Winch Mounting Kit - 2nd Release version VPLEP0490
Winch Cover Kit VPLEP0428
Crush Cans VPLEP0431
Parking Aid Sensors (Optional) LR137889
Camera Mounting Kit (Optional) VPLEB0437
Defender-X 'ONLY' H-Panels VPLEB0443
Defender-X 'ONLY' Grille LR129440

Winch Mounting Kit (Bill of Materials) - VPLEP0427

NOTE
  • In kit VPLEP0427 x2 (Q1) and x2 (L1) will need to be discarded as these are replaced by stainless steel fixings (SS1) and (SS2) to be used in install step 5 only.

Winch Mounting Kit (Bill of Materials) - VPLEP0490

Winch Cover Kit (Bill of Materials) - VPLEP0428 / VPLEB0437 / LR137889

Crush Cans (Bill of Materials) - VPLEP0431

Defender-X bumper parts (Bill of Materials) - VPLEB0443 / LR129440

NOTE
  • For Defender-X vehicles 'ONLY' the following parts are required to be ordered separately.
REMOVAL INSTRUCTIONS
1
CAUTION
  • For vehicles installed with coil suspension 'ONLY'.

If the remote control electric winch is also being installed in conjunction with the winch mounting kit, replace the front coil springs with the correct kit below listed.For additional information, please refer to the official Workshop Manual. Shock Absorber and Spring Assembly - [+] Coil Suspension (204-01 Front Suspension) . If not then proceed to next step.

  • 6 Cyl 90 L8BM-5B302-AA VPLEI0604.
  • 6 Cyl 110/130 L8BM-5B302-BA VPLEI0605.
  • 4 Cyl 90 L8B2-5C314-KA LR140233.
  • 4 Cyl 110/130 L8B2-5C314-EA LR140355.
2

Disconnect the vehicle start-up battery. For additional information, please refer to the official Workshop Manual. 12V System Disconnect and Connect (414-00 Battery and Charging System - General Information)

3

Remove radiator grille.

  • For additional information, please refer to the official Workshop Manual. Radiator Grille (501-08 Exterior Trim and Ornamentation)
4
NOTE
  • Do not remove fog lamps if present.

Remove front bumper.

  • For additional information, please refer to the official Workshop Manual. Front Bumper (501-19 Bumpers)
5

Remove x4 fixings to remove the front bumper support bracket.

6

Remove x6 fixings and x1 electrical connector to remove the lower grille.

  • For additional information, please refer to the official Workshop Manual. Hood Latch Panel (501-02 Front End Body Panels)
7

Remove x6 fixings and x1 electrical connector to remove the upper grille.

  • For additional information, please refer to the official Workshop Manual. Hood Latch Panel (501-02 Front End Body Panels)
8
NOTE
  • This step is 'ONLY' For PHEV vehicles.

Remove x4 fixings to separate the grille from the shroud.

9
NOTE
  • This step is 'ONLY' For PHEV vehicles.

Remove x3 slats from the grille and discard.

10
CAUTION
  • Be aware of any sharpe edges when cutting.
NOTE
  • This step is 'ONLY' For PHEV vehicles.

Use an appropriate tool to cut where illustrated along the dashed lines and discard the removed blue section. Then file down any sharpe edges.

11
CAUTION
  • Be aware of any sharpe edges when cutting.
NOTE
  • This step is 'ONLY' For PHEV vehicles.

Use an appropriate tool to cut where illustrated along the dashed lines and discard the removed blue section. Then file down any sharpe edges.

12
CAUTION
  • Be aware of any sharpe edges when cutting.
NOTE
  • This step is 'ONLY' For PHEV vehicles.

On the shroud use an appropriate tool to cut where illustrated along the dashed lines and discard the removed blue section. Then file down any sharpe edges.

13
NOTE
  • This step is 'ONLY' For PHEV vehicles.

Install x4 fixings to secure the grille back to the shroud.

14

Remove hood latch panel.

  • For additional information, please refer to the official Workshop Manual. Hood Latch Panel (501-02 Front End Body Panels)
15

Remove front bumper armature.

  • For additional information, please refer to the official Workshop Manual. Front Armature (501-19 Bumpers)
16
NOTE
  • For vehicles with active grille 'ONLY'.

Cut the lower active vane connector and heat shrink the exposed wire. Tape the cut active vane harness to the main vehicle harness securely.

  • For additional information, please refer to the official Workshop Manual. Wiring Harness (418-02 Wiring Harnesses)
17

Release x6 clips and remove the radiator air vent from the vehicle.

