Painless Performance Products 10140 wire harness Installation Instructions

Wire Harness Installation

Instructions

For Installing:

#10140 Customizable Weatherproof

Chassis Harness – 26 Circuit

Manual #90531

Painless Performance Products Division

Perfect Performance Products, LLC

2501 Ludelle St., Fort Worth, Texas 76105-1036

Phone (800) 423-9696

We have attempted to provide you with as accurate instructions as possible, and are always concerned about corrections or improvements that can be made. If you have found any errors or omissions, or if you simply have comments or suggestions concerning these instructions, please write us at the address on the cover and let us know about them. Or, better yet, send us a fax at (817) 244-4024 or e-mail us at [email protected]. We sincerely appreciate your business.

Perfect Performance Products, LLC shall in no event be liable in contract or tort (including negligence) for special, indirect, incidental, or consequential damages, such as but not limited to, loss of property damage, or any other damages, costs or expenses which might be claimed as the result of the use or failure of the goods sold hereby, except only the cost of repair or replacement.

90531 Installation Manual

January 14, 2014

Copyright

 1994 by Perfect Performance Products, LLC

NOTE :

If your vehicle has an existing harness, you will want to retain it for the possible re-use of various Pigtails & Connector housings, particular to your application.

If you do not have an existing harness, there is a package of terminals included with the harness that will enable you to make most of the connections needed.

Replacement lighting pigtails & sockets can be readily obtained from your local parts distributor

TABLE OF CONTENTS

List of Figures………………………………………………………………………………………… ii

List of Tables………………………………………………………………………………………….

List of Diagrams…………………………………………………………………………………….. ii ii

1.0 Introduction………………………………………………………………………………………….. 1

2.0 About These Instructions……………………………………………………………………….. 1

3.0 Contents of the Painless Wire Harness Kit……………………………………………….. 2

4.0 Tools Needed…………………………………………………………………………………………. 2

5.0 Pre-Installation and General Harness Routing Guidelines……………………………. 2

6.0 Harness General Installation Instructions………………………………………………….. 4

6.1 Rough Installation…………………………………………………………………………. 4

6.2 Harness Attachment………………………………………………………………………. 4

6.3

6.4

Grounding the Automobile……………………………………………………………..

Terminal Installation and Making Connections…………………………………..

5

5

6.5 Testing the System……………………………………………………………………….. 5

7.0 GM - Specific Circuit Connections……………………………………………………………… 6

7.1 Early GM Alternator - External Regulator…………………………………………. 6

7.2 Late GM Alternator - Internal Regulator………………………………………….. 6

7.3 GM One-Wire Alternator………………………………………………………………… 7

7.4 GM Ignition System………………………………………………………………………. 7

7.5 Steering Column Wiring - Turn Signal & Ignition Switch Connections… 9

8.0 Ford - Specific Circuit Connections…………………………………………………………… 10

8.1 Ford Alternator…………………………………………………………………………….. 10

8.2 Ford Ignition System…………………………………………………………………….. 10

8.3

8.4

Steering Column Wiring - Turn Signal Connections…………………………...

Steering Column Wiring - Ignition Switch Connections………………………

12

12

9.0 Mopar - Specific Circuit Connections…………………………………………………………. 15

9.1 Mopar Alternator…………………………………………………………………………… 15

9.2

9.3

9.4

Mopar Ignition System……………………………………………………………………

Steering Column Wiring - Turn Signal Connections…………………………….

Steering Column Wiring - Ignition Switch Connections……………………….

15

17

17

10.0 All Makes - Specific Circuit Connections……………………………………………………… 19

10.1 Generator Charging System…………………………………………………………….. 19

10.2 Generator to Alternator Conversion………………………………………………….. 19

10.3 Connecting to Ammeter and the Maxi-Fuse……………………………………….. 20

10.4 Interior Lighting……………………………………………………..……………………… 21

10.5 Headlight Section "A"………………………………………………………………………. 21

10.6 Headlight Section "B"………………………………………………………………………. 22

10.7 Instrument Panel Wiring………………………………………………………………….. 22

10.8 Brake Light Switch…………………………………………………………………………… 23

10.9 Tail Section Wiring…………………………………………………………………………… 23

10.10 Helpful Hints for Tail Section Wiring………………………………………………….. 25

11.0 Wire Connection Index and Fuse Requirements…………………………………………… 25 i

LIST OF FIGURES

Figure 3.1 The Painless Wire Harness Kit………………………………………………………….. 2

Figure 7.1 Early GM Alternator - External Regulator…………………………………………… 6

Figure 7.2A Late GM Alternator - Internal Regulator…………………………………………….. 7

Figure 7.2B High Output Wire…………………………………………………………………………….. 7

Figure 7.3 Maxi-Fuse……………………………………………………………………………………….. 8

Figure 7.4 GM Ignition System………………………………………………………………………….. 8

Figure 7.5 GM Turn Signal Connectors……………………………………………………………….. 9

Figure 8.1A Ford Alternator…………………………………………………………………………………. 11

Figure 8.1B High Output Wire……………………………………………………………………………… 11

Figure 8.2 Ford Ignition System………………………………………………………………………… 12

Figure 8.3 Ford Ignition Switch Connectors………………………………………………………… 14

Figure 8.4 Ford Ignition Diagram………………………………………………………………………. 14

Figure 9.1A Mopar Alternator……………………………………………………………………………… 15

Figure 9.1B High Output Wire…………………………………………………………………………….. 16

Figure 9.2 Mopar Ignition System……………………………………………………………………… 17

Figure 10.1 Generator Charging System………………………………………………………………. 19

Figure 10.2 Ammeter and Maxi-Fuse…………………………………………………………………… 19

Figure 10.3 Interior Lighting……………………………………………………………………………….. 20

Figure 10.4A Typical Fan Relay Installation……………………………………………………………. 21

Figure 10.4B Headlight Section "A" Wiring…………………………………………………………….. 21

Figure 10.5 Dimmer Switches…………………………………………………………………………….. 22

Figure 10.6 Headlight Section "B" Wiring…………………………………………………………….. 23

Figure 10.7 Integrated Brake Light and Separate Turn/Brake Lights………………………. 24

LIST OF TABLES

Table 7.1 GM Ignition and Turn Signal Wiring…………………………………………………… 10

Table 8.1 Ford Ignition and Turn Signal Wiring…………………………………………………. 13

Table 9.1 Mopar Ignition and Turn Signal Wiring (1 of 2)…………………………………… 18

Table 9.1 Mopar Ignition and Turn Signal Wiring (2 of 2)…………………………………… 18

Table 11-1 Fuse Requirements………………………………………………………………………….. 25

Table 11-2 Wire Connection Index (1 of 3)…………………………………………………………. 26

Table 11-2 Wire Connection Index (2 of 3)…………………………………………………………. 27

Table 11-2 Wire Connection Index (3 of 3)…………………………………………………………. 28

LIST OF DIAGRAMS

Diagram 1 Chassis Wiring Suggested Routing…………………………………………………….. 29

Diagram 2 Instrument Panel Section Wiring……………………………………………………….. 30

Diagram 3 Engine Wiring………………………………………………………………………………….. 31 ii

1.0

2.0

INTRODUCTION

You have purchased what we at Painless Performance Products believe to be the most up-to-date and easiest-toinstall automotive wire harness on the market. It is designed for easy installation, even if you have no electrical experience.

All kits have a built-in-anti-theft feature. Removing the fuse labeled "coil" from the fuse block will prevent the vehicle from starting.

The proper fuses have been pre-installed in the fuse block. In addition, all wires are color-coded. This will help you identify the different circuits during installation and later on if additions to the overall system are necessary. For fuse specifications and wire color designations, see Section 11.0.

The Painless wire harness is designed to be used in vehicles with a General Motors - keyed steering column, or other steering columns, depending on the kit purchased. All wire is 600 volt, 125  c, TXL. Standard automotive wire is GPT,

300 volt, 80  c, with PVC insulation.

This complete automobile wiring system has been designed with three major groups incorporated into it:

ENGINE/HEADLIGHT GROUP

Includes high beam, low beam, park, right turn, left turn, electric fan, horn, starter solenoid and battery feed, alternator and alternator exciter wire, distributor, water temperature, oil pressure, and air conditioning.

