Painless Performance 8 Circuit, 12 Circuit Race Car Kit, 12 Circuit Race Car Fuse Block, 8 Switch Dash Mounted, 8 Switch Roll Bar Mounted Switch Panel Instructions
Below you will find brief information for Race Car Kit 8 Circuit, Race Car Kit 12 Circuit, Race Car Fuse Block 12 Circuit, Switch Panel 8 Switch Dash Mounted, Switch Panel 8 Switch Roll Bar Mounted. This document provides step-by-step instructions for installing the Painless Performance wire harness kits for race cars. The kits include a fuse block, dimmer switch, steering column pigtail wires, and other components. This guide covers the 50001 8-circuit competition wire harness kit, the 50002 12-circuit racing application kit, the 50101 12-circuit replacement fuse block, and the 50201/50202 8-circuit switch panel.
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Wire Harness Installation
Instructions
For Installing:
Part #50001 – Race Car Kit/8 Circuit
Part #50002 – Race Car Kit/12 Circuit
Part #50101 – Race Car Fuse Block/12 Circuit
Part #50201 – 8 Switch Dash Mounted Panel
Part #50202 – 8 Switch Roll Bar Mounted Panel
Manual #90502
Perfect Performance Products, LLC
Painless Performance Products Division
9505 Santa Paula Drive
Fort Worth, TX 76116
800-423-9696 phone ٠ 817-244-4024 fax
Web Site: www.painlessperformance.com
E-Mail: [email protected]
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. We sincerely
appreciate your business.
For Technical Questions
E-mail:
[email protected]
Tech Line: 800-423-9696
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.
P/N 90502 Painless Wiring Manual
7
th
Edition March 2002
Copyright © 1993 by Perfect Performance Products, Inc.
TABLE OF CONTENTS
List of Figures.…………………………………………………………………………
List of Tables.…………………………………………………………………………. ii ii
1.0 Introduction…………………………………………………………………………………………………….. 1
2.0 1 About These Instructions…………………………………………………………………………………...
Needed…………………………………………………………………………………………………… 2
4.0
5.0
Pre-installation and General Harness Routing Guidelines………………………………………. 2
General Harness Installation Instructions……………………………………………………………..
5.1
5.2
5.3 Harness
5.4
5.5
Grounding the Automobile………………………………………………………………………
Rough Installation………………………………………………………………………………….
Attachment………………………………………………………………………………. 4
Terminal Installation and Making Connections ………………………………………….
Testing the System…………………………………………………………………………………
3
3
3
4
5
6.0 50002 12-Circuit Racing Application Wire Harness Kit…………….……………..……………..
6.1 Contents of the 50002 Wire Harness Kit……….…………………………………………..
50002 Specific Circuit Connections……………………………………………………………
5
6.2
6.3
5
5
Wire 11
8.0
9.0
6.4
8-Circuit 16
7.1
7.2
Contents of the 50001 Wire Harness Kit…………………………………………………….. 16
Installation and Connections…………………………………………………………………….. 16
7.3 Wire Connection Index and Fuse Requirements………………………………………….. 17
7.4
50201/50202 8-Circuit Switch Panel…………………………………………………………………..
8.1
8.2
8.3
18
Contents of the Switch Panel Kit……………………………………………………………….. 18
Installation and Connections…………………………………………………………………….. 18
50201/50202 Wire Connection Index…………………………………………………………. 21
50101 Replacement Fuse Block……………………………………………………………………………
9.1
9.2
21
Contents of the 50101 Replacement Fuse Block Kit……………………………………… 21
Installation and Connections……………………………………………………………………… 21
i
Figure 6.1
Figure 6.2
Figure 6.3
Figure 6.4
Figure 6.5
Figure 6.6
Figure 6.7
Figure 6.8
Figure 6.9
Figure 6.10
Figure 6.11
Figure 6.12
Figure 7.1
Figure 8.1
Table 6.1
Table 6.2
Table 6.3
Table 7.1
Table 8.1
Table 8.2
LIST OF FIGURES
Early GM Alternator – External Regulator………………………………………………..
Late GM Alternator – Internal Regulator…………………………………………………
Fusible Link………………………………………………………………………………………….
GM Ignition (Start/Run) System……………………………………………………………..
Turn Signal and Ignition Switch Connectors…………………………………………….
Ammeter and Fusible Link………………………………………………………………………
Interior Lighting…………………………………………………………………………………….
“Headlight Section A” Wiring…………………………………………………………………..
Dimmer Switches…………………………………………………………………………………..
“Headlight Section B” Wiring…………………………………………………………………..
50002 Instrument Panel Connections……………………………………………………….
50002 Engine Section Connections…………………………………………………………..
50001 Relay and Fuse Placement……………………………………..……………………..
50201/50202 Switch Panel Connectors………………………………..…………………..
LIST OF TABLES
GM Ignition, Turn Signal Wiring and Switch Panel Wiring……..……………………. 8
Fuse Requirements…………………………………………………………………………………. 11
50002 Wire Connection Index………………………………………………………………….. 12
50001 Wire Connection Index and Fuse Requirements……………………………….. 17
50002 and 50201/50202 Wire Connection Index………………………………………… 20
50201/50202 Wire Connection Index…………………………………………………………. 21
ii
10
11
14
15
18
19
8
9
9
10
6
6
7
7
1.0 INTRODUCTION
You have purchased what we at Perfect Performance Products, Inc. believe to be the most up-to-date and easiest-toinstall automotive racing wire harness or accessory on the market. It is designed for easy installation, even if you have no electrical experience.
