Land Rover Defender 2002 Electrical Library Rover Manual
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DEFENDER 2002 MY ELECTRICAL LIBRARY LRL 0389ENG Published by Land Rover © Land Rover 2001 All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form, electronic, mechanical, recording or other means without prior written permission from Land Rover Group.
CONTENTS DEFENDER 02MY 1 INTRODUCTION .......................................................................... 1.1 ABOUT THIS DOCUMENT ............................................................................... 1.1 ELECTRICAL PRECAUTIONS ......................................................................... 1.3 ABBREVIATIONS ............................................................................................. 1.5 HOW TO USE THIS DOCUMENT .................................................................... 1.7 FAULT DIAGNOSIS .......................................................................................... 1.9 WIRE COLOUR CODES ................................................................................. 1.10 FUSE DETAILS ............................................................................ 2.1 UNDER SEAT FUSE BOX ................................................................................ 2.2 PASSENGER COMPARTMENT FUSE BOX .................................................... 2.4 EARTH POINTS AND HEADERS ................................................ 3.1 DESCRIPTION AND OPERATION .............................................. 4.1 ANTI–THEFT ALARM AND CENTRAL DOOR LOCKING (CDL) ..................... 4.1 ENGINE IMMOBILISATION .............................................................................. 4.7 WINDOWS ...................................................................................................... 4.11 HEATED SEATS ............................................................................................. 4.13 DIAGNOSTIC SOCKET .................................................................................. 4.14 STARTING AND CHARGING – 300 Tdi ......................................................... 4.15 STARTING AND CHARGING – Td5 ............................................................... 4.18 ANTI–LOCK BRAKING SYSTEM (ABS) ......................................................... 4.21 AIR CONDITIONING – 300 Tdi ....................................................................... 4.25 AIR CONDITIONING – Td5 ............................................................................. 4.28 HEATER .......................................................................................................... 4.31 HEATED REAR WINDOW .............................................................................. 4.32 HEATED FRONT SCREEN ............................................................................ 4.33 WIPERS AND WASHERS .............................................................................. 4.34 BRAKE AND REVERSE LAMPS .................................................................... 4.37 HEAD, SIDE AND TAIL LAMPS ...................................................................... 4.39 HEADLAMP LEVELLING ................................................................................ 4.44 FOG LAMPS ................................................................................................... 4.46 DIRECTION INDICATOR/HAZARD WARNING LAMPS ................................. 4.48 INTERIOR LAMPS – NON ANTI-THEFT ALARM ........................................... 4.51 INTERIOR LAMPS – ANTI-THEFT ALARM .................................................... 4.53 INTERIOR ILLUMINATION ............................................................................. 4.56 INSTRUMENTS .............................................................................................. 4.58 HORNS ........................................................................................................... 4.64
CONTENTS 2DEFENDER 02MY CLOCK ............................................................................................................ 4.65 CIGAR LIGHTER ............................................................................................ 4.66 ACCESSORY SOCKETS ................................................................................ 4.67 TRAILER SOCKET ......................................................................................... 4.68 AUDIO SYSTEM ............................................................................................. 4.69 FUEL PUMP .................................................................................................... 4.71 OVERSPEED WARNING ................................................................................ 4.73 CONNECTOR ............................................................................... 5.1 CONNECTOR REFERENCE NUMBERS ......................................................... 5.1
INTRODUCTION DEFENDER 02MY 1.1 INTRODUCTIONABOUT THIS DOCUMENT General This document is intended to assist in diagnosing electrical faults, and should be used in conjunction with the Electrical Circuit Diagrams. The document is divided into the following sections. 1.INTRODUCTION – Includes Electrical Precautions, a list of Abbreviations and general information on how to use this document. 2.FUSE DETAILS – Provides details of location, rating in Amperes, and circuit(s) protected. 3.EARTH POINTS AND HEADERS – Provides details of earth points and earth headers, including a plan view of the vehicle to aid location. 4.DESCRIPTION AND OPERATION – Provides an explanation of how each of the systems operate. 5.CIRCUIT REFERENCE NUMBERS – Provides a list of circuit reference numbers against a model or feature to which they apply. 6.CONNECTOR DETAIL – Details of connectors including a location photograph, face view and pin-out table. NOTE: Before starting electrical checks on the vehicle, ensure that relevant mechanical functions operate satisfactorily. References References to the LH or RH side given in this document are made when viewing the vehicle from the rear. Operations covered in this document do not include reference to testing the vehicle after repair. It is essential that work is inspected and tested after completion and, if necessary, a road test of the vehicle is undertaken, particularly where safety related items are concerned. CAUTION: Before undertaking any electrical work on a vehicle ALWAYS read the ELECTRICAL PRECAUTIONS.