DASH GROUP

Includes wires to connect gauges, indicator lights, and switches to their proper sources.

REAR LIGHT GROUP

Includes tail lights, dome lights (see Paragraph 10.4.2), left and right turn signals, brake lights, and fuel sender.

Installation requires four (4) easy steps: 1. Mount the fuse block

2. Route the wires

3. Cut off the excess wire

4. Terminate the wires

ABOUT THESE INSTRUCTIONS

The contents of these instructions are divided into major Sections, as follows:

1.0

2.0

3.0

Introduction

About These Instructions

Tools Needed

4.0

5.0

6.0

Contents of Painless Wire Harness Kit

Pre-Installation and General Harness Routing Guidelines

General Harness Installation Instructions

7.0

8.0

GM - Specific Circuit Connection Details

Ford - Specific Circuit Connection Details

9.0 Mopar - Specific Circuit Connection Details

10.0 All Makes - Specific Circuit Connection Details

11.0 Wire Connection Index and Fuse Requirements

Sections are divided into subsections and Paragraphs. Throughout these instructions, the Figure numbers refer to illustrations and the Table numbers refer to information in table form. These are located in Sections or Paragraphs corresponding to the number. Always pay special and careful attention to any and any text marked

Caution

.

Notes

, especially those in the Tables,

1

3.0

CONTENTS OF THE PAINLESS WIRE HARNESS KIT

E

F

G

H

A

B

C

D

Refer to Figure 3-1 to take inventory. See that you have everything you're supposed to have in this kit. If anything is missing, contact the dealer where you obtained the kit or Painless Performance at (800) 423-9696. The Painless

Wire Harness Kit should contain the following items:

The Main Wire Harness, with the Fuse Block wired in and fuses installed.

Headlamp Connector Cables. (Extra Headlamp Cables are available separately under P/N 80300.)

Maxi Fuse w/ Holder

Firewall Grommet (large)

2 Fender Well Grommets (for Headlamps)

1 package of Nylon Tie Wraps

2 GM Ignition Switch and Turn Signal Switch Connectors w/ Terminals (if applicable)

Parts Box, containing a GM Alternator Connector, Terminals, Splices, etc. This booklet, P/N 90531 Painless

Wiring Manual.

Figure 3-1 The Painless Wire Harness Kit

4.0

TOOLS NEEDED

In addition to your regular tools, you will need, at least, the following tools:

Crimping Tool

Wire Stripper

Note: Use a quality tool to avoid over-crimping.

Test Light or Volt Meter

Electric Drill

1-1/4" Hole Saw

Small (10 amp or less) Battery Charger

5.0

PRE-INSTALLATION AND GENERAL HARNESS ROUTING GUIDELINES

The installation of your wire harness mainly consists in two parts:





The physical routing and securing of the wire harness, wires, and groups.

The proper connection of the individual circuits.

2

These two major tasks are not separate steps, but are integrated together. That is, you will route some wires and make some connections, route some more wire and make some more connections.

We cannot tell you how to physically route the harness in your automobile. That depends a great deal upon the particular make of automobile and to what extent you want to secure and conceal the harness. We do offer some general guidelines and routing practices starting in Section 5.2, GENERAL installation instructions in Section 6.0, and precise instructions concerning the electrical connections you will make beginning in Section 7.0. To help you begin thinking through the installation of your wire harness, read the following sections:

5.1

Familiarize yourself with the harness by locating each of the harness sections in the following list.

(Whenever a particular harness section is referred to in these instructions it is shown "all caps": ENGINE

SECTION A.) Note that, according to the particular harness you have purchased, some of these sections may not be present, and some are not labeled:

ACCESSORY SECTION SWITCHES

ACCESSORY SECTION B+

DIMMER SWITCH SECTION (See Section 3.2)

BRAKE SECTION

ALTERNATOR SECTION

ENGINE SECTION A

TURN SIGNAL SECTION (See Section 3.3)

HEADLIGHT SECTION A

HEADLIGHT SECTION B

IGNITION SWITCH SECTION (See Section 3.3)

INSTRUMENT PANEL SECTION

RADIO SECTION

SPEAKER SECTION

TAIL SECTION

Note: For complete information concerning the individual circuits and wires that make up the harness

SECTIONS, see Section 11.0.

5.2

5.3

Decide where the fuse block will be mounted. The Painless Wire Harness is designed for the fuse block to be mounted on the driver's side, under the dash.

Decide which of the following circuits you will be using in your system and where the harness groups or wires will be routed:

ROUTING LOCATION AND PLACEMENT

Emergency Flashers

Horn

Dome Lights

Lights

Wipers

Air Conditioner

Electric Cooling Fan

Coil

Turn Signals

Radio Ignition Switched Power

Radio Constant Power

Gauges

Accessories

3

6.0

5.4

Where will the following harness groups be routed?

Headlights

Engine

Dash

Tail Lights

5.5

A good exercise is to lay out the wire harness on the floor beside your automobile and identify all the

SECTIONS. You will want to route the harness through and around open areas. Inside edges provide protection from hazards and also provide places for tie wraps, clips and other support.

Route the harness away from sharp edges, exhaust pipes, and hood, trunk and door hinges.

5.6

5.7

Plan where harness supports will be located. Allow enough slack at places where movement could occur

(body to frame, frame to engine, etc.). Use a support every 12 inches unless the harness routes under the floor carpet.

5.8

5.9

At wire ends don't depend on the terminals to support the harness. The weight of the harness could cause terminals to disconnect or copper wire strands to break.

The wires should be bundled into groups. Use nylon ties, poly split loom, or tape.

HARNESS GENERAL INSTALLATION INSTRUCTIONS

6.1

6.2

Rough Installation

CAUTION: DISCONNECT THE POWER FROM YOUR VEHICLE BY REMOVING THE NEGATIVE

(BLACK) BATTERY CABLE FROM THE BATTERY.

Note: Make no wire connections or permanent mounting of any kind at this time!

6.1.1 Position the fuse block in its mounting area.

6.1.2 Drill a 1-1/4" (1.25") hole near the fuse block for engine and headlight group wires to pass through

(ALTERNATOR SECTION, ENGINE SECTION A, and HEADLIGHT SECTION A).

6.1.3 Install the Firewall grommet. Route engine and headlight group wires through the grommet and position the harness groups in the areas decided upon in Sections 5.3 and 5.1.

6.1.4 Route dash group (ACCESSORY SECTION B+, ACCESSORY SECTION SWITCHES, HEADLIGHT

SECTION B, INSTRUMENT PANEL SECTION and RADIO SECTION) upward to rear of dash and temporarily tie in place.

6.1.5 Position group TAIL SECTION, on the rear floor pan area decided upon in Sections 5.3 and 5.4.

Harness Attachment

Note: Harness routing and shaping is and should be a time-consuming task. Taking your time will enhance the beauty of your installation. Please be patient and TAKE YOUR TIME!

6.2.1 Permanently mount the fuse block. (Note: The fuse block does not have to be grounded.)

6.2.2 A silicone based lubricant may need to be added to the weatherproof seal of the fuse block. This will aid in the installation and removal of the fuse block cover.

6.2.3 Mold harness groups to the contour of floor pan, firewall, fender panels, and any other area where wires or harness groups are routed. Remember to route the harness away from sharp edges, exhaust pipes, hood, trunk and door hinges, etc.

6.2.4 Attach harness groups to your automobile with clips or ties starting at the fuse block and working toward the rubber grommet for the front groups and along the floor pan for the rear group. The dash wires should be routed out of the way of any under-dash obstacles, such as cowl vent, air conditioning, radio, etc.

Note: Do not tighten tie wraps and mounting devices at this time. Make all harness attachments

LOOSELY.

6.2.5 When used every 1-1/2" or so on the visible areas of the harness, the plastic wire ties make a very attractive assembly. A tie installed in other areas every 6" or so will hold the wires in place nicely.

Remember to take your time!

4

6.3

6.4

6.5

Grounding the Automobile

A perfectly and beautifully wired automobile will nevertheless have bugs and problems if everything is not properly grounded. Do not go to the careful effort of installing a quality wire harness only to neglect proper grounding.