18
WARNING
  • Make sure to wear suitable personal protective equipment.
CAUTION
  • Only cut and discard the sections of rubber seal as illustrated.
NOTE
  • Image looking from front of part.

Use suitable tooling to cut the illustrated sections along the dashed lines from the radiator air vent. Discard the removed blue sections.

19
WARNING
  • Make sure to wear suitable personal protective equipment.
CAUTION
  • Only cut and discard the sections of rubber seal as illustrated.

Use suitable tooling to cut the illustrated sections along the dashed lines from the radiator vent. Discard the removed blue sections.

Fitting Instruction
1
NOTE
  • For vehicles installed with pusher fan, unplug and route harness from the fan inside the venting. The harness will be secured to the winch cradle.

Install the radiator air vent back to the vehicle using x6 retaining clips.

2

Reposition the auxiliary radiator(s) if present to gain access to the rear of the crush can mountings.

3

Remove and discard x4 clips as illustrated.

4

Install the bracket (N) to the winch mounting cradle (E) using x2 fixings (L1) and (Q1).

  • Torque: 30Nm
5

Install the winch guide plate (Q) to the front armature (E) using Stainless Steel fixings (SS1) and (SS2) as illustrated.

  • Torque: 22Nm
6

Install the grille (J) to the winch mounting cradle (E) using the fixings (H1) and (R1) as illustrated.

  • Torque: 10Nm
7
NOTE
  • For vehicles without a front undershield installed.

Install the brackets (F) to the winch mounting cradle brackets (C) using the bolts (H1) and the nuts (R1).

8
CAUTION
  • Install, but do not fully tighten the bolts.
NOTE
  • This step must be completed on both sides of the vehicle.

Install the winch mounting cradle brackets (C) to the vehicle using x2 fixings (Q1) and the x2 bolts retained during the front armature removal. Repeat step on both sides of the vehicle.

9
CAUTION
  • Install, but do not fully tighten the bolts.
NOTE
  • This step must be completed on both sides of the vehicle.

Noting the correct orientation install the new crush cans (B). Position with the inside fixings (C1) and additional washers (D1).

10
WARNING
  • Install the handed brackets (A) as illustrated. Failure to do so will affect the winch cradle strength.
NOTE
  • This step must be completed on both sides of the vehicle.

Noting the correct orientation position the brackets (A) as illustrated.

11
CAUTION
  • Install, but do not fully tighten the bolts.
NOTE
  • This step must be completed on both sides of the vehicle.

Install the outside fixings (A1) and washers (D1) and the nuts (J1) to secure the crush can and brackets.

12
CAUTION
  • Install, but do not fully tighten the bolts.
NOTE
  • This step requires the aid of another technician.
  • This procedure must be completed on both sides.

Install the winch cradle.

  1. Install but do not fully tighten x4 fixings (E1).
  2. Install but do not fully tighten x3 fixings (B1) and (J1).
13
NOTE
  • This step is applicable 'ONLY' to vehicles installed with front pusher fan.

Attach pusher fan vehicle harness to the highlighted clamp points on the crush can and rear of the winch cradle.

14
NOTE
  • This step must be completed on both sides of the vehicle.

Raise the cradle and crush cans against the square support brackets and fully tighten the x4 bolts as illustrated.

  1. Tighten x2 fixings (C1). Torque: 55 Nm
  2. Tighten x2 fixings (A1). Torque: 110 Nm
15

Move the winch mounting cradle to the furthest forward position.

16
CAUTION
  • M12 torque is critical for cradle impact deflection.
NOTE
  • This step must be completed on both sides of the vehicle.

Fully tighten the fixings.

  1. Tighten x6 fixings (J1) and (B1). Torque: 55 Nm
  2. Tighten x8 fixings (E1). Torque: 55 Nm
17
CAUTION
  • Complete this step 'ONLY' for vehicles equipped 'WITH' a 'Front Undershield' - VPLEP0436.
  • Air vent lip seal should be in front of the grille.
  • Spacer (K) 'NOT' used.
  • Install, but do not fully tighten the bolts (B1) and (L1) for the cradle leg (G).
NOTE
  • This step must be completed on both sides of the vehicle.

Install the spacer blocks (T) using the fixings (F1) and (Q1). The protection bar is to be installed at the same time as the cradle legs (G). Install, but do not fully tighten the bolts (B1) and (L1) for the cradle legs (G).