The 50002 fuse block can be easily attached to any under-dash location. By using the optional Dimmer Switch
Extension cable (not included) you can mount the fuse block under the dash on the passenger side. There is enough length to the wire at all engine, dash, and trunk locations to complete the installation without splicing. The fuse block, voltmeter, fuel gauge, oil pressure gauge, temperature gauge, turn signal lights, dimmer switch, and dash lights are all pre-wired, allowing for easy hookup. The proper fuses and flashers have been pre-installed in the fuse blocks. 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.
PPPI Wire Harness Kits are 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 TXL (cross-linked polyethylene), 600 volt,
125 degrees c.
Standard automotive wire is GPT, 300 volt, 80 degrees c. with PVC insulation.
The 50002 12-Circuit Racing Wire Harness Kit has been designed with three major groups incorporated into it:
ENGINE/HEADLIGHT GROUP
REAR LIGHT GROUP
Includes high beam, low beam, park, right turn, left turn, electric fan, water pump, horn, starter solenoid and battery feed, alternator and alternator excitor wire, distributor, water temperature, and oil pressure.
Includes tail lights, left and right turn signals, brake light, fuel sender, dome
light and electric fuel pump.
ACCESSORY GROUP Includes wires to connect tail and headlamps, ignition, fuel pumps, water pump, cooling fan, and an accessory.
The 50001 8-Circuit Racing Wire Harness Kit consists of two major groups:
DASH GROUP Provides for switching of lights, two fuel pumps, water pump, cooling fan, start and ignition, and an accessory.
ACCESSORY GROUP Includes wires to connect tail and headlamps, ignition, fuel pumps, water pump, cooling fan, and an accessory.
2.0 ABOUT THESE INSTRUCTIONS
These instructions provide information for the installation of the 50001 8-circuit competition Wire Harness Kit, the
50002 12-circuit Racing Application Wire Harness Kit, the 50101 12-circuit Replacement Fuse Block, and the
50201/50202 8-circuit Switch Panel. The contents of these instructions are divided into major Sections, as follows:
1.0 Introduction
2.0 About These Instructions
Needed
4.0 Pre-Installation and Harness Routing Guidelines
5.0 General Installation Instructions
6.0 50002 Racing Application Wire Harness Kit
7.0 50001 8-Circuit Racing Wire Harness Kit
8.0 50201/50202 8-Circuit Switch Box/Panel
9.0 50101 Replacement Fuse Block
Sections are further divided into Paragraphs and Steps. Throughout, the Figure numbers refer to illustrations and the Table numbers refer to information in table form. These are located in or near the sections or paragraphs to which they correspond. Always pay special and careful attention to any Notes, especially those in the Tables, and any text marked CAUTION.
1
3.0 TOOLS NEEDED
In addition to your regular tools, you will need, at least, the following tools:
Crimping tool Note: Use a quality tool to avoid over-crimping.
Continuity tester (Test light or ohm meter)
Electric drill
1-1/4" Hole saw
Small (10 amp or less) battery charger
4.0 PRE-INSTALLATION & HARNESS ROUTING GUIDELINES
The installation of your wire harness kit consists mainly in two parts:
• The physical routing, positioning, and securing of the wire harness, wire groups, and individual wires.
• The proper electrical connection of the individual circuits.
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, secondarily, to what extent you want to secure and conceal the harness. We do offer some general guidelines and routing practices starting in Paragraph 4.2, GENERAL installation instructions in Section 5.0, and precise instructions concerning the electrical connections you will have to make in beginning in Section 6.0. To help you begin thinking through the installation of your wire harness, read the following sections:
4.1 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.
4.1.1 The eleven SECTIONS of the 50002 12-Circuit Racing Application Wire Harness Kit are listed immediately following. For complete information concerning the individual circuits and wires that make up these harness SECTIONS, see Section 6.3.
ACCESSORY SECTION SWITCHES
ACCESSORY SECTION B+
DIMMER SWITCH SECTION
ENGINE SECTION
ENGINE SECTION A
HEADLIGHT SECTION A
HEADLIGHT SECTION B
IGNITION SWITCH SECTION
INSTRUMENT PANEL SECTION
TAIL SECTION
TURN SIGNAL SECTION
4.1.2 The two SECTIONS of the 50001 8-Circuit Competition Wire Harness Kit are listed immediately following. For complete information concerning the individual circuits and wires that make up these harness SECTIONS, see Section 7.3.
ACCESSORY SECTION B+
INSTRUMENT PANEL SECTION
4.1.3 The 50101 12-Circuit Replacement Fuse Block and the 50201/50202 8-Circuit Switch Panel wire assignments are not separated into SECTIONS.
4.2 Decide where and how the Fuse Block or Switch Panel will be mounted. PPPI Wire Harness Kits are designed for the fuse block to be mounted on the driver's side, under the dash. If you want to install the fuse block on the passenger side, you must obtain the Dimmer Switch Extension Cable at the dealer where you obtained this wire harness kit.
2
4.3 Decide which of the following circuits you will be using in your system and where the harness groups or wires will be routed:
Emergency Flashers ____________________________________________________
Horn ____________________________________________________
Dome Lights ____________________________________________________
Lights ____________________________________________________
Wipers ____________________________________________________
Electric Fuel Pump(s)
Electric Cooling Fan
Turn Signals
____________________________________________________
____________________________________________________
____________________________________________________
Radio (Ign. switched B+) ____________________________________________________
Gauges ____________________________________________________
Accessories ____________________________________________________
4.4 A good exercise is to lay out the wire harness on the floor beside your automobile and identify all the
SECTIONS.