Note: The Painless Wire Harness Kit includes no ground wire except the black wire from the two headlamp connectors. You must supply ground wire (14-16 gauge) for all circuits.

6.3.1 Connect a Ground Strap or Cable (even a 10-gauge wire is too small) from the Negative Battery terminal to the automobile chassis (frame).

6.3.2 Connect a Ground Strap from the Engine to the chassis. DO NOT RELY UPON THE MOTOR

MOUNTS TO MAKE THIS CONNECTION.

6.3.3 Connect a Ground Strap from the Engine to the Body.

6.3.4 If you have a fiberglass body you should install a terminal block to ground all your Gauges and

Accessories. Ground the Terminal Block with at least a 12-gauge wire to the chassis.

Terminal Installation and Making Connections

Note: In the following steps you will be making the circuit connections. Before you start, you should carefully read Sections 7.0 through 10.0, as appropriate, and continually refer to Section 11.0, DOUBLE-

CHECKING your routing and length calculations before cutting any wires and making connections. Give special attention to Turn Signal and Ignition Switch connections. These can be somewhat confusing.

6.4.1 Have all needed tools and connectors handy.

6.4.2 Select the correct size terminal for the wire and stud application.

6.4.3 Determine the correct wire length and cut the wire. Remember to allow enough slack in the harness and wires at places where movement could possibly occur, such as automobile body to frame, frame to engine, etc. Double-check your calculations.

6.4.4 Strip insulation away from wire. Strip only enough necessary for the type of terminal lug you are using.

Note: In the following step, make sure that the terminal is crimped with the proper die in the crimping tool. An improper crimp will NOT make a good connection.

6.4.5 Crimp the terminal onto the wire.

CAUTION: DO NOT OVER-CRIMP!

6.4.6 Connecting the harness throughout the groups is a redundant process. Make sure that each wire is

FIRST properly routed and THEN attach. DO NOT ATTACH FIRST THEN ROUTE AFTERWARD.

6.4.7 When all wires are attached, tighten the mounts and ties to secure harness permanently.

Testing The System

6.5.1 Use a small (10 amp or less) battery charger to power up the vehicle for circuit testing. If there is a problem anywhere, the battery charger's low amperage and internal circuit breaker will provide circuit protection.

CAUTION: IF YOU HAVE NOT YET DISCONNECTED THE BATTERY FROM THE AUTOMOBILE,

DO SO NOW! DO NOT CONNECT THE BATTERY CHARGER WITH THE BATTERY CONNECTED.

Connect the battery charger's NEGATIVE output to the automobile chassis or engine block and its POSITIVE output to the automobile's positive battery terminal.

6.5.2 INDIVIDUALLY turn on each light, ignition, wiper circuit, etc. and check for proper operation.

Note: The turn signals will not flash properly if you do not have both the front and rear bulbs installed and connected.

6.5.3 When all circuits check out THEN attach the battery cable to the battery for vehicle operation.

5

7.0

GM - SPECIFIC CIRCUIT CONNECTIONS

Note: Your alternator may not appear exactly as represented in the Figures. The circuits are wired the same way, though.

7.1

Early GM Alternator (before 1969) - External Regulator. See Figure 7-1.

7.1.1 With a short 16-gauge jumper wire, connect Voltage Regulator terminals 3 & 4 together. Connect

ALTERNATOR SECTION wire #914 (wht) to Voltage Regulator terminal 3 or 4.

7.1.2 Connect ALTERNATOR SECTION wire #915 (red) to the Alternator Output lug (Bat).

7.1.3 Connect a 14-gauge wire from Voltage Regulator terminal 2 to Alternator terminal R. Connect a 14gauge wire from Voltage Regulator terminal F to Alternator terminal F.

7.1.4 Connect a 16-gauge ground wire from the Alternator Ground lug (G) to chassis ground.

7.2

Figure 7-1 Early GM Alternator - External Regulator

Late GM Alternator (after 1972) - Internal Regulator. See Figure 7-2.

7.2.1 Connect ALTERNATOR SECTION wire #914 (wht) to Alternator terminal 1. Connect ALTERNATOR

SECTION wire #915 (red) to the Alternator Output lug (Bat).

7.2.2 Connect a short 14-gauge jumper wire from Alternator terminal 2 to the Alternator Output lug

(Bat).

7.2.3 A connector and terminal spades for late GM Alternators are included in the parts box.

* Under some circumstances the connection of the alternator will not allow the engine to be shut off. If this occurs a diode will need to be installed inline on wire #914. This will prevent the alternator from back feeding into the ignition system and thus causing the engine to run with the ignition switch turned off. The Radio Shack part number for the diode is 276-1661.

It is to be installed with the stripe

towards the alternator.

Alternator

Figure 7-2A Late GM Alternator - Internal Regulator

6

#914

7.3 GM One-Wire Alternator.

7.3.1 Connect ALTERNATOR SECTION wire #915 (red) to the Alternator Output lug (Bat).

Insulate and stow ALTERNATOR SECTION wire #914 (wht). Do not install jumper wire. No wires are connected to Alternator terminals 1 & 2. If alternator output is greater than 65 amps refer to

Figure 7-2B and the caution below.

7.3.2 When using a 1-wire alternator you can either use a voltmeter or ammeter. A WARNING LIGHT

CANNOT BE WIRED IN.

CAUTION:

IF USING AN ALTERNATOR WITH AN OUTPUT LARGER THAN 65 AMPS, YOU WILL ALSO NEED

TO USE THE RED 10 GAUGE WIRE #960 AND THE RED 8 GAUGE WIRE INCLUDED IN THE BOX. THE WIRE END

WITH THE RING TERMINAL AND RUBBER BOOT WILL CONNECT TO THE ALTERNATOR OUTPUT LUG WITH

#915. ROUTE THE OTHER END TO THE MAXI FUSE TERMINAL WITH WIRE #916. CUT THE WIRE AND CRIMP

ON A RING TERMINAL. NOW INSTALL A RING TERMINAL ON THE REMAINING RED 8 GAUGE WIRE AND

ATTACH IT TO THE STARTER SIDE TERMINAL OF THE MAXI FUSE. CUT THE 8 GAUGE RED WIRE TO LENGTH,

CRIMP ON A RING TERMINAL AND ATTACH IT TO THE MAIN SOLENOID LUG WITH THE POSITIVE BATTERY

CABLE. SEE FIGURE 7-2B.

Figure 7-2B High Output Wire

* These terminals will not be used on One Wire alternators. They will normally have a black plastic plug which blocks off the terminals.

** If you do not have a One Wire alternator refer to

Figure7-2A.

7

7.4

GM Ignition (Start/Run) System. See Figure 7-4.

Note: If you are going to install an ammeter, see Section 10.3 first.

7.4.1 With crimping tool, attach Maxi Fuse (Figure 7-3) onto end of ENGINE SECTION A (single) 10 ga. wire #916 (red) AFTER having routed wire from the Fuse Panel to the Starter Solenoid. This serves as a fuse to protect the entire harness. DO NOT OMIT IT!

7.4.2 Connect wire #916 - with Maxi Fuse installed - to the Starter Solenoid Battery terminal. This is the same lug that the large red cable from the battery is normally connected to.

7.4.3 Connect ENGINE SECTION A wire #919 (pur) to the Starter Solenoid Start (S) terminal. (See illustration on page 31)

Figure 7-3 Maxi Fuse

Figure 7-4 GM Ignition (Start-Run) System

7.4.4 If you are using the Ballast Resistor, mount it away from other wiring or hoses. The Ballast Resistor gets very hot during operation. Connect ENGINE SECTION A wire #920 (pnk) to one end of the

Ballast Resistor. Connect the other end of the Ballast Resistor to the Ignition Coil B+ terminal with

14-gauge wire (you may have enough pink wire left over to accomplish this). If you are not using a

Ballast Resistor, connect wire #920 directly to the Ignition Coil B+ terminal.

Note: The ballast resistor has been deleted from this kit due to lack of consumer usage. If one is needed in your application, please call Painless Performance at 800-423-9696 for assistance.

Important Note! For HEI systems route wire #920 (pnk) to the Distributor and attach it to the terminal labeled BAT. No Ballast Resistor is required.

