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MGRGPGBG



Member Since: 19 Dec 2017
Location: New York
Posts: 25

United States 2009 Defender 110 Puma 2.4 SW Alpine White
Under Seat Fuse Box Help 2.4

I am hoping you guys can help me with troubleshooting my 2.4 TDCI build. I have posted here before, but to summarize, I am in the USA, and was able to get a used 2.4tdci that was imported already. I am building up a D110SW.

I tried to show as much detail in the pictures as to what my wire loom looks like in the seat box. I need to figure out whats missing, what has been butchered, and what needs to be corrected!



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Here is a listing of what I have electrically. I will hunt through the electrical manual this weekend and try to track down the plug relay combination to figure out what is what.

Maybe someone put together a cheat sheet already with the wire combinations decoded?

Black Relay with White Stripe
Yellow Plug
White/Red Wire
Brown/Gray Wire
Brown/Red Wire
Black/Orange Wire

Black Relay with White Stripe
Yellow Plug
Brown/Green Wire
Brown/Green Wire
Brown/Orange Wire
Blue/Red Wire

Black Relay with White Stripe
Yellow Plug
Brown/Orange Wire
Brown/Gray Wire
Black/Green Wire
Purple/White Wire

Black Relay with White Stripe
Yellow Plug
Brown/Gray Wire
Brown/Orange Wire
Black/Brown Wire
Black/Blue Wire

Black Relay
Green Plug
Black Wire
Black Wire
Black/Gray Wire
1-Blue Wire from loom splits into 2-Blue wires into plug
5 wires in the plug back total

Relay – Missing
White Plug
Blue/Red Wire
Red/Yellow Wire
Black Wire
Black/Gray Wire

Gray Relay
Black Plug
Brown/Orange Wire
Yellow/Black Wire
Blue/Green Wire
Brown/Orange Wire – One end in the plug, the other end has a spade connector

15 amp Blade Fuse Holder
Brown Wire
Brown/Orange Wire

30 amp Blade Fuse Holder + I don’t know what
Brown/Gray Wire
Brown/White Wire


If you guys have any pictures of a finished early 2.4 Puma seat box I would appreciate it – so I can label it and put it in the right order for trouble shooting.

Thanks in advance - Mark

Post #728950 14th Sep 2018 4:36pm
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dorsetsmith



Member Since: 30 Oct 2011
Location: dorset
Posts: 2866

United Kingdom 2003 Defender 90 Td5 HT Caledonian Blue

http://www.defender2.net/forum/topic56773....t+fuse+box


cheat sheet


Click image to enlarge




Click image to enlarge
 pickup 90 TD5 2006

HT 90 TD5 2003


Last edited by dorsetsmith on 14th Sep 2018 8:50pm. Edited 4 times in total

Post #728954 14th Sep 2018 5:38pm
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MGRGPGBG



Member Since: 19 Dec 2017
Location: New York
Posts: 25

United States 2009 Defender 110 Puma 2.4 SW Alpine White


Click image to enlarge


Thank you for the link - I will start reading through it.

Based on this picture, am I correct in stating that I do not need #1, and #'s 5-9 if I do not have ABS, A/C or heated screen?

I am only concerned with #2,3, & 4

I am missing the Pektron Relay based on one of the other pictures in the thread and information that another member here sent me.


Side note - I have an aftermarket A/C From Coolair Logan as well as aftermarket Heated Screen kit. Both of theses kits have their own sets of relays separate from the original loom that I will be installing.

Post #728957 14th Sep 2018 5:53pm
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MGRGPGBG



Member Since: 19 Dec 2017
Location: New York
Posts: 25

United States 2009 Defender 110 Puma 2.4 SW Alpine White

Ok - so I was able to decode the wire colors and get it all sorted out.

I do not have the #1, 8, or 9 in my wiring loom.

The #4 glow plug relay is the one with the brown/orange wire that has the spade connector. This wire should be coming from the loom to the plug. I have no idea why it was cut and the connector added. I do not see any cut wires in the loom so I have no idea where I should be attaching this possibly?


Click image to enlarge


I do have an extra large black fuse holder with two wires and one was cut but I’ll figure that out last. In the picture (left side) it has two large gauge brown/white wires going to it. This one isn't listed anywhere from what I see.



Click image to enlarge

Post #729602 17th Sep 2018 8:10pm
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dorsetsmith



Member Since: 30 Oct 2011
Location: dorset
Posts: 2866

United Kingdom 2003 Defender 90 Td5 HT Caledonian Blue

large gauge brown/white wires 4.0mm used from fuse box to start relay, ignition switch, ABS relay, and ABS unit too pickup 90 TD5 2006

HT 90 TD5 2003

Post #729628 17th Sep 2018 9:07pm
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MGRGPGBG



Member Since: 19 Dec 2017
Location: New York
Posts: 25

United States 2009 Defender 110 Puma 2.4 SW Alpine White


Click image to enlarge






So I found one of these pictures online and the other two are from a forum member.