  • Tighten x2 fixings (F1). Torque: 30Nm
18
CAUTION
  • Complete this step 'ONLY' for vehicles 'WITHOUT' 'Front Undershield' - VPLEP0436.
  • Install, but do not fully tighten the x2 bolts.

Install a spacer (K) to the lower part of each of the legs (G) using fixings (B1).

  • Install, but do not fully tighten x2 fixings (B1).
19
CAUTION
  • Complete this step 'ONLY' for vehicles 'WITHOUT' 'Front Undershield' - VPLEP0436.

Secure the upper part of each of the legs (G) to the winch mounting cradle using x4 fixings (L1) and (Q1).

  • Torque: 30Nm
20
CAUTION
  • Complete this step 'ONLY' for vehicles 'WITHOUT' 'Front Undershield' - VPLEP0436.

Tighten x2 fixings (B1).

  • Torque: 110 Nm
21

Tighten x4 fixings.

  • Torque: 30Nm
22

Install the remote control electric winch at this point if required.

23
CAUTION
  • Air vent lip seal should be outside of the winch lower air vent.

Install the lower winch air vent (I).

  1. Install x6 fixings (H1) and x4 fixings (R1).
  2. Torque: 4Nm
24
NOTE
  • Make sure the lip seals are straight with no distortion on the lip edges.

Trim and instal the lip seal (M) to the upper and the lower venting as illustrated.

25
WARNING
  • Make sure to wear suitable personal protective equipment.
CAUTION
  • Only cut and discard the section of the hood latch panel as illustrated.
NOTE
  • Image looking from front of part.

Use suitable tooling to cut the illustrated section along the dashed lines of the hood latch panel. Discard the removed blue section.

26
WARNING
  • Make sure to wear suitable personal protective equipment.
NOTE
  • Image looking from rear of part.

Use suitable tooling to cut the illustrated section along the dashed lines from the front bumper support bracket. Discard the removed blue section.

27
WARNING
  • Make sure to wear suitable personal protective equipment.
CAUTION
  • For vehicles equipped with a plug-in hybrid electric vehicle pedestrian speaker.
NOTE
  • Image looking from rear of part.

Use suitable tooling to cut the illustrated section along the dashed lines from the front bumper support bracket. Discard the removed blue section.

28

Install the hood latch panel. For additional information, please refer to the official Workshop Manual. Hood Latch Panel (501-02 Front End Body Panels)

29
NOTE
  • This step is 'ONLY' For PHEV vehicles.

Install the plug-in hybrid electric vehicle speaker bracket (L) and the modified front bumper support bracket to the hood latch panel using the retained fixings.

  1. Install the speaker into the speaker bracket (L).
  2. Connect the link lead (S) from the 'Remote Control Electric Winch Kit' - VPLEP0426. If harness modification is required, refer to the electrical wiring repair section. For additional information, please refer to the official Workshop Manual. Wiring Harness (418-02 Wiring Harnesses)
30

Install x6 fixings and x1 electrical connector to install the upper grille.

31
WARNING
  • Make sure to wear suitable personal protective equipment.

Use suitable tooling to cut the illustrated sections along the dashed lines from the front brake air vents. Discard the removed blue parts.

  • Drill a hole as illustrated on both of the front brake air vents.
  • 7 mm drill bit
32

Install the front brake cooling vents on both sides of the vehicle.

33
NOTE
  • Retain the license plate and the license plate fixings.

Remove the license plate and the license plate fixings.

34
NOTE
  • Retain the license plate plinth and the license plate plinth fixings.

Remove the license plate plinth if installed.

35
NOTE
  • The x2 removed parking aid sensors will be replaced with x2 black parking aid sensors (LR137889) that get installed to the winch cover.

Remove and discard the x2 parking aid sensors from the front bumper.

  1. Disconnect the parking aid sensor harness from the parking aid sensor.
  2. Remove the parking aid sensor from the front bumper.
36
NOTE
  • Vehicles equipped with a front proximity camera.

Disconnect the front proximity camera.

37
NOTE
  • Vehicles equipped with a front proximity camera.

Remove the arrowed tape and the arrowed clip securing the camera harness to the front wiring harness.

38

Release x14 wiring harness clips.

39

Remove the camera housing and the camera from the front bumper grille part.

  • Remove x3 fixings.
40
NOTE
  • Before removing the front camera from its housing, note the orientation of the camera so you know which way up ut should be when you reinstall it later.

Remove the front proximity camera from the camera housing.