7.4.5 The Ignition Coil NEGATIVE (-) terminal is connected to the Distributor. Also Connect ENGINE

SECTION A wire #923 (pur/wht) to the Ignition Coil NEGATIVE (-) terminal. This is the tachometer source. If you are not using a tachometer, insulate and stow wire #923.

7.4.6 A 14-gauge wire connected from the Starter Solenoid Ignition (l) terminal to the ignition coil side of the Ballast Resistor is optional. This wire (the dashed line in Figure 7-4) serves as a ballast resistor BYPASS during engine starting. However, if the starter solenoid shorts out, which is not unusual, the engine will stop running and will not restart as long as this wire is connected. You may therefore choose to omit it. If you are not using a Ballast Resistor, leave the Starter Solenoid

Ignition (l) terminal unconnected and do not install the bypass wire.

8

7.5 Steering Column Wiring - Turn Signal & Ignition Switch Connectors

7.5.1

There are two different turn signal switch plugs on most tilt columns. The difference is in the length of the male plug that is mounted ON THE COLUMN. One plug is 3-7/8” (3.875”) long and the other is 4-1/4" (4.250"). This is only a difference of 3/8" (0.375"), so measure the plug carefully. The Wire Harness Kit has included two different female connectors to mate with the column-mounted plug. See Figure 7-5 to determine which female connector is correct for your automobile.

Cut Turn Signal Section wires to length and install terminals provided. Choose the proper plug and install the terminals according to Table 7-1, as shown in Figure 7-5. The GM wire color codes have been included for reference.

Note: The terminals will only insert into the connector ONE WAY, as shown in Figure 7-5. Make certain you are inserting the wire into the CORRECT LOCATION as the terminals are difficult if not impossible to remove once inserted.

Figure 7-5 GM Turn Signal Connectors

7.5.2 Cut Ignition Section wires to length and install terminals provided. See Table 7-1 and Figure 7-

5 for color codes, wire numbers, and wire designations for the Ignition Switch Connectors.

7.5.3 IGNITION SECTION wire #919 (pur) must be cut and spade terminals installed.

These spade terminals are to be connected to the Neutral Safety Switch at the base of the steering column. If using a neutral safety switch on a floor shifter or in the

transmission, the (pur) #919 needs to be routed to the neutral safety switch, cut and

connected to it, then continued on to the starter solenoid.

7.5.4 The harness does not support seat belt buzzers or key alarms.

7.5.5 To supply power to a fuel injection harness use ENGINE SECTION A wire #920 (pnk) as the fused ignition power source.

9

TURN SIGNAL SECTION

GM

Color

Blk

Lt.Blu

Dk.Blu

Brn

Pur

Ylw

Grn

Wht

Designation

Horn

LF Turn Signal

RF Turn Signal

Hazard Flasher

Turn Flasher

LR Turn Signal

RR Turn Signal

Stop Lamp Switch

IGNITION SWITCH SECTION

Pur/Wht Ignition Start

953

926

925

951

952

949

948

918

Painless

Wire No.

919

932

933

934

Painless

Color

Blk

Lt.Blu

Dk.Blu

Brn

Pur

Ylw

Grn

Wht

Painless

Color

Pur

Brn

Orn

Red

Turn Signal

Connector

G

H

J

K

L

M

N

P

Table 7-1 GM Ignition & Turn Signal Wiring

8 FORD - SPECIFIC CIRCUIT CONNECTIONS

8.1 Ford Alternator (2 configurations). See Figures 8-1A and 8-1B.

Note: Your Alternator may not appear exactly as represented in Figure 8-1. The circuits are wired the same way, though.

8.1.1 Connect ALTERNATOR SECTION wire #915 (red) to the Alternator Output lug (Bat). Connect

ALTERNATOR SECTION wire #914 (wht) to the Voltage Regulator (l) terminal.

CAUTION: IF USING AN ALTERNATOR WITH AN OUTPUT LARGER THAN 65 AMPS,

YOU WILL ALSO NEED TO USE JUMPER WIRE #960 (RED), INCLUDED IN BOX. THE

WIRE END WITH THE RING TERMINAL AND RUBBER BOOT WILL CONNECT TO THE

ALTERNATOR OUTPUT LUG. ROUTE THE OTHER END TO THE STARTER RELAY. CUT

THE WIRE AND CRIMP ON A RING TERMINAL. INSTALL ON RELAY TERMINAL WITH

CABLE COMING FROM BATTERY. SEE FIGURE 8-1B.

8.1.1 Connect a 14-gauge jumper from the Voltage Regulator A terminal to the Alternator Output lug

(Bat).

8.1.2 Connect a 14-gauge wire from the Voltage Regulator S terminal to the Alternator Stator (S) terminal. Connect a 14-gauge wire from the Voltage Regulator F terminal to the Alternator Field

(F) terminal.

8.1.3 Connect the Alternator Ground lug and the Voltage Regulator to chassis ground.

8.1.4 An alternate (and less-used) method is to omit the Alternator Stator wire, install a 14-gauge jumper across Voltage Regulator terminals A & S, and connect wire #914 to either the A or S terminal of the Voltage Regulator. The FIELD wire and wire #915 are connected as above. Do

NOT install a jumper as in Paragraph 8.1.2. The Voltage Regulator Ignition (l) terminal is not connected. Install ground wires as in Paragraph 8.1.4. This alternate configuration is illustrated in dashed lines in Figure 8-1A.

8.2 Ford Ignition (Start/Run) System. See Figure 8-2.

Brn

Orn

Red

Painless

Wire No.

Accessory Fuse Panel

Ignition Switched Fuse Panel

Battery B+

Note: If you are going to install an ammeter, see Section 10.3 first.

Note: Original ignition module wire should be retained if possible. Connectors for the module are no longer serviced.

10

8.2.1 With crimping tool, attach the Maxi Fuse (Figure 7-3) onto end of ENGINE SECTION A (single)

10 ga. wire #916 (red) AFTER having routed wire (with or without ammeter) from the Fuse

Panel to the Starter Relay. This serves as a fuse to protect the entire harness. DO NOT OMIT IT!

8.2.2 Connect wire #916 - with Maxi Fuse installed - to the Starter Relay Battery terminal. This is the same lug that the large red cable from the battery is normally connected to.

8.2.3 Connect ENGINE SECTION A wire #919 (pur) to the Starter Relay Start (S) terminal.

Figure 8-1A Ford Alternator (2 configurations)

Figure 8-1B High Output Wire

8.2.4 If you are using the Ballast Resistor, mount it away from other wiring or hoses. The Ballast

Resistor gets very hot during operation. Connect ENGINE SECTION A wire #920 (pnk) to one end of the Ballast Resistor. Connect the other end of the Ballast Resistor to the Ignition Coil B+ terminal with 14-gauge wire (you may have enough pink wire left over to accomplish this). If you are using a Ballast Resistor, connect wire #920 directly to the Ignition Coil B+ terminal.

Note: The Ballast Resistor has been deleted from this kit due to lack of consumer usage. If one is needed in your application, please call Painless Performance at 800-423-9696 for assistance.

8.2.5 The Ignition Coil NEGATIVE (-) terminal is connected to the Distributor. Also connect ENGINE

SECTION A wire #923 (pur/wht) to the Ignition Coil NEGATIVE (-) terminal. This is the tachometer source. If you are not using a tachometer, insulate and stow wire #923.

8.2.6 Connect a 14-gauge wire from the Starter Relay Ignition (l) terminal to the ignition coil side of the Ballast Resistor. This wire serves as a ballast resistor BYPASS during engine starting. If you are not using a ballast resistor, leave the Starter Relay Ignition (l) terminal unconnected and do not connect the bypass wire.

8.2.7 Be sure the large, red battery cable is connected from the other side of the Starter Relay to the

Starter Motor.

11

Figure 8-2 Ford Ignition (Start/Run) System

8.3 Steering Column Wiring - Turn Signal Connections

8.3.1 Connect the nine (9) TURN SIGNAL SECTION wires to your automobile's existing Turn Signal

Connector according to Table 8-1. Ford wire color codes are provided for reference. Ford has not been uniform in assigning wire colors over the years; so you may find that the wire colors in your existing Ford harness differ from those shown.

