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LAND ROVER ACCESSORY FITTING INSTRUCTIONS

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LAND ROVER

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
  • Due to the nature of this accessory it is recommended for retailer installation only. If a customer attempts to install this accessory themselves they will require a copy of the workshop manual links within this procedure.
NOTE
  • This procedure contains illustrations showing certain components removed to provide extra clarity.
NOTE
  • Make sure the wireless remote is fully charged.
NOTE
  • Overload interrupt unit power lead (A4), ignition / crank and ground lead from relay module (A3), winch power lead (A1), winch ground lead (A2).
Fitting Instruction
1

Disconnect the vehicle start-up battery. For additional information, please refer to the official Workshop Manual. Startup Battery Disconnect and Connect (414-00)

2

Cut the active vane connector and heat shrink the exposed wires. Tape up the harness in a secure location. For additional information, please refer to the official Workshop Manual. Wiring Harness (418-02)

3
NOTE
  • The orientation of the hexagonal sealing connector may need to be moved flush with the mounting plate to clear the screw head.
  • To aid installation hand start the screws (N) and hook the module over screws before tightening.

Install the relay module box (B) to the winch cradle.

  • Install the 2 screws (N).
  • Torque: 4 Nm
4
CAUTION
  • Remove the bolt and make sure the thread length is 16 mm minimum. If below 16 mm then replace bolt with the M8 x 16mm one supplied loose in the electric winch kit.
  • Lower the winch into the cradle for connection with lead (A3). The aid of a second technician is necessary.

Secure the relay module ground lead from (A3) the relay module box to the negative lead attachment location.

  • Torque: 12 Nm
5
CAUTION
  • Avoid trapping the harness and route the harness away from any sharp objects.
NOTE
  • The aid of a second technician is necessary.
  • Movement of the winch unit may be necessary for access.

Lower the winch (A) into the winch cradle.

6

Install the supplied convoluting to the full length of leads A1 (power), A2 (ground), A3 (ignition / crank), and A4 (overload interrupt unit power lead). Feed both the leads and convolute through specified grommets.

7
NOTE
  • Convolute is not shown in following images for clarity.

Feed both the power lead (A1) and convoluting through the winch upper ducting (D) and the overload interrupt unit (C). If the arrowed hole is not present in the winch upper ducting then make a 30 mm hole approximately 50 mm from the edge of the upper ducting as shown.

8
NOTE
  • This step requires the aid of another technician.
  • Do not secure the winch upper ducting (D) at this stage.

Lower the winch upper ducting (D) into the correct position as illustrated.

9

Feed the ground cable (A2) through the winch upper ducting and secure the grommet.

10
NOTE
  • This step requires the aid of another technician.
  • Do not secure the winch upper ducting (D) at this stage.

Lower the winch upper ducting (D) into the correct position as illustrated.

11
CAUTION
  • Avoid trapping the harness and route the harness away from any sharp objects.

Feed the cables through, removing slack behind the winch ducting. Secure with clips (H) and (G) to the winch cradle and the vehicle frame.

12
CAUTION
  • Avoid trapping the harness and route the harness away from any sharp objects.

Feed both the leads through the vehicle body and secure with clips (H) and (I) as illustrated . Loosely cable tie the leads to the engine compartment wiring harness.

13
CAUTION
  • Avoid trapping the harness and route the harness away from any sharp objects including nuts, bolts and moving parts.
  • Make sure the ground cable has enough clearance from surrounding parts when routing to the body ground post.

Attach the negative lead to the body ground post. Secure to the metal cross frame with 2 edge clips (V) as illustrated.

  • Torque: 12 Nm
14

Feed the positive lead (A1) along the body harness and to the rear of the positive terminal box. Remove the terminal cover.

15
NOTE
  • Depending on which fuse locations are used either side of the terminal cover sections may be removed.

Cut out the highlighted section of the terminal cover. Install the fuse (F) and the positive lead (A1) to the terminal C6 with 2 bolts (Q). Install the terminal cover.

  • Torque: 12 Nm
16
CAUTION
  • Avoid trapping the harness and route the harness away from any sharp objects including nuts, bolts and moving parts.
  • Make sure the ground cable has enough clearance from surrounding parts when routing to the body ground post.