INTRODUCTION 1.2DEFENDER 02MY Battery Voltage Open Circuit Voltage Test Before commencing diagnosis of electrical problems, verify the condition of the battery is acceptable by using the open circuit voltage test. 1. Switch off all electrical loads on the vehicle. 2. Adjust digital multimeter to read dc volts on the appropriate scale. 3. Connect test probes across battery terminals ensuring that polarity is correct and record the voltage displayed. A reading of 12.3 V or more is acceptable; any battery which reads less than this will need charging. NOTE: If the vehicle has been used within a period of 8 hours prior to the test, surface charge must be removed from the battery by switching the headlamps on for approximately 30 seconds. Wait a further 60 seconds before checking the open circuit voltage. Battery voltage is used as a known reference for ascertaining whether or not circuits are receiving sufficiently high voltage for components to function correctly. This reference is only a guide since most electronic circuits are designed to function over a wide range of voltages. In addition, consideration must be given to readings affected by voltage drop across certain components and fluctuations due to cable lengths.
INTRODUCTION DEFENDER 02MY 1.3 ELECTRICAL PRECAUTIONS General The following guidelines are intended to ensure the safety of the operator whilst preventing damage to the electrical and electronic components fitted to the vehicle. Where necessary, specific precautions are detailed in the relevant sections of this document, reference of which should be made prior to commencing repair operations. Equipment – Prior to commencing any test procedure on the vehicle, ensure that the relevant test equipment is working correctly and any harness or connections are in good condition. This particularly applies to mains lead or connections. WARNING: Before commencing work on an ignition system, all high tension terminals, adaptors and diagnostic equipment for testing should be inspected to ensure that they are adequately insulated and shielded to prevent accidental personal contact and to minimise the risk of shock. Wearers of surgically implanted pacemaker devices should not work in close proximity to ignition circuits or diagnostic equipment. Polarity – Never reverse connect the vehicle battery and always observe correct polarity when connecting test equipment. High Voltage Circuits – Whenever disconnecting live ht circuits, always use insulated pliers and never allow the open end of the ht lead to come into contact with other components, particularly ECUs. Since high voltage spikes can occur on the terminals of the coil while the engine is running, exercise caution when measuring the voltage at these points. Connectors and Harnesses – The engine compartment of a vehicle is a particularly hostile environment for electrical components and connectors. Always ensure these items are dry and oil free before disconnecting and connecting test equipment. Never force connectors apart either by using tools or by pulling on the wiring harness. Always ensure locking tabs are disengaged before removal and note orientation to enable correct reconnection. Ensure that any protective covers and substances are replaced if disturbed. Before removing a faulty component, refer to the Workshop Manual for removal procedures. Ensure the ignition switch is turned to the OFF position, the battery is disconnected (see Battery Disconnecting) and any disconnected harnesses are supported to avoid any undue strain at the terminals. When replacing the component keep oily hands away from electrical connection areas and push connectors home until any locking tabs fully engage.
INTRODUCTION 1.4DEFENDER 02MY Battery Disconnecting Before disconnecting the battery, switch off all electrical equipment. If the radio is to be serviced, ensure the security code has been deactivated. When the battery is disconnected, certain data such as radio code and clock time will be lost. CAUTION: To prevent damage to electrical components, ALWAYS disconnect the battery when working on the vehicle electrical systems. The earth lead must be disconnected first and reconnected last. Always ensure that battery leads are routed correctly and are not close to any potential chafing points. Battery Charging Recharge the battery out of the vehicle and keep the top well ventilated. While being charged or discharged, and for approximately fifteen minutes afterwards, batteries emit hydrogen gas. This gas is inflammable. Always ensure any battery charging area is well ventilated and that every precaution is taken to avoid flames and sparks. Disciplines Switch off ignition prior to making any connection or disconnection in the system as electrical surge caused by disconnecting live connections can damage electrical components. Ensure hands and work surfaces are clean and free of grease, swarf, etc. as grease collects dirt which can cause tracking or high-resistance contacts. When handling printed circuit boards, treat them as you would a disc – hold by the edges only; note that some electrical components are susceptible to body static. Connectors should never be subjected to forced removal or refit, especially inter-board connectors. Damaged contacts will cause short-circuit and open-circuit conditions. Prior to commencing testing, and periodically during testing, touch a good earth, i.e. cigar lighter socket, to discharge body static as some electrical components are vulnerable to static electricity. Grease for Electrical Connectors Some under bonnet and under body connectors are protected against corrosion by the application of a special grease during production. Should connectors of this type be disturbed, repaired, or replaced, a grease of this type, available under part number BAU 5811, should again be applied. Do not apply grease to any connectors that do not have grease applied as standard. NOTE: The use of other greases must be avoided as they can migrate into relays, switches, etc. contaminating the contacts and leading to intermittent operation or failure.
INTRODUCTION DEFENDER 02MY 1.5 ABBREVIATIONS General A Ampere ABS Anti-lock braking system ac Alternating current A/C Air Conditioning ATF Automatic transmission fluid BUS Databus CAN Controller area network Cav Cavity Cct Circuit CCU Central control unit CDL Central door locking CHMSL Centre high mounted stop lamp Col Colour dc Direct current DCU Diagnostic control unit EAT Electronic automatic transmission EBD Electronic braking force distribution ECM Engine control module ECT Engine coolant temperature ECU Electronic control unit EKA Emergency key access ETC Electronic traction control FFuse FL Fusible link HDC Hill descent control HRW Heated rear window HT High tension ISO International Organisation for Standardisation LED Light emitting diode LH Left hand LHD Left hand drive MIL Malfunction indicator lamp NAS North American specification PWM Pulse width modulated RRelay RF Radio frequency