4.5 You will want to route the harness through and around open areas. Inside edges provide extra protection from hazards and also provide places for tie wraps, clips and other support.
4.6 Route the harness away from sharp edges, exhaust pipes, and hood, trunk and door hinges.
4.7 Plan where harness supports will be located. Use a support every 12 inches unless the harness routes under the floor carpet.
4.8 Allow enough slack in the harness at places where movement could possibly occur (body to frame, frame to engine, etc.).
4.9 At wire ends, don't depend on the terminals to support the harness. The weight of the harness could cause terminals to disconnect.
4.10 The wires should be bundled into harness groups. Use nylon ties, poly split loom, or tape.
5.0 GENERAL INSTALLATION INSTRUCTIONS
5.1 GROUNDING THE AUTOMOBILE
A perfectly and beautifully wired automobile will nevertheless have problems if everything is not properly grounded. Don't go to the careful effort of installing a quality wire harness only to neglect proper grounding.
Note: PPPI Wire Harness Kits include no ground wire except the black wire from the Switch Panel, and the ground wire for the 50001 fuse block. You must supply ground wire (14-16 gauge) for all other circuits.
5.1.1 Connect a Ground Strap or Cable (even a 10-gauge wire is too small) from the Negative Battery terminal to the automobile chassis (frame).
5.1.2 Connect a Ground Strap from the Engine to the chassis. DO NOT RELY UPON THE MOTOR
MOUNTS TO MAKE THIS CONNECTION.
5.1.3 Connect a Ground Strap from the Engine to the Body.
5.1.4 If you have a fiberglass body you should install a terminal block to ground all your gauges, lights, and accessories. Ground the Terminal Block and everything connected to it will be grounded.
5.2 ROUGH
CAUTION: DISCONNECT THE POWER FROM YOUR VEHICLE BY REMOVING THE
NEGATIVE BATTERY TERMINAL FROM THE BATTERY.
Note: Your kit comes equipped with a fusible link. This safety device is designed to go between wire
#816 and the battery source for overall harness protection.
Note: Make no wire connections or permanent mounting of any kind at this time!
3
5.2.1
Position the Fuse Block and/or Switch Panel in their intended locations. Refer to the
Introduction and Paragraph 4.2 if you want to mount the fuse block on the passenger side of your automobile.
5.2.2 Drill a 1-1/4" (1.25") hole near the fuse block for engine and headlight group wires to pass through (ENGINE SECTION, ENGINE SECTION A, and HEADLIGHT SECTION A).
5.2.3 Install the firewall grommet. Route engine and headlight group wires through the grommet and position the harness groups in the areas decided upon in Paragraphs 4.3 and 4.4.
5.2.4 Route dash group (ACCESSORY SECTION B+, ACCESSORY SECTION SWITCHES,
HEADLIGHT SECTION B, and INSTRUMENT PANEL SECTION) upward to rear of dash and temporarily tie in place.
5.2.5 Position rear group (TAIL SECTION), on floor pan area decided upon in Paragraphs 4.3 and
4.4.
5.3 HARNESS ATTACHMENT
Note: Harness routing and shaping should be a time-consuming task. Taking your time will enhance the beauty of your installation. Please be patient and TAKE YOUR TIME!
5.3.1 Permanently mount fuse block.
5.3.2
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.
5.3.3 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 the cowl vent, radio, etc.
Note: Do not tighten tie wraps and mounting devices at this time. Make all harness attachments
LOOSELY.
5.3.4 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.
5.4 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 6.0 through 10.0 as applicable, and continually refer to the wire connection indexes, 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.
5.4.1 Have all needed tools and connectors handy.
5.4.2 Select the correct size terminal for the wire and stud application.
5.4.3 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.
5.4.4
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. DO NOT OVER-CRIMP!
5.4.5 Crimp the terminal onto the wire.
5.4.6 Connecting the harness throughout the groups is a repeating process. Make sure that each wire is
FIRST properly routed and THEN attach. DON’T ATTACH FIRST THEN ROUTE
AFTERWARD.
5.4.7 When all wires are attached, tighten the mounts and ties to secure harness permanently.
4
5.5 TESTING THE SYSTEM
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. 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.
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. YOU WILL SIMPLY DEFEAT THE PURPOSE OF USING THE
CHARGER.
5.5.2 Individually turn on each light, ignition, wiper circuit, etc, and check for proper operation.
5.5.3 When all circuits check out THEN attach the battery cable to the battery for vehicle operation.
6.0 50002 12-CIRCUIT RACING APPLICATION WIRE HARNESS KIT
6.1 CONTENTS OF THE 50002 WIRE HARNESS KIT
Take inventory to see that you have everything you're supposed to have in this kit. If anything is missing, go to the dealer where you obtained the kit or contact Perfect Performance Products, Inc. at (817) 244-
6898. The 50002 Wire Harness Kit should contain the following items:
● The Main Wire Harness, with the Fuse Block wired in and fuses installed.
● Dimmer Switch Cable. This cable comprises the DIMMER SWITCH SECTION. It connects into the harness at the white 3-pin connector. The optional Dimmer Switch Extension Cable (not included) is inserted here if you are mounting the Fuse Block on the passenger side of your automobile.