8.3.2 If there is any doubt, be on the safe side. Trace the wire(s) with an ohmmeter, circuit tester, or test light. DON'T GUESS!

Note: Disconnect one end of the wire you are tracing. If you leave it connected, there is the possibility of tracing it back through some other circuit and getting false results.

8.3.3 Connect the Horn Ground wire to chassis ground. The Painless harness has no corresponding ground wire, nor does it support seat belt buzzers or key alarms.

8.4 Steering Column Wiring - Ignition Switch Connections

8.4.1 Connect the wires of the IGNITION SWITCH SECTION according to Table 8-1. Figure 8-3 represents three (certainly not all) possible Ford ignition switch connector configurations and how they should be wired to the Painless steering column pigtail connector.

Note: The connectors are shown from the wire side, NOT the connection side. It is important to understand the difference.

Again, trace the wires if in doubt.

8.4.2 On some Fords, the Ignition Switch is designed to bypass the ballast resistor during start. In

Table 8-1, the red/blu wire supplies power to the coil, bypassing the ballast resistor when the switch is in the "Start" position. Once the engine has started and the switch is released (Run), power is supplied to the coil (through the ballast resistor) by the (variously-colored) wire shown.

Jumper these two terminals to the Ignition Switch Connector and connect IGNITION SECTION wire #931 (pnk) to one or the other. DO NOT ROUTE AN ADDITIONAL WIRE. The ballast resistor bypass circuit was wired at Paragraph 8.2.4.

8.4.3 IGNITION SWITCH SECTION wire #919 (pur) needs to be routed to the neutral safety switch, cut and connected to it. If the switch is mounted on the floor shifter, add some length of wire to reach it. FOR SAFETY, PLEASE USE A NEUTRAL SAFETY SWITCH!

12

TURN SIGNAL SECTION

Ford

Color

Grn

Wht/Blu

Grn/Wht

Orn/Blu

Grn/Orn

Wht/Red

Blu

Ylw

Dk.Blu

Designation

Stop Light

RF Turn Signal

LF Turn Signal

RR Turn Signal

LR Turn Signal

Hazard Flasher

Turn Flasher

Horn

Horn Ground*

IGNITION SWITCH SECTION

Painless

Wire No.

918

925

926

948

949

951

952

953

Gnd

Painless

Color

Wht

Blu

Lt.Blu

Grn

Ylw

Brn

Pur

Blk

----

Brn/Pur or Wht/Blu¹

Red/Blu

Blk/Grn or Blk/Ylw

Gry, Gry/Ylw, or Blk

Ylw

Start

Ignition Coil (start)

Accessory Fuse Panel

Ignition Switched Fuse Panel

Battery B+

919

----

932

933

934

Pur

----

Brn

Orn

Red

2.

NOTES:

1. Wire may be one of the colors shown, or some other color. See Paragraph 8.3.1.

Jumper to wire #931. See Paragraph 8.4.2.

Table 8-1 Ford Ignition and Turn Signal Wiring

*Note: If your vehicle has the horn ground (typically a Dark Blue Wire) it must be grounded to the car chassis. It will NOT be connected with the turn signal switch wires.

13

Figure 8-3 Ford Ignition Switch Connectors (See note on Page 10, Section 8.2)

Figure 8-4 Ford Ignition Diagram (Duraspark II Systems)

14

9 MOPAR - SPECIFIC CIRCUIT CONNECTIONS

9.1 Mopar Alternator. See Figure 9-1

Note: Your Alternator may not appear exactly as represented in Figure 9-1. The circuits are wired the same way, though.

9.1.1 Mopar uses one of two kinds of voltage regulators: An electronic regulator and a mechanical one. The electronic voltage regulator is represented in Figure 9-1. It does not matter how the two terminals are connected, so long as they are BOTH connected. The mechanical regulator has terminals marked "F" (Field) and "l" (Ignition). In contrast to the electronic regulator, it DOES make a difference how the mechanical regulator is connected.

9.1.2 Connect ALTERNATOR SECTION wire #914 (wht) to the Alternator Field (F) terminal as shown in

Figure 9-1A. Connect ALTERNATOR SECTION wire #915 (red) to the Alternator Output lug

(Bat).

CAUTION: IF USING AN ALTERNATOR WITH AN OUTPUT LARGER THAN 65 AMPS, YOU

WILL ALSO NEED TO USE JUMPER WIRE #960 (RED), INCLUDED IN BOX. THE WIRE END WITH

THE RING TERMINAL AND RUBBER BOOT WILL CONNECT TO THE ALTERNATOR OUTPUT LUG.

ROUTE THE OTHER END TO THE STARTER. CUT THE WIRE AND CRIMP ON A RING TERMINAL.

INSTALL ON STARTER TERMINAL WITH CABLE COMING FROM BATTERY. SEE FIGURE 9-1B.

9.1.3 Connect a 14-gauge wire from the Alternator terminal where wire #914 is connected to either of the ELECTRONIC Voltage Regulator terminals OR terminal (l) of the MECHANICAL Voltage

Regulator. On existing Mopar harnesses, this would be a blue wire.

9.1.4 Connect a 14-gauge wire from the other Alternator Field terminal (as shown in Figure 9-1) to the second terminal of the ELECTRONIC Voltage Regulator OR terminal (F) of the MECHANICAL

Voltage Regulator. On existing Mopar harnesses, this would be a green wire.

9.1.5 Finally, be sure BOTH the alternator and the voltage regulator itself are grounded.

Figure 9-1A Mopar Alternator

9.2 Mopar Ignition (Start/Run) System. See Figure 9-2

Note: If you are going to install an ammeter, see Section 10.3 first.

9.2.1 Connect ENGINE SECTION A (single) 10-gauge red wire #916 (with or without ammeter) to the

Starter Relay Battery Terminal. Retain excess wire.

15

Figure 9-1B High Output Wire

9.2.2 With crimping tool, attach the Maxi Fuse (Figure 7-3) onto remaining length of red 10-gauge wire. It serves as a fuse to protect the entire harness. DO NOT OMIT IT! Connect this wire from the Starter Motor Battery terminal, as shown in Figure 9-2. USE ONLY 10-GAUGE WIRE.

9.2.3 Connect ENGINE SECTION A wire #919 (pur) to the Starter Relay Ignition (l) terminal.

9.2.4 Connect a 14-gauge wire from the Starter Relay Ground (G) terminal to the center terminal of the transmission mounted Neutral Safety Switch. Older Mopar neutral safety switches have only one terminal. On newer switches, the two outside terminals are for backup lights. Use existing wiring to connect these two terminals as shown in Figure 9-2.

9.2.5 If using a harness with the GM column connectors, but using the Mopar Neutral Safety Switch, or neutral safety switch on a floor shifter, you will need to splice together the purple (pur) wires at the steering column wiring.

9.2.6 If the Neutral Safety Switch is mounted in the floor shifter, connect the Starter Relay Ground (G) terminal to chassis ground. Refer to Paragraph 9.4.2 to wire the Neutral Safety Switch.

9.2.7 If you are using the Ballast Resistor (Figure 3-1), mount it away from other wiring or hoses. The ballast resistor gets very hot during operation. Connect ENGINE SECTION A wire #920 (pnk) to one end of the Ballast Resistor. Connect the other end of the ballast resistor to the Ignition Coil

POSITIVE (+) terminal with 14-gauge wire (you may have enough pink wire left over to accomplish this). If you are not using a Ballast Resistor, connect wire #920 directly to the Ignition Coil B+ terminal.

Note: The Ballast Resistor has been deleted from this kit due to lack of consumer usage. If one is needed in your application, please call Painless Performance at 800-423-9696 for assistance.

9.2.8 Connect a 14-gauge wire from the Starter Relay Ignition (l) terminal to the ignition coil side of the

Ballast Resistor. This wire serves as a ballast resistor BYPASS during engine starting. You must add a diode (8 amp min., 100 PIV) to this wire as shown in Figure 9-2. If you are not using a ballast resistor, do not connect this wire.

9.2.9 The Ignition Coil NEGATIVE (-) terminal is connected to the Distributor. Also connect ENGINE

SECTION A wire #923 (pur/wht) to the Ignition Coil NEGATIVE (-) terminal. This is the tachometer source. If you are not using a tachometer, insulate and stow wire #923.