Loosely cable tie leads (A1) and (A2) to the engine compartment wiring harness as illustrated.

17
CAUTION
  • Avoid trapping the harness and route the harness away from any sharp objects including nuts, bolts and moving parts.

Attach the antenna (E) to the top of the positive terminal cover. Route the lead back through the front of the engine compartment following the power lead route and loosely secure using cable ties.

18

Feed the antenna cable (E) through the overload interrupt unit power lead grommet. Secure lead with clip (H) into the winch upper ducting.

19

Attach the antenna cable (E) coaxial connector to the coaxial connector on the rear of the winch unit. Secure to the winch cables with a cable tie.

20

Connect lead (A4) to the overload interrupt unit.

21
CAUTION
  • Avoid trapping the harness and route the harness away from any sharp objects including nuts, bolts and moving parts.

 

  1. Connect lead (A3) to the input receptacle on the winch power lead and secure with Clip (Y) to the upper winch ducting.
  2. Secure clip to the winch cradle
  3. Feed the ignition / crank lead (A3) and in-line connector through the upper winch ducting, securing the grommet.
  4. Secure the connector to the vehicle body using clip (X).
22
CAUTION
  • Avoid trapping the harness and route the harness away from any sharp objects including nuts, bolts and moving parts.

Connect the ignition and crank harness (K) to the in-line harness from the relay module.

23

Remove the cowl panel. For additional information, please refer to the official Workshop Manual. Cowl Panel (501-02)

24
CAUTION
  • Avoid trapping the harness and route the harness away from any sharp objects including nuts, bolts and moving parts.
NOTE
  • Left hand drive vehicle shown.
  • Bundle up excess cable as shown. Secure with cable ties or suitable tape.
  • Refer to following step for routing through to the electronic junction box.
  • Remove the convoluting on lead (K) before routing through the secondary bulkhead right panel.

Following the positive lead routing, route the ignition / crank lead (K) through the secondary bulkhead right panel up to the electronic junction box.

25

Route lead (A3) through the arrowed available hole in the secondary bulkhead right panel if accessible. Otherwise route through the grommet on the top of the panel as illustrated. If required drill a hole in the secondary bulkhead right panel in the position illustrated.

26

For right hand drive vehicles route the ignition / crank lead (A3) up to the junction box as shown. The lead will be tied to the cowl panel on installation.

27

Release the 4 clips and remove the electronic junction box cover.

28
CAUTION
  • Make sure all grommets are completely sealed.
NOTE
  • Protective convoluting for the ignition / crank lead should not pass into the junction box.

For access remove all electronic junction box harness connectors and harness grommets. Feed wire (A3) through the top grommet.

29
CAUTION
  • Do not attempt to repair any part of a wiring harness unless appropriate training has been received.

Using a suitable tool make a small cutout at the top of the grommet for lead (A3) to pass into the electronic junction box. For additional information, please refer to the official Workshop Manual. Wiring Harness (418-02)

30
NOTE
  • Left hand drive vehicle shown.

Connectors C1BB03A and C1BB03B used. For additional information refer to the Electrical Information section in Topix.

31
NOTE
  • Right hand drive vehicle shown.

Connectors C1BB03A and C1BB03B used. For additional information refer to the Electrical Information section in Topix.

32
CAUTION
  • Do not fully remove anti-backout lock.
  • Do not attempt to repair any part of a wiring harness unless appropriate training has been received.
NOTE
  • Refer to electrical wiring diagrams in the Electrical Information section in Topix for more information.

Black crank wire of lead (A3) connects to Engine Junction Box (EJB) A, connector C1BB03A - pin 16. Red ignition wire of lead (A3) connects to EJB B, connector C1BB03B - pin 10. Remove connector covers. Inspect the relevant pins in each connector to ascertain if splicing is required. For additional information, please refer to the official Workshop Manual. Wiring Harness (418-02)

  1. Inspect pin 16 on EJB A connector C1BB03A and pin 10 on EJB B connector C1BB03B to determine if a splice is required.
  2. If a splice is required, use splice (S1) to splice the relevant wire from lead A3 into it's relevant pin on the EJB connector.
  3. Use heat shrink (S2) to seal splice.
  4. If a splice is not required, move out the anti-backout lock and install the wires from lead A3 into its relevant pin on the EJB connector.
33
CAUTION
  • Failure to correctly seal the electronic junction box grommet may result in serious damage to the vehicles electrical system.
  • Avoid trapping the harness and route the harness away from any sharp objects.