● Steering Column "Pigtail" cables. These cables constitute the TURN SIGNAL SECTION and the
IGNITION SWITCH SECTION. Both sections are unlabeled. These cables connect into the main harness at the white 6-pin and 9-pin connectors. See Figure 6.5 for GM-keyed column connector pin assignments. grommet
● 1 Package of nylon tie wraps
● 2 GM turn signal connectors (See Figure 6.5).
● 2 GM Ignition Switch Connectors (See Figure 6.5).
● Parts box, containing the Fusible Link (See Figure 6.3), a GM alternator connector, terminals, splices, etc.
● Race Car Wire Harness Installation Instructions PIN 90502 (This booklet)
6.2 50002 SPECIFIC CIRCUIT CONNECTIONS
If you have not already done so, read Sections 4.0 and 5.0 of these instructions and think through the installation of the harness kit before securing or cutting any wires.
5
6.2.1 Early GM Alternator (before 1969)- External Regulator. See Figure 6.1.
Note: Your Alternator may not appear exactly as represented in the Figures, but the circuits are wired the same.
A. With a short 16-gauge jumper wire, connect
Voltage Regulator terminals 3 & 4 together.
Connect ENGINE SECTION wire #814 (wht)
to Voltage Regulator terminal 3 or 4.
Regulator
B. Connect ENGINE SECTION wire #815 (red)
to the Alternator Output lug (Bat).
C. Connect a 14-gauge wire from Voltage
terminal 2 to Alternator terminal R.
Connect a 14-gauge wire from Voltage
Regulator terminal F to Alternator terminal F.
D. Connect a 16-gauge ground wire from
the Alternator Ground lug (G) to chassis ground.
6.2.2 Late GM Alternator (after 1972)
Internal Regulator. See Figure 6.2.
Figure 6.1 Early GM Alternator - External Regulator
A. Connect ENGINE SECTION wire #814
(wht) to Alternator terminal 1. Connect
ENGINE SECTION wire #815 (red) to the
Alternator Output lug (Bat).
B. Connect a short 14-gauge jumper wire from Alternator terminal 2 to the Alternator Output lug (Bat).
C. A connector and terminal spades for late GM Alternators are included in the parts box.
6.2.3 GM One-Wire Alternator.
A. Connect ENGINE SECTION wire #815 (red) to the Alternator Output lug (Bat).
B. Insulate and stow ENGINE SECTION wire
#814 (wht). Do not install jumper wire. No wires are connected to Alternator terminals 1 & 2.
C. When using a 1-wire alternator you must use a voltmeter or ammeter. A warning light cannot be wired in.
6.2.4 GM Ignition (Start/Run) System. See Figure 6.4.
Note:If you are going to install an ammeter, see
Section 6.2.6
first.
Figure 6.2 Late GM Alternator
Internal Regulator
A. With crimping tool, attach Fusible Link (Figure 6.3) onto end of ENGINE SECTION (single) 10 ga. wire #816 (red) AFTER having routed wire from the Fuse Panel to the Starter Solenoid. This link is 2 gauges smaller than wire #816 and serves as a fuse to protect the entire harness. DO NOT OMIT IT!
B. Connect wire #816-with fusible link installed - to the Starter Solenoid Battery terminal. This is the same lug that the large red cable from the battery is normally connected to.
C. Connect ENGINE SECTION A wire #819 (ppl) to the Starter Solenoid Start (S) terminal.
D. 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 #820 (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 #820 directly to the Ignition Coil POSITIVE (+) terminal.
6
Note:Older model vehicles ('55 -'59) used Ballast Resistors. From about '59 to about '74 Resistor Wire was used, and from about '74 on HEI electronic ignition has been employed.
E. The Ignition Coil NEGATIVE (-) terminal is connected to the Distributor.
Also connect ENGINE SECTION A wire #823 (ppl/wht) to the Ignition
Coil NEGATIVE (-) terminal. This is the tachometer source. If you are not using a tachometer, insulate and stow wire #823.
F. A 14-gauge wire connected from the Starter Solenoid Ignition (I) terminal to the ignition coil side of the Ballast Resistor is optional. This wire (the dashed line in Figure 6.4) 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 Figure 6.3 Fusible Link wire is connected. You may therefore choose to omit it. If you are not using a ballast resistor, leave the Starter Solenoid Ignition (I) terminal unconnected and do not install the bypass wire.
G. When using an HEI Distributor connect wire #820 (pnk) to the BAT B+ terminal of the Distributor using one of the blue "push-on" splices provided. If a Tach is used wire #823 (ppl/wht) is connected to the TACH terminal, using one of the blue "push-on" splices.
6.2.5 Turn Signal & Ignition Switch Connectors. See Table 6.1 and Figure 6.5.
A. There are differing Turn Signal plugs on most tilt columns. The difference is in the length of the male plug that is mounted ON THE COLUMN. One is 4-1/4"
(4.25") long and the other is 3-7/8"(3.875").
This is a mere 3/8"
(0.375") difference, so measure the plug carefully. This kit has included female connectors to mate with either size column-mounted plug. See Figure 6.5 to determine which connector is correct for your vehicle.
The TURN SIGNAL SECTION wires have already been terminated for you. Choose the proper connector and install the contacts according to Table 6.1 and Figure
6.5.
Note: The contacts will only insert into the connectors ONE WAY, as shown in Figure
6.5. Make certain you are inserting the wires into the CORRECT LOCATIONS as the contacts are difficult if not impossible to remove once inserted.