9.2.10 Be sure the large, red battery cable is connected from the Battery to the Starter Motor Battery terminal (the same place the Maxi Fuse is connected).

16

Figure 9-2 Mopar Ignition (Start/Run) System

9.3 Steering Column Wiring - Turn Signal Connections

Refer to Table 9-1. Check your existing wiring (by tracing the wire, if necessary) against the data given.

9.3.1 Connect the nine (9) wires of the TURN SIGNAL SECTION to your automobile's existing Turn Signal

Connector according to Table 9-1. Mopar wire color codes for a number of years are provided for reference. Mopar has not been uniform in assigning wire colors over the years; so you may find that the wire colors in your existing Mopar harness differ from those shown.

9.3.2 If there is any doubt, be on the safe side. Trace the wire(s) with an ohmmeter, circuit tester, or test light. DON'T GUESS!

Note: Disconnect one end of the wire you are tracing. If you leave it connected, there is a possibility of tracing it back through some other circuit and getting false results.

9.4 Steering Column Wiring - Ignition Switch Connections

9.4.1 Connect the wires of the IGNITION SWITCH SECTION according to Table 9-1.

9.4.2 IGNITION SWITCH SECTION wire #919 (pur) is to be connected to a Neutral Safety Switch.

However, Mopar switches are mounted in the transmission. The transmission-mounted neutral safety switch was wired at Paragraph 9.2.4. FOR SAFETY, PLEASE USE A NEUTRAL SAFETY

SWITCH!

9.4.3 If the switch is mounted on a floor shifter, add some length of wire to #919 purple (pur) and route it to the neutral safety switch, cut and connect to it.

9.3.3 If your existing Turn Signal Connector requires a Horn Ground wire, install one. The TURN SIGNAL

SECTION has no ground wire, nor does it support seat belt buzzers, key alarms, or shifter lights.

17

1970-74 WITHOUT TILT COLUMN

TURN SIGNAL CONNECTOR

Mopar

Color

Designation Painless

Wire No.

Painless

Color

Wht

Tan

Grn

Brn

Grn

Pnk

Stop Light Switch

RF Turn Signal

LF Turn Signal

RR Turn Signal

LR Turn Signal

Hazard Flasher

Red

Blk

Turn Flasher

Horn

IGNITION SWITCH CONNECTOR

Ylw¹

Blk

Blu

Red

Vio

Ylw²

Ylw²

Orn

NOTES:

Ignition Start

Accessory Fuse Panel

Ignition Switched Fuse Panel

Battery B+

Ground

Buzzer Switch

Buzzer Switch

Gear Shift Lamp

1.

2.

3.

919

932

933

934

----

³

³

³

918

925

926

948

949

951

952

953

12 gauge wire

20 gauge wire

The Painless harness does not support these.

Table 9-1 Mopar Ignition and Turn Signal Wiring 1 of 2

Wht

Blu

Lt.Blu

Grn

Ylw

Brn

Pur

Blk

Pur

Brn

Orn

Red

----

----

----

----

TURN SIGNAL CONNECTOR

Designation 79 w/tilt 79 w/o tilt

Stop Light

RR Turn Signal

LR Turn Signal

Turn Signal Flasher

Hazard Signal Flasher

RF Turn Signal

Wht

Dk.Grn

Ylw

Pur

Brn

Dk.Blu

Wht

Brn

Dk.Grn

Red

Pnk

Tan

LF Turn Signal

Horn

Lt.Blu

Blk

Lt.Grn

Blk

Not supported by the Painless wire harness:

Horn

Horn Ground

Key Alarm

Key Alarm

R Corner Lamp

L Corner Lamp

Corner Feed Lamp

----

----

Pnk

Blk

Blk/Wht

Gry

Brn

Blk/Red

Blk

----

----

Tan/Wht

Lt.Grn/Blk

Vio

Table 9-1 Mopar Ignition and Turn Signal Wiring 2 of 2

18

82 RWD w/o tilt

Wht

Brn/Red

Dk.Grn/Red

Red

Pnk

Tan

Lt.Grn

Blk/Red

----

Blk

Blk/Lt.Blu

Lt.Blu

Tan/Wht

Lt.Grn/Blk

Vio

82 RWD w/tilt

Wht

Brn/Red

Dk.Grn/Red

Red

Pnk

Tan

Lt.Grn

Blk/Red

----

----

----

----

Tan/Wht

Lt.Grn/Blk

Vio

10.0 ALL MAKES - SPECIFIC CIRCUIT CONNECTIONS

10.1 Generator Charging System. See Figure 10-1.

10.1.1 Connect Generator ARMATURE terminal (A) to Voltage Regulator terminal A. Connect Generator

FIELD terminal (F) to Voltage Regulator terminal F. Use 14-gauge wire (color optional) for FIELD and 12-gauge wire for Armature.

10.1.2 Be sure both the generator and the voltage regulator are securely grounded. The voltage regulator may have a terminal for this purpose (labeled "G") or you may have to ground the regulator case.

10.1.3 Connect ALTERNATOR SECTION wire #915 (red) to Voltage Regulator terminal B.

10.1.4 Insulate and stow ALTERNATOR SECTION wire #914 (wht).

Figure 10-1 Generator Charging System

10.2 Generator to Alternator Conversion

10.2.1 You may be able to convert your generator charging system to use an alternator and external regulator without altering or re-routing existing wires.

10.2.2 Install the new alternator and replace the existing generator voltage regulator with the new, alternator compatible one.

10.2.3 Connect the existing wiring according to either Section 7.0, 8.0 or 9.2, as appropriate.

Figure 10-2 Ammeter & Maxi Fuse

19

10.3 Connecting an Ammeter and the Maxi Fuse. See Figure 10-2.

10.3.1 Most, but not all Ammeters must be inserted IN SERIES onto the ENGINE SECTION A (single) 10gauge wire #916 (red) that routes from the Fuse Panel to the Starter Solenoid on GM (Section

7.4) and from the Fuse Panel to the Starter Relay on Ford (Section 8.2) and Mopar (Section

9.2).

10.3.2 The overall physical length of this circuit should be as short as possible (allow some slack, however). You may have to cut wire #916 and you may have to add some additional length of 10gauge wire. USE ONLY 10-GAUGE WIRE OR LARGER.

10.3.3 Route wire #916 (from the Fuse Panel) and connect to the Ammeter NEGATIVE terminal. To complete the installation, follow ONE of the next three (3) paragraphs, as appropriate.

10.3.4 If you are using a GM starter, route the remainder of wire #916 from the Ammeter POSITIVE terminal to the Maxi Fuse terminal. Connect the other side of the Maxi Fuse (Figure 7-3) to the

Starter Solenoid Battery (B+) terminal.

10.3.5 If you are using a Ford starter with a starter relay, route the remainder of wire #916 from the

Ammeter POSITIVE terminal to the Maxi Fuse terminal. Connect the other side of the Maxi Fuse

(Figure 7-3) to the Starter Solenoid Battery (B+) terminal.

10.3.6 If you are using a Mopar starter with a starter relay, route the remainder of wire #916 from the

Ammeter POSITIVE terminal to the Maxi Fuse terminal. Connect the other side of the Maxi Fuse

(Figure 7-3) to the Starter Solenoid Battery (B+) terminal.

CAUTION: BOTH AMMETER TERMINALS MUST ABSOLUTELY BE ISOLATED FROM

GROUND. IF EITHER AMMETER TERMINAL COMES IN CONTACT WITH GROUND A

HARNESS FIRE IS INEVITABLE. USE EXTREME CARE AND DILIGENCE IN CONNECTING

AMMETERS.

CAUTION: BE SURE YOUR AMMETER'S CURRENT (AMPS) RATING EXCEEDS THE

CURRENT OUTPUT OF YOUR ALTERNATOR. PERFECT PERFORMANCE PRODUCTS, LLC

DOES NOT RECOMMEND USING ANY AMMETER RATED AT LESS THAN 65 AMPS. DO

NOT USE AN AMMETER WITH ANY HIGH OUTPUT ALTERNATOR (MORE THAN 65

AMPS).