Install connector covers securing with a cable tie. Install all electronic junction box connectors to the junction box making sure lead (K) is securely fastened to the harness. Make sure enough wire is fed through and secured within the grommet cut out. Reseal the grommet using a suitable silicone sealant. For additional information, please refer to the official Workshop Manual. Wiring Harness (418-02)

34
NOTE
  • Refer to the Electrical Information section in Topix for more information.

Check if 5 amp micro fuses are populated in EJB A - slot F8 and EJB B - slot F9. If micro fuses are not present, install the micro fuse (W) from the winch electrics kit (VPLEP0426) into the vacant slot. Refer to the electrical wiring diagram document, that can be found in the electrical information section of TOPIx - EJLR 03 22 21_1E - DEFENDER Fuse and Relay Locations.

35

Replace the electronic junction box cover.

36

Connect the vehicle start-up battery. For additional information, please refer to the official Workshop Manual. Startup Battery Disconnect and Connect (414-00)

37
NOTE
  • Make sure the winch switch is set in the on position.
  • For more information refer to the Warn winch instructions.

Turn on the winch. The toggle switch at the rear of the winch will flash green when switched on.

38
CAUTION
  • Never pair more than one winch and one remote at a time.
NOTE
  • For more information refer to the Warn winch instructions.

To pair the remote make sure the vehicle ignition is switched off and follow the steps:

  1. Navigate to the pairing icon and press select.
  2. Press and hold select and the right button simultaneously for 3 seconds to bring up the pairing confirmation menu.
39

 

  1. To continue pairing, select the green check mark icon by navigating with the left or right buttons and press select.
  2. After selecting the green check mark icon, a timer will begin counting down from 30 seconds.
  3. During the 30 seconds, turn the vehicle ignition on (without starting the engine).
  4. The winch should now be paired. If unsuccessful (red cross will show), turn the vehicle ignition off. Make sure the vehicle is fully shut down, check the alarm is on and lights have turned off. Now restart the pairing process from step 39.
40
NOTE
  • Refer to Warn winch manual for instructions.
  • When the engine is cranked the crank wire will give a voltage spike of approximately 12v.

Turn on the vehicle ignition and test the operation of the remote control electric winch. If the winch does not operate, make sure the winch engine junction box connectors are correctly inserted and the ignition and crank wires are receiving 12v. Refer to electrical wiring diagrams in the Electrical Information section in Topix for more information.

41

Disconnect the vehicle start-up battery. For additional information, please refer to the official Workshop Manual. Startup Battery Disconnect and Connect (414-00)

42
CAUTION
  • Avoid trapping the harness and route the harness away from any sharp objects.

For right hand drive vehicles secure harness (K) to the tabs on the underside of the cowl panel.

43

Install the cowl panel. For additional information, please refer to the official Workshop Manual. Cowl Panel (501-02)

44
CAUTION
  • Avoid trapping the harness and route the harness away from any sharp objects.

Tighten all cables with installed cable ties and clips.

45
CAUTION
  • Failure to secure the cables risks contact with the vehicle air conditioning fan unit.

Secure the P-clip (U) to the positive winch cable (A1) and install on the winch body where illustrated. Secure all other leads to the positive lead.

  • Torque: 7 Nm
46
NOTE
  • Move the winch over the securing holes on the cradle.

Secure the winch to the cradle using bolts (L) with nuts (P) and the rope lanyard using the pin and clip (T) where arrowed.

  • Torque: 40 Nm
47

Secure the winch upper ducting with the x4 M6 x 20mm fixings (H1) from the winch mounting kit or bull bar mounting kit.

  • Torque: 10 Nm
© Land Rover 2016