Figure 6.4
GM Ignition (Start/Run) System
B. Connect the wires of the IGNITION
SWITCH SECTION to the two (2) GMstyle Ignition Connectors according to
Figure 6.5 and Table 6.1. The contacts are in the Parts Box.
C. IGNITION SWITCH SECTION wire
#819 (ppl) has been cut and spade lugs installed to be connected to the Neutral
Safety Switch at the base of the steering
column. If the switch is mounted on the
floor shifter, add some wire to reach it.
FOR SAFETY, PLEASE USE A
NEUTRAL SAFETY SWITCH!
D. The harness does not support seat belt buzzers or key alarms.
E. To supply power to a throttle body or tuned port fuel injection use ENGINE SECTION A wire #820
(pnk) as the fused ignition power source.
7
NOTE: Red 834 will need to spliced and routed to both ignition switch connectors when using a column mounted GM ignition switch.
Figure 6.5 Turn Signal and Ignition Switch Connectors
Designation Wire No. Color
Turn Signal Section
Horn
LF Turn Signal
RF Turn Signal
Hazard Flasher
Turn Flasher
LR Turn Signal
RR Turn Signal
Stop Lamp Switch
853
826
825
851
852
849
848
818
Ignition Switch Section
Ign. Start
Ign. Coil
Acc. Fuse Block
Ign. Switch B+
Battery B+
819
831
832
833
834
Battery Fuse Block ----
Switch Panel Ground 861
Ppl
Pnk
Brn
Orn
Red
----
Blk
Blk
Lt.Blu
Blu
Brn
Ppl
Ylw
Grn
Wht
50201/50202 Instrument Panel Section
Ign. Start
Ign. Coil
Acc. Fuse Block*
Ign. Switched B+
Battery B+
Ground
Headlights
Taillights
Elec.Water Pump
Elec.Fuel Pump #1
Elec.Fuel Pump #2
Elec.Cooling Fan
819
831
832
833
834
861
807
829
862
847
863
801
* Used with the 50002 system only.
Ppl
Pnk
Brn
Orn
Red
Blk
Blu/Ylw
Brn
Blu
Ylw/Wht
Grn
Gry/Wht
Turn Signal Connector
G
H
J
K
L
M
N
P
Table 6.1 GM Ignition, Turn Signal Wiring, and Switch Panel Wiring
8
6.2.6 Connecting an Ammeter and the Fusible Link. See Figure 6.6.
A. The Ammeter must be inserted IN SERIES onto the ENGINE SECTION
(single) 10-gauge wire #816 (red) that routes from the Fuse Panel to the
Starter Solenoid on GM (Section 6.2.4) and from the Fuse Panel to the
Starter Relay on Ford and Mopar.
B. The overall physical length of this circuit should be as short as possible
(allow some slack, however). You may have to cut wire #816 and you may have to add some additional length of 10-gauge wire. USE ONLY
10-gauge wire. Figure 6.6 Ammeter &
C. Route wire #816 (from the Fuse Panel) and connect to the Ammeter Fusible Link
NEGATIVE terminal. To complete the installation, follow ONE of the next three paragraphs, as appropriate.
D. If you are using a GM starter, route the remainder of wire #816 from the Ammeter POSITIVE terminal to the Starter Solenoid Battery (B+) terminal. This is the terminal the battery cable is connected to. Splice the Fusible Link or Maxifuse (Figure 6.3) onto the end of wire #816 and connect to the Starter Solenoid Battery (B+) terminal. E. If you are using a Ford starter with a starter relay, route the remainder of wire #816 from the Ammeter POSITIVE terminal to the Starter Relay Battery
(B+) terminal. This is the terminal the battery cable is connected to. Splice the Fusible Link or
Maxifuse (Figure 6.3) onto the end of wire #816 and connect to the Starter Relay Battery (B+) terminal.
F. If you are using a Mopar starter with a starter relay, route the remainder of wire #816 from the
Ammeter POSITIVE terminal to the Starter Relay Battery (B+) terminal, and from this terminal to the
Starter Solenoid Battery (B+) terminal. This is the terminal the battery cable is connected to. Splice the
Fusible Link or Maxifuse (Figure 6.3) onto the end of wire #816 and connect 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, INC.
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).
6.2.7 Interior Lighting. See Figure 6.7.
A. 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. 12V
(B+) is continually present at the light bulbs.
B. You should leave your existing interior light wiring intact. The 50002 harness supplies only the 12V (B+) to the circuit via TAIL SECTION wire #845 (wht).
C. Locate the existing 12V feed wire and connect it to
TAIL SECTION wire #845.
6.2.8 HEADLIGHT SECTION A. See Figure 6.8.
Figure 6.7 Interior Lighting
A. Connect HEADLIGHT SECTION A wire #824
(grn) to the Horn's hot terminal. TURN SIGNAL
SECTION wire #853 (blk) was connected in the
Turn Signal Connector section of these instructions.
The Horn Relay is pre-wired into the Fuse Panel.
9
B. C o n n e c t
HEADLIGHT
SECTION A #808
(lt.grn) and #809
(tan) to BOTH head-lamps. These are the hi- and low- beam wires.
Connect the black wires of the headlamp connectors to Chassis Ground.
You should have enough wire to accomplish this.
Should you need to pass these wires through a fender well, use grommets. Don't
Figure 6.8 HEADLIGHT SECTION A Wiring grommets onto the wires
BEFORE you connect them.