Figure 10-3 Interior Lighting (GM Style Jamb Switch – Painless Part #80170)

20

10.4 Interior Lighting. See Figure 10-3

10.4.1 Interior Lights are switched through the door switches and the dash-mounted headlight switch, which is usually rotated counter-clockwise to turn on. These switches apply ground to the circuit.

YOU WILL NEED TO SUPPLY THESE GROUND WIRES. 12V is continually present at the light bulbs.

See Figure 10-6.

10.4.2 If possible leave your existing interior light wiring intact. The Painless harness supplies the 12V feed (B+) to the circuit via TAIL SECTION wire #945 (wht) and a ground via TAIL SECTION wire

#961 (blk).

Figure 10-4A Typical Fan Relay Installation (Fan Relay Kit – Painless Part #30101)

Figure 10-4B HEADLIGHT SECTION A Wiring

10.5 HEADLIGHT SECTION A. See Figure 10-4B.

10.5.1 Connect HEADLIGHT SECTION A wire #924 (grn) to the Horn's hot terminal. TURN SIGNAL

SECTION wire #953 (blk) was connected in the Turn Signal Connector section of these instructions. The Horn Relay is pre-wired into the Fuse Panel.

10.5.2 Connect HEADLIGHT SECTION A wires #908 (lt.grn) and #909 (tan) to the green and tan wires of

BOTH Headlamp Connectors. Connect the black wires of the Headlamp Connectors to Chassis

Ground. You should have enough wire to accomplish this. You have been supplied with two small grommets (Figure 3-1) should you need to pass these wires through a fender well. Don't forget to heat shrink both sides of the pre-installed butt connectors on the headlight pigtails.

10.5.3 Connect HEADLIGHT SECTION A wire #927 (brn) to ALL front Park Lights. Connect HEADLIGHT

SECTION A wire #925 (blu) to the RIGHT FRONT Turn Signal. Connect wire #926 (lt.blu) to the

LEFT FRONT Turn Signal.

21

Note: Don't confuse Park Lights with Turn Signals.

10.5.4 Connect HEADLIGHT SECTION A wire #901 (gry/wht) to the Electric Fan Relay. This wire is an activation wire for the relay, NOT A POWER FEED. The other end of wire #901 is in the

ACCESSORY SECTION SWITCHES and should be connected to the electric fan switch in the dash.

Wire #906 is the power feed wire for the electric fan switch. The diagram on page 31 shows a typical fan relay installation.

Note: The wire connected to the fan in Figure 10-4B will need to come from a fan relay output terminal. Wire #901 (gry/wht) from the ACCESSORY SECTION SWITCHES is an activation wire for a fan relay only. It will NOT power an electric fan by itself.

10.5.5 Connect the DIMMER SWITCH SECTION Extension Cable (Figure 3-1) to its mating connector in the harness (if applicable) and your floor-mounted Dimmer Switch or column-mounted Dimmer

Switch.

Figure 10-5 Dimmer Switches (Push Button Style – Painless Part #80150)

10.6

HEADLIGHT SECTION B Wiring. See Figure 10-6.

10.6.1 Connect the 6 wires of HEADLIGHT SECTION B, the Dome and Interior Light return circuit, and the

Headlamp Switch Ground as shown. If you do not have a GM headlight switch, you should trace out the wires of your existing harness and connect the new harness according to Table 11-2.

Note: On late-style GM headlight switches, the park lights terminal to which wire #927 (brn) is connected (shown in Figure 10-6) has been omitted. In this case, wire #927 must be connected as indicated by the dashed line in Figure 10-6.

10.7 Instrument Panel Wiring

10.7.1 Connect the wires of the INSTRUMENT PANEL SECTION as indicated in Table 11-2. Insulate and stow any wires you do not use.

10.7.2 Connect a jumper from wire #935 (red/wht) to all Gauges' power or “I” terminals. Connect a jumper from wire #930 (brn) to all Gauges' Instrument Lighting terminals. Connect a jumper to all

Gauges' Ground terminals and connect to Chassis Ground.

22

Figure 10-6 HEADLIGHT SECTION B (GM Style Switch – Painless Part #80152)

10.8 Brake Section

10.8.1 Connect BRAKE SECTION wires #917 (orn) and #918 (wht) to the Brake Light Switch wherever it may be mounted.

10.8.2 The Third Brake Light wire is pre-connected on the Switch end. Connect TAIL SECTION wire #950

(orn) to the Third Brake Light if applicable.

10.9 Tail Section Wiring

10.9.1 Connect the wires of the TAIL and TURN SIGNAL SECTIONS as indicated in Table 11-2 with the exception of #918 (wht), #948 (grn), #949 (ylw) and #950 (orn).

10.9.2 These 4 wires will be connected according to one of the diagrams shown in Figure 10-7. Which diagram you will use depends on whether or not you have one bulb on each side of the vehicle that is for the brake/tail and Turn Signal Lights (this is referred to as integrated lights) or you have more than one bulb on each side and the Brake and Turn Signal Lights are hooked to different bulbs (referred to as separate Brake/Turn Lights).

Note A: If you have Integrated Brake Lights you must use bulbs that have two (2) filaments in them such as in an 1157 bulb.

Note B: The three wires shown in these diagrams are connected to the "brighter" of the two filaments when using a two-filament bulb (the Tail Lights are usually connected to the

"Dimmer" filament). The Tail Lights, License Plate Lights, Reverse Lights, etc. are not shown on the diagrams for clarity.

Note C: In the separate Brake Light diagram the arrangement shown is only one of several ways to wire a vehicle. The important thing is that the Brake and Turn Signal Lights use completely separate bulbs.

23

Figure 10-7 Integrated Brake Lights & Separate Turn/Brake Lights

24

10.10 Helpful Hints for Tail Section Wiring

10.10.1 When you have Integrated Brake Lights on your vehicle the Turn Signal switch acts as a brain to control when the Lights in the rear are on constantly (braking) or flashing (turning) or a combination of both. The Turn Signal switch you use must be built to do this! If you are

using a steering column out of a salvage yard that was originally in a vehicle that had

separate Brake Lights then the switch will not work for Integrated Brake Lights.

10.10.2 Almost all light bulbs get the ground they need through the socket housing. If you mount your socket housing into anything other than a grounded metal part then you will need to provide a separate ground wire.

11.0 WIRE CONNECTION INDEX AND FUSE REQUIREMENTS

11.1

Wire Connection Index

In each section, connect the wire, as identified by its wire color, to the appropriate item in the CONNECT TO column. Pay close attention to the Notes in this section, as identified by a small, raised number such as the one at the end of this sentence.

Table 11-2 is divided into sections that correspond to the sections of your wire harness. (ACCESSORY

SECTION B+, DIMMER SWITCH SECTION, etc.). The index is divided vertically into six columns. COLOR,

GAUGE, NUMBER, CONNECT TO, ORIGIN, and SECTION OF ORIGIN.

The columns labeled ORIGIN and SECTION OF ORIGIN are for your reference ONLY. The items in these columns tell you where each wire originates (ORIGIN) and from which section (SECTION OF ORIGIN) of the harness.

The column labeled NO. contains a 900-series number that is used to identify various wires in the wiring diagrams that are a part of these instructions.

Many (but not all) of the wire numbers occur TWICE in this index. That is because you will be connecting

BOTH ENDS of many of the particular wire segments. However, some wire segments are pre-connected at one end. For instance, all wires originating from the fuse panel and certain other wires such as those originating from the fuse panel and certain other wires such as those originating from the horn relay, the dimmer switch, and the instrument panel section. These pre-connected wires are identified by an asterisk

(*) in the ORIGIN column.