  1. Remove the front proximity camera from the camera housing. Retain the front proximity camera (S2).
  2. Discard the camera housing.
41
NOTE
  • This step 'ONLY' applies to Defender-X vehicles. If your vehicle is not a Defender-X then proceed to next step.

Order H-panels - VPKEB00443. Then use suitable tooling to cut off the clips on both H-panels as illustrated along the dashed lines. Then proceed to step 44.

42
CAUTION
  • There are multiple cut guide lines on the front bumper lower cover. There is a risk of irreversible damage to the part if the correct cut guide lines are not followed.
NOTE
  • This step 'ONLY' applies to non-Defender-X vehicles. If your vehicle is a Defender-X then proceed to step 44.

Identify and mark the correct cut guide lines on the back of the front bumper that was removed in removal step 4.

43
WARNING
  • Make sure to wear suitable personal protective equipment.
CAUTION
  • There are multiple cut guide lines on the surface of the part. Make sure the correct cut guide lines are followed as illustrated.
  • If the vehicle has a satin wrap then this must be removed from the front bumper lower cover.
NOTE
  • This step 'ONLY' applies to non-Defender-X vehicles. If your vehicle is a Defender-X then proceed to next step.

Use suitable tooling to cut the illustrated section along the dashed lines from the front bumper lower cover. Discard the removed blue section.

  1. Use the cut guide lines on the front bumper lower cover.
  2. Use a drill to make corner radiuses along the cut line.
44
WARNING
  • Make sure to wear suitable personal protective equipment.

Use suitable tooling to cut the illustrated section along the dashed lines from the front bumper upper cover. Discard the removed blue section.

  1. Using the dimensions provided cut and discard the highlighted sections.
  2. For vehicles equipped with a front proximity camera, cut and discard the highlighted section using a 40 mm hole cutter.
45
WARNING
  • Make sure to wear suitable personal protective equipment.

Use suitable tooling to cut and discard the illustrated section along the dashed lines from the front bumper upper cover. Discard the removed blue section.

  • 12 mm drill bit
46
NOTE
  • This step is 'ONLY' for vehicles installed with front proximity camera.

Using a suitable cutting tool cut a hole for the front camera cable routing.

  • 40 mm drill bit
47
WARNING
  • Make sure to wear suitable personal protective equipment.
NOTE
  • Image looking from front of part.

Use suitable tooling to cut the illustrated section along the dashed lines from the upper bumper grille. Discard the removed blue section.

  • 25 mm drill bit
48
WARNING
  • Make sure to wear suitable personal protective equipment.
CAUTION
  • For Defender-X vehicles 'ONLY', the lower bumper grille (LR129440) must be ordered. Discard the lower bumper grille that was removed from the vehicle.

Using a suitable tool cut the illustrated section along the dashed lines from the lower bumper grille. Discard the removed blue section.

  • Retain part of the lower bumper grille (S1).
49
WARNING
  • Make sure to wear suitable personal protective equipment.
NOTE
  • Image looking from rear of part.

Use suitable tooling to cut the illustrated section along the dashed lines from the front bumper carrier. Discard the removed blue section.

50
CAUTION
  • This step must be completed when the part is not installed to the vehicle.

Using the strengthening bar as a guide (H), drill the x5 locations on the lower bumper grille part (S1), retained from step 47. Countersink the holes produced in part (S1) for the screws (K1) on the opposite side.

  • 4 mm drill bit
51

Trim and install safe edge (P) to the lower bumper grille part (S1).

52
NOTE
  • Image looking from underneath part.

Install the strengthening bar (H) to the front bumper carrier.

  1. Locate the strengthening bar (H) to the front bumper carrier.
  2. Install the lower bumper grille (S1) over the strengthening bar (H) using the x5 screws (K1).
53

Assemble and install the front bumper. For additional information, please refer to the official Workshop Manual. Front Bumper (501-19 Bumpers)

54

Install the x2 black parking aid sensors (U) to the parking aid sensor brackets that are part of the winch cover (P).

  • Install the x2 tow eye cover retaining clips (N1).
55

Inspect the correct orientation of the cover securing clips.

56
NOTE
  • For vehicles equipped with the front proximity camera follow steps 56 to 60. If not then proceed to step 61.
  • If the front proximity camera will be installed then the camera mounting kit (VPLEB0437) must be ordered.

Apply tape in the area shown to protect the grille section when cutting part (P) in next step.

57
NOTE
  • This step 'ONLY' applies to vehicles with front proximity camera.

For the front proximity camera fitting cut out the indented areas visible on the inside of the winch cover.