C. Connect HEADLIGHT SECTION A wire #827 (brn) to ALL front Park Lights. Connect HEADLIGHT
SECTION A wire #825 (blu) to the RIGHT FRONT Turn Signal. Connect wire #826 (lt.blu) to the
LEFT FRONT Turn Signal.
Note: Don't confuse Park Lights with Turn Signals.
D. Connect HEADLIGHT SECTION A wire
#801 (gry/wht) to the Electric Fan hot
terminal. The gry/wht wire #806 of
ACCESSORY SECTION B+ and gry/wht wire #801 of ACCESSORY SECTION
SWITCHES (neither shown) connect to the Electric Fan Switch in the dash.
E. Connect DIMMER SWITCH SECTION wires #807, #808, and #809 to your floor- mounted Dimmer Switch. If you have a column-mounted Dimmer Switch, you may need to run additional wire up the column. See Figure 6.9.
Figure 6.9 Dimmer Switches
6.2.9 HEADLIGHT SECTION B Wiring. See Figure 6.10.
Connect the 5 wires of HEADLIGHT SECTION B and the Dome Light Ground as shown. If you don't have a GM headlamp switch, you should trace out the wires and connect the new harness according to Table 6.1.
6.2.10 Instrument Panel Wiring
A. Connect the wires of the INSTRUMENT PANEL SECTION as indicated in Table 6.3. Insulate and stow any wires you do not use.
B. Connect a jumper from wire #835 (red/wht) to all Gauges' B+ terminals. Connect a jumper from wire
#830 (brn) to all Gauges' Instrument Lighting terminals. Connect a jumper to all gauges' Ground terminals and connect to Chassis Ground.
10
6.2.11 Brake Light Switch
A. Connect ENGINE SECTION A wires #817 (orn) and #818 (wht) to the Brake Light Switch whether it is attached close to the master cylinder or on the steering column.
B. The Third Brake Light wire is pre-connected on the Switch end. Connect TAIL SECTION wire
#850 (orn) to the Third Brake Light if applicable.
6.3 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 any Notes in this section, as identified by a Figure 6.10 HEADLIGHT SECTION small, raised number such as the one at the end of this sentence. B Wiring
Table 6.3 is divided into sections that correspond to the SECTIONS of the 50002 wire harness,
(ACCESSORY SECTION B+, DIMMER SWITCH SECTION, etc.). The Index is divided vertically into six columns: COLOR, GA., NO., CONNECT TO, COMES FROM, and FROM SECTION.
The columns labelled COMES FROM and FROM SECTION are for your reference ONLY. The items in these columns tell you where each wire originates (COMES FROM) and from which section (FROM
SECTION) of the harness.
The column labelled NO. contains an 800-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 block 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 COMES FROM column.
6.4 FUSE REQUIREMENTS
Headlight/Dome............................................. 25
Emergency Flashers/Stop............................... 15
Turn Signals/Wiper........................................ 15
Gauges/Radio................................................. 10
Horn/Accy. B+............................................... 20
Electric Cooling Fan....................................... 20
Electric Fuel Pump(s)..................................... 20
Coil................................................................. 30
Electric Water Pump...................................... 10
Ignition Accessory (Center)........................... 15
Ignition Accessory (Lower Right).................. 20
Table 6.2 Fuse Requirements
11
Color Ga. No. Connect To:
ACCESSORY SECTION SWITCHES
Gry/Wht
1
Blue
2, 3
Ylw/Wht
Green
14
14
14
14
801 Cooling Fan Switch
862 Water Pump Switch
7
7
847 Fuel Pump #1 Switch
863 Fuel Pump #2 Switch
7
7
Comes From:
Cooling Fan
Water Pump
Fuel Pump #1
Fuel Pump #2
From Section:
Headlight Section A
Engine Section
Tail Section
Tail Section
ACCESSORY SECTION B+ (This section is not used when using a 50201 or 50202 switch panel)
Blue
Gry/Wht
Blue
2
Ylw/Wht
Ppl/Wht
Tan
16
14
14
14
14
14
805 Wiper Switch B+
806 Fan Switch B+
864 Water Pump Switch B+
861 Fuel Pump #1 Switch B+
6
865 Optional Accessory B+
866 Optional Accessory B+
Fuse Block*
Fuse Block*
Fuse Block*
Fuse Block*
Fuse Block*
ENGINE SECTION
White
Red
Blue
3
Red
14
12
14
10
814 Alternator Excitor
815 Alternator B+
862 Water Pump B+
816 Battery at Str.Solenoid B+
Fuse Block*
Fuse Block*
Water Pump Switch Accy. Section Switches
Fuse Block*
ENGINE SECTION A
Orange
4
White
Purple
Pink
Lt.Grn
Lt.Blu/Blk
Ppl/Wht
16
16
12
14
18
18
18
817 Brake Switch B+
818 Brake Switch
819 Starter Solenoid
820 Coil B+
821 Temp. Sending Unit
822 Oil Pressure Sending Unit
823 Tachometer Source
HEADLIGHT SECTION A