The various wire /relays have been sorted out and from what I can tell the brown/orange from the glow plug relay needs to go to the 60amp fuse block. Where does the other leg of the fuse block go? Does this leg go directly to the under seat fuse box?

Could anyone share a picture and description of wire colors and locations for this fuse block?

Thanks - Mark

Post #729828 18th Sep 2018 9:09pm
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dorsetsmith



Member Since: 30 Oct 2011
Location: dorset
Posts: 2866

United Kingdom 2003 Defender 90 Td5 HT Caledonian Blue


Click image to enlarge



Click image to enlarge


brown/orange from the glow plug relay go to wire splice and the main relay also fuse 39 and ECM holder fuse not 60 amp fuse in the wiring digram, but have seen the post with the pic that you posted you must have same build loom Exclamation

( red arrow show glow plug feed back to ecm not part of your problem )

This wiring digram showing your loom is not available from LRJ site Exclamation have been looking for it long time with no luck pickup 90 TD5 2006

HT 90 TD5 2003

Post #729869 19th Sep 2018 8:45am
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MGRGPGBG



Member Since: 19 Dec 2017
Location: New York
Posts: 25

United States 2009 Defender 110 Puma 2.4 SW Alpine White

Thank you - I was using your diagram and when I saw pictures online of my loom setup I knew something had to be different. I thought I was going crazy but at least now I know I am just somewhat crazy building a 2.4 tdci from scratch in the US.

Hopefully I can find out some more information on my loom setup. I just need a few of the wires traced to confirm what I feel the setup was before the wires were cut.

Post #729888 19th Sep 2018 12:19pm
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dorsetsmith



Member Since: 30 Oct 2011
Location: dorset
Posts: 2866

United Kingdom 2003 Defender 90 Td5 HT Caledonian Blue

Right just have email Idea see below pickup 90 TD5 2006

HT 90 TD5 2003


Last edited by dorsetsmith on 19th Sep 2018 2:17pm. Edited 1 time in total

Post #729898 19th Sep 2018 2:08pm
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dorsetsmith



Member Since: 30 Oct 2011
Location: dorset
Posts: 2866

United Kingdom 2003 Defender 90 Td5 HT Caledonian Blue

Where does the other leg of the fuse block go? Does this leg go directly to the under seat fuse box see C06622-1


Click image to enlarge



Right this may help the 60amp fuse that not shown on the diagram is fitted as shown below

Click image to enlarge
 pickup 90 TD5 2006

HT 90 TD5 2003

Post #729899 19th Sep 2018 2:14pm
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MGRGPGBG



Member Since: 19 Dec 2017
Location: New York
Posts: 25

United States 2009 Defender 110 Puma 2.4 SW Alpine White

OK - so if I understand it correctly:

1. Cable from Battery Positive goes into the underseat fuse box on one side
2. Run a 6 gauge (4mm) brown wire from the opposite side of this fuse box into the 60 amp Maxi Fuse holder
3. The Glow Plug Relay wire goes into the other side of the Maxi Fuse Block Holder?

Post #729906 19th Sep 2018 2:51pm
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dorsetsmith



Member Since: 30 Oct 2011
Location: dorset
Posts: 2866

United Kingdom 2003 Defender 90 Td5 HT Caledonian Blue

Brown/Orange 2.0D Wire on glow plug relay is going to coil (2)



Yellow/Black Wire from relay N/o switch (3)and go to the glow plugs on the engine




Blue/Green Wire from relay coil (4) go to ECM and will switch to neg then glow plugs are needed



Brown/Orange 6.0D Wire from relay (1) go to (C0621 maxi Fuse Block) and then from fuse to C0622 brown wire 10.0D C0622 is power in put to under seat fuse box



Click image to enlarge






Click image to enlarge



Click image to enlarge
 pickup 90 TD5 2006

HT 90 TD5 2003


Last edited by dorsetsmith on 19th Sep 2018 5:53pm. Edited 4 times in total

Post #729910 19th Sep 2018 3:34pm
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MGRGPGBG



Member Since: 19 Dec 2017
Location: New York
Posts: 25

United States 2009 Defender 110 Puma 2.4 SW Alpine White

Yes - I agree that is what I currently have setup

But this brings me back to my confusion on the maxi Fuse Block and the spade connector on the glow plug relay


Brown/Orange Wire – One end in the plug, the other end has a spade connector (does the spade end go into the Maxi Fuse Block?)

Post #729912 19th Sep 2018 4:09pm
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