58
NOTE
  • This step 'ONLY' applies to vehicles with front proximity camera.

Cut 8 mm from the camera mount (T2) tabs. Install the mount to the winch cover through the cut outs. Make sure to move fully forward.

59
NOTE
  • This step 'ONLY' applies to vehicles with front proximity camera.

Mark and drill x2 holes in the winch cover using the camera mount (T2) as a guide.

  • 1 mm drill bit
60
NOTE
  • This step 'ONLY' applies to vehicles with front proximity camera.

Install the x2 camera mount fixings (T1).

61

Locate the x2 front inner parking aid sensor electrical connectors.

  1. Parking aid sensor electrical connectors.
  2. If installed, locate the front proximity camera electrical connector.
62

Install the winch bar (O) to the winch mounting cradle using x2 fixings (Y1), (W1) and (U1).

  • Torque: 24 Nm
63
CAUTION
  • Allow to dry for a minimum of 2 minutes between steps 1 and 2.

Clean and apply promoter.

  1. Using the cleaner (X) supplied in the kit, clean the illustrated areas.
  2. Using the adhesion promoter (Y) supplied in the kit, wipe the illustrated areas.
64

Install the dual-lock strips (W) supplied in the kit.

  1. Cut the dual-lock strips (W) to size and peel off the backing from the x5 pieces you have cut.
  2. Apply the cut dual-lock strips (W) to each of the x5 winch bar brackets.
65

Apply a second dual-lock strips (W) velcro down onto the existing x5 strips.

66
NOTE
  • This step requires the aid of another technician.
  • The winch cover (P) must be positioned close to the front of the vehicle to allow the parking aid sensor harnesses to be connected.

Position the winch cover (P) close to the front of the vehicle and connect the parking aid sensor harness to the parking aid sensor (U) in the winch cover (P). Complete step on both sides of the winch Cover.

67
NOTE
  • This step 'ONLY' applies to vehicles with front proximity camera.

Attach the front proximity camera (S2) to the camera harness.

  • The front proximity camera harness will already have been fed through the grille part of the front bumper.
68
CAUTION
  • Take care when handling the camera. Avoid touching the camera lens.
NOTE
  • This step 'ONLY' applies to vehicles with front proximity camera.

Carefully install the front proximity camera (S2) into the camera housing (T3). Install the camera and housing onto the previously installed bracket (T2). Secure the camera housing to the camera bracket using the screw (T1).

69

Install the winch cover (P).

  1. Engage x2 retaining clips.
  2. Install x2 fixings (T1). Torque: 6 Nm
70
NOTE
  • Make sure winch cover (P) is clean.

Using the dual-lock strips to secure winch cover (P) to winch bar (O).

  1. Pull up the trailing edge of the winch cover (P) to reveal the dual-lock strips (W) underneath
  2. Peel off the backing from the x5 pieces of dual-lock strips (W) and let the winch cover move back to its natural state. Push down on the winch cover surface for 15 seconds to make sure a good adhesive bond.
71
CAUTION
  • Make sure the pins are located correctly along the top edge of the lower winch cover.

Install the winch cover (R) using x2 fixings (M1).

72
CAUTION
  • Make sure the license plate plinth is installed correctly and is not distorted.
NOTE
  • Complete step only if required.
  • For China market vehicles do not complete this step. Proceed to steps 73 to 76.

Install the license plate plinth then install the license plate.

73
NOTE
  • Complete step 'ONLY' for China market vehicles.

Remove the x3 location pins from the license plate plinth as illustrated.

74
NOTE
  • Complete step 'ONLY' for China market vehicles.

Attach the supplied template (Z) against the winch cover and secure in position using tape.

75
CAUTION
  • Make sure the license plate plinth is installed correctly and is not distorted.
  • The China license plate plinth must be installed rotated 180 degrees.
NOTE
  • Complete step 'ONLY' for China market vehicles.

Install the China license plate plinth to the winch cover as illustrated.

  1. Drill 5 holes in the winch cover at the locations defined by the template. 6mm drill bit.
  2. Remove the template.
  3. Locate the license plate plinth, rotated 180 degrees, against the winch cover. Make sure all the holes in the license plate plinth align with the holes in the winch cover.
  4. Install the license plate plinth to the winch cover using x5 fixings (Z1) and (Z2).
76
NOTE
  • Complete step 'ONLY' for China market vehicles.

Install the license plate to the license plate plinth.

© Land Rover 2016