11.2

Fuse Requirements

Table 11-1 Fuse Requirements

25

Color Ga. No. Connect to

Gry/Wht

1

Blk/Wht

1

Blk/Wht

1

Blu

Gry/Wht

1

Red

Red/Wht

Red/Blk

Red/Blu

Org

Org/Wht

Blu/Ylw

Lt.Grn

Tan

Org

2

Wht

Wht

Red

Blk/Wht

Red

Red

16

16

16

16

18

16

18

18

16

18

14

14

14

10

14

10

10

14

16

14

14

901

902

904

905

906

959

903

997

996

995

998

907

914

915

902

960

916

908

909

917

918

Pur

3

Pnk

12

14

Lt.Grn 18

Lt.Blu/Blk

1

18

Pur/Wht

1

Red

18

18

Grn

Blu

Lt.Blu

14

18

18

Brn

Lt.Grn

Tan

Gry/Wht

18

16

16

18

919

920

921

922

923

954

924

925

926

927

908

909

901

Table 11-2 Wire Connection Index, 1 of 3

ACCESSORY SECTION

SWITCHES

Cooling Fan Switch

AC/Heat Switch

ACCESSORY SECTION B+

AC/Heat Switch B+

Wiper Switch B+

Cooling Fan Switch B+

Clock B+

Cigar. Lighter/Acc B+

Acc. #5 Power (B+)

Acc. #4 Power (B+)

Acc. #3 Power (IGN.B+)

Acc. #2 Power (IGN.B+)

DIMMER SWITCH SECTION

Dimmer Switch

Dimmer Switch

Dimmer Switch

BRAKE SECTION

Brake Switch Power B+

Brake Switch

ALTERNATOR SECTION

Alternator Exciter

Alternator B+

A/C Compressor

High Output Wire

ENGINE SECTION A

Battery Positive or Starter Solenoid

(Large Terminal)

Start Solenoid ("S" Terminal)

Coil B+

Temperature Sending Unit

Oil Pressure Sending Unit

Tachometer Source

Electric Choke

HEADLIGHT SECTION A

Horn B+

Right Front Turn Signal

Left Front Turn Signal

Park Lights

High Beam

Low Beam

Fan Relay

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Wire Starting Point Section of Starting

Point

Fan Relay

A/C Compressor

Fuse Panel*

Fuse Panel*

Fuse Panel*

Fuse Panel*

Fuse Panel*

Fuse Panel*

Fuse Panel*

Fuse Panel*

Fuse Panel*

Headlight Switch

High Beam

Low Beam

Fuse Panel*

Turn Signal Switch

Fuse Panel*

Fuse Panel*

A/C Central Switch

Alt. Output Post

Fuse Panel*

Ignition Switch Start

Fuse Panel*

Temperature Gauge

Oil Pressure Gauge

Tachometer

Fuse Panel*

Horn Relay*

Turn Signal Switch

Turn Signal Switch

Headlight Switch

Dimmer Switch

Dimmer Switch

Fan Switch

Headlight Section A

Engine Section A

Fuse Panel

Fuse Panel

Fuse Panel

Fuse Panel

Fuse Panel

Fuse Panel

Fuse Panel

Fuse Panel

Fuse Panel

Headlight Section B

Headlight Section A

Headlight Section A

Fuse Panel

Turn Signal Section

Fuse Panel

Fuse Panel

Accy. Section Switches

Alternator Section

Fuse Panel

Ignition Switch Section

Fuse Panel

Instrument Panel Section

Instrument Panel Section

Instrument Panel Section

Fuse Panel

Fuse Panel

Turn Signal Section

Turn Signal Section

Headlight Switch Section

Dimmer Switch Section

Dimmer Switch Section

Accessory Section

Switches

Color

Red/Blk

1,5

Blu/Ylw

1

Brn

Brn

Brn

Orn

6

Brn

Orn

Red

Pur

Red/Wht

1

Ga.

12

14

Grn

Lt.Blu

Blu

Brn

4

Pnk

Lt. Grn

18

18

Lt.Blu/Blk

1

18

Pur/Wht

1

18

Orn/Blk

1

18

18

18

18

18

16

10

14

18

18

14

12

12

18

No.

928

907

929

927

930

959

932

933

934

919

935

936

937

938

930

939

921

922

923

955

Fuel Gauge

Connect to

HEADLIGHT SECTION B

Headlight Switch B+

Headlight Switch

Headlight Switch

Headlight Switch

Headlight Switch

Headlight Switch B+

IGNITION SWITCH SECTION

Ignition Switch Accessory

Ignition Switch Ignition

Ignition Switch B+

Ignition Switch Start

INSTRUMENT PANEL SECTION

Voltmeter Source & Gauges B+

High Beam Indicator

Left Turn Indicator

Right Turn Indicator

Instrument Panel Lighting

Temperature Gauge

Oil Pressure Gauge

Tachometer

Accessory #1

Orn/Blk

1

Red

Red/Blk

Wht

Grn

Ylw

Pnk

Brn

Orn

Blk

16

18

18

18

14

14

18

14

18

18

970

940

941

945

948

949

939

929

950

961

Accessory #6

RADIO SECTION

Radio B+ Unswitched (Constant)

Radio B+ Switched

TAIL SECTION

Dome Lights B+

Right Rear Turn Signal

Left Rear Turn Signal

Fuel Sending Unit

Tail Lights

Third Brake Light

Dome Light Ground

Table 11-2 Wire Connection Index, 2 of 3

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Wire Starting Point

Fuse Panel*

Dimmer Switch

Tail Lights

Park Lights

Instr. Panel Lighting

Fuse Panel*

Inline Fuse

Fuse Panel*

Fuse Panel*

Starter Solenoid

Fuse Panel*

Dimmer Switch* Dimmer Switch Section

Left Front Turn Signal* Turn Signal Section

Right Front Turn Sig.* Turn Signal Section

Headlight Switch Headlight Section B

Fuel Sending Unit

Temp. Sending Unit

Tail Section

Engine Section A

Oil Pres. Sending Unit Engine Section A

Tachometer Source Engine Section A

Fuse Panel* Fuse Panel

Fuse Panel*

Fuse Panel*

Fuse Panel*

Fuse Panel*

Turn Signal Switch

Turn Signal Switch

Fuel Gauge

Headlight Switch

Section of Starting

Point

Fuse Panel

Dimmer Switch Section

Tail Section

Headlight Section A

Instrument Panel Section

Fuse Panel

Accessory Fuse Holder

Fuse Panel

Fuse Panel

Engine Section A

Fuse Panel

Fuse Panel

Fuse Panel

Fuse Panel

Fuse Panel

Turn Signal Section

Turn Signal Section

Instrument Panel Section

Headlight Section B

Turn Signal Switch* Turn Signal Section

Interior Light Harness Near Fuse Panel

Brn 14 951

TURN SIGNAL SECTION

Emergency Flasher Switch B+ Emer. Flasher Relay* Fuse Panel

Pur

Blk

Grn

Ylw

Blu

Wht

Lt.Blu

18

16

18

14

18

14

14

952

953

948

949

925

918

926

Turn Signal Switch Flasher B+

Horn Switch

Turn Signal Switch

Turn Signal Switch

Turn Signal Switch

Turn Signal Switch

Turn Signal Switch

Turn Flasher Relay*

Horn Relay*

Fuse Panel

Fuse Panel

Right Rear Turn Signal Tail Section

Left Rear Turn Signal Tail Section

Right Front Turn Signal Headlight Section A

Brake Switch Engine Section A

Left Front Turn Signal Headlight Section A

Table 11-2 Wire Connection Index, 3 of 3

NOTES:

1. 2-color wires: 2 nd color (stripe) may not be intense color. Observe two-color wires closely.

2. From fuse panel to brake switch.

3. The neutral safety switch is located at the base of General Motors and Ford steering columns and in Mopar transmissions. Do not attempt to defeat your automobile's neutral safety switch. If your automobile does not have a neutral safety switch, please install one.

4. This wire needs to go from the headlight switch to the instrument panel lights.

5. This wire is power for the portion of the headlight switch that goes out to the headlights and front parking lights.

6. This wire is power for the portion of the headlight switch that goes out to the instrument panel lights and the tail lights. NOTE: This wire is only used if your headlight switch has two power input terminals.

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Painless Performance Limited Warranty

and Return Policy

Chassis harnesses, fuel injection harnesses, and Striker ColdShot units are covered under a lifetime warranty.

All other products manufactured and/or sold by Painless Performance are warranted to the original purchaser to be free from defects in material and workmanship under normal use.

Painless Performance will repair or replace defective products without charge during the first

12 months from the purchase date. No products will be considered for warranty without a copy of the purchase receipt showing the sellers name, address and date of purchase. You must return the product to the dealer you purchased it from to initiate warranty procedures.

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NOTES:

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