Fuse Block*
Turn Signal Switch Turn Signal Section
Ignition Switch Start Ign. Switch Section
Fuse Block*
Temp. Gauge Instrument Panel Section
Oil Pressure Gauge Instrument Panel Section
Tachometer Instrument Panel Section
Green
Blue
Lt.Blue
Brown
Lt.Grn
Tan
Gry/Wht
14
18
18
18
14
14
14
824 Horn B+
825 Right Front Turn Signal
826 Left Front Turn Signal
827 Parking Lights
808 High Beam
809 Low Beam
801 Cooling Fan
Horn Relay* (Fuse Block)
Turn Signal Switch Turn Signal Section
Turn Signal Switch Turn Signal Section
Headlight Switch
Dimmer Switch
Dimmer Switch
Fan Switch
Headlight Section B
Dimmer Switch Section
Dimmer Switch Section
Accy. Section Switches
HEADLIGHT SECTION B
Red/Blk
Brown
Brown
12
18
18
828 Headlight Switch B+
Headlight
Switch
7
Headlight
827 Headlight Switch
830 Headlight Switch
Fuse Block*
Dimmer Switch
Tail Lights
Parking Lights
Dimmer Switch Section
Tail Section
Headlight Section A
Instr.Panel Lighting Instrument Panel Section
DIMMER SWITCH SECTION
Blu/Ylw
Lt.Grn
Tan
14
14
14
807 Dimmer Switch
808 Dimmer Switch
809 Dimmer Switch
Headlight Switch
High Beam
Low Beam
Headlight Section B
Headlight Section A
Headlight Section A
Table 6.3 50002 Wire Connection Index, 1 of 2
12
Color
IGNITION SWITCH SECTION
Pink
Brown
14 831 Ignition Switch Coil B+
7
8
18 832 Ignition Switch Accy. B+
Orange 18 833 Ignition Switch Accy. B+
7
7
Fuse Block*
Accy. Power Relay* (Fuse Block)
Red
Purple
5
Black
12 834 Ignition Switch B+
12 819 Ignition Switch Start
860
7
Fuse Block*
Starter Solenoid
Ground Fuse
Engine Section A
INSTRUMENT PANEL SECTION
Red/Wht 18
Green
Lt.Blue
Blue
Brown
Pink
Lt.Grn
18 836 High Beam Indicator
18
18
18
18
18
Lt.Blu/Blk 18
Ppl/Wht
835 Radio & Gauges B+
837 Left Turn Indicator
838 Right Turn Indicator
830 Instr.Panel Lighting
839 Fuel Gauge
821 Temperature Gauge
822 Oil Pressure Gauge
Tachometer
Fuse Block*
Dimmer Switch*
Fuel Sending Unit
Temp.Sending Unit
Oil Pres.Sending Unit
Tachometer Source
Dimmer Switch Section
Left Front Turn Signal* Turn Signal Section
Right Front Turn Signal* Turn Signal Section
Headlight Switch Headlight Section B
Tail Section
Engine Section A
Engine Section A
Engine Section A
TAIL SECTION
White 14 845 Dome Lights B+
Green 18 848 Right Rear Turn Signal
Ylw/Wht 14 847 Fuel Pump #1 B+
Green
Yellow 18 849 Left Rear Turn Signal
Pink
3
14 863 Fuel Pump #2 B+
18 839 Fuel Sending Unit
Brown 14 829 Tail Lights
Orange 18 850 Third Brake Light
Fuse Block*
Turn Signal Switch
Fuel Pump #1 Switch
Fuel Pump #2 Switch
Turn Signal Switch
Fuel Gauge
Headlight Switch
Turn Signal Switch*
Turn Signal Section
Accy. Section Switches
Accy. Section Switches
Turn Signal Section
Instr. Panel Section
Headlight Section B
Turn Signal Section
TURN SIGNAL SECTION
Brown
Purple
Black
14 851 Emergency Flasher Switch B+ Emergency Flasher*
14 852 Turn Signal Switch Flasher B+ Turn Flasher*
18 853 Horn Switch Ground Horn Relay*
Green 18 848 Turn Signal Switch
Yellow 18 849 Turn Signal Switch
Blue 18 825 Turn Signal Switch
White
Lt.Blu
16 818 Turn Signal Switch
18 826 Turn Signal Switch
Right Rear Turn Signal
Left Rear Turn Signal
Fuse Block
Fuse Block
Fuse Block
Tail Section
Tail Section
Right Front Turn Signal Headlight Section A
Brake Switch Engine Section A
Left Front Turn Signal Headlight Section A
NOTES:
1.
2.
3.
4.
5.
6.
7.
8.
2-color wires: 2nd color (stripe) may not be intense color. Observe two-color wires closely.
Wire has identification tag.
May be Orn/Blk in some kits.
From fuse block to turn signal switch. Brake switch B+ is taken from the turn signal switch.
This wire is cut and spade lugs have been installed so that your existing neutral safety switch circuit can be wired into your harness. 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.
Jumper this wire to Fuel Pump #2 Switch B+ to supply power. Not necessary if you are using a 50201/50202
Switch Panel.
These wires are connected to the 50201/50202 Switch Panel, if used.
This wire must be connected for the accessories in the fuse block to power up.
Table 6.3 50002 Wire Connection Index, 2 of 2
13
Figure 6.11 50002 Instrument Panel Connections
14
Figure 6.12 50002 Engine Section Connections
15
7.0 50001 8-CIRCUIT COMPETITION WIRE HARNESS KIT
The 50001 8-circuit relay-activated wiring system is designed to give maximum output with the utmost reliability. The relays enable the switches to activate the circuit with low current (amperage) requirements for extended life of the switches and the system.
7.1 CONTENTS OF THE 50001 WIRE HARNESS KIT
Take inventory to see that you have everything you're supposed to have in this kit. If anything is missing, go to the dealer where you obtained the kit or contact Perfect Performance Products, Inc. at
(817) 244-6898. The 50001 Competition Wire Harness Kit should contain the following items:
• The main harness, with the fuse block wired in and fuses and relays installed.
• Spare fuses
• 1 fusible link (See Figure 6.3)
• 1 firewall grommet
• Parts box, containing terminals, splices, etc.
• 1 package nylon tie wraps
• Race Car Wire Harness Installation Instructions part number 90502 (this booklet)
7.2 INSTALLATION AND CONNECTIONS (Refer to Table 7.1)
Because PPPI incorporates uniform wire color coding and wire numbering, the detailed individual circuit connections provided in Section 6.0 also apply to the installation of the 50001 8-Circuit system.
See Table 7.1.
If you have not already done so, read Sections 4.0 and 5.0 of these instructions and think through the installation of the harness kit before securing or cutting any wires.
7.2.1 General
A. Mount the 50001 Fuse/Relay Block in the desired interior location and route the
INSTRUMENT PANEL SECTION (tagged wires) toward the 50201 or 50202 Switch Panel, if used, or toward the dash. Again, see Section 6.0 for individual circuit details. Cut individual wires to length and terminate them to the proper locations according to Table 7.1.
B. Route the ACCESSORY SECTION B+ to the Water Pump, Fuel Pumps, Ignition, etc., according to Table 7.1. Route 10-gauge wire #816 (red) to the Battery POSITIVE (+) terminal or the Starter Solenoid BATTERY terminal to provide power to the system. Install the Fusible
Link or Maxifuse (Figure 6.3) between the battery source and the end of the 10-gauge Red wire for system protection. Refer to Section 6.0 as needed.
C. If you are not using a second fuel pump, INSTRUMENT PANEL SECTION wire #868 (grn) can be used to switch any other accessory, which would receive power through ACCESSORY
SECTION B+ wire #863 (grn).
7.2.2 If you are NOT using a 50201/50202 Switch Panel
A. In the INSTRUMENT PANEL SECTION, connect wire #828 (blu/ylw) and #829 (brn) to the appropriate terminals of your Headlamp Switch. Wire #828 supplies power to headlamps by energizing the Headlight Relay, whereas wire #829 supplies power directly to tail lamps. If you are using a GM Headlamp Switch, see Figure 6.10.
B. Connect Wires #833 (orn), #831 (pnk), and #819 (pur) to the appropriate terminals of your
Ignition Switch. If you are using a GM-keyed Ignition Switch, see Figure 6.5. Wire #833 supplies power to the accessory of your choice, switched through the Ignition Switch. Wire
#819 is the Starter Solenoid START, and wire #831 is the Ignition Coil (RUN) wire.
C. Wire #867 (red) is constant 12 VDC (B+). It is used to supply power to the switches of the
50201/50202 Switch Panel. If you are not using a Switch Panel, connect wire #867 to the B+ side of the switches you are using to activate the relays in the system.
16
7.2.3 If you ARE using a 50201/50202 Switch Panel
A. The 50201/50202 Switch Panel can be thought of as taking the place of several switches normally
mounted in the dash, including the Ignition Switch. All INSTRUMENT PANEL SECTION wires
EXCEPT 18-gauge wire #867 (red) and l4 gauge wire #829 (brn) energize
their respective relays which in turn connect power to the various accessories (water pump,
fuel pump(s), starter solenoid, etc.)
B. Connect 18-gauge wire #867 (red) to Switch Panel 12-gauge wire #770.
C. Switch Panel 18-gauge wire #732 (brn) is not used with the 50001 Wire Harness Kit.
7.3 WIRE CONNECTION INDEX AND FUSE REQUIREMENTS
FUSE REQUIREMENTS
Switches................................................................................... 10
Ignition..................................................................................... 30
Accessory................................................................................. 15
Electric Fuel Pump #1............................................................. 20
Electric Fuel Pump #2............................................................. 20
Electric Cooling Fan................................................................ 15
Electric Water Pump................................................................ 15
Lights....................................................................................... 20
Color
ACCESSORY SECTION B+
WIRE CONNECTION INDEX
INSTRUMENT PANEL SECTION
Red
Black
Purple
Gry/Wht
1
Ylw/Wht
Green
Brown
10
14
14
14
870
801
847
863
Starter Solenoid START Orange
Cooling Fan
Fuel Pump #1
Fuel Pump #2
829 Lights
Ylw/Wht
Green
Blue
2
18
18
18
18
833
861
868
864
18
Ign. Sw. Accy.
Fuel Pump #1 Switch
Fuel Pump #2 Switch
Water Pump Switch
831
Blu/Ylw
Blue
2
Pink
Orange
14
14
820 Ignition Coil
869 Accessory
NOTES:
1.
2.
Blu/Ylw 14 828 Headlamp Sw. (Headl)
2-color wires: 2nd color may not be intense. Observe 2-color wires closely.
May be Orn/Blk in some kits.
Table 7.1 50001 Wire Connection Index and Fuse Requirements
17
7.4 RELAY PLACEMENT See Figure 7.1.
Figure 7.1 50001 Relay and Fuse Placement
8.0 50201/50202 8-CIRCUIT SWITCH PANEL
8.1 CONTENTS OF THE SWITCH PANEL KIT
Take inventory to see that you have everything you're supposed to have in this kit. If anything is missing, go to the dealer where you obtained the kit or contact Perfect Performance Products, Inc. at (817) 244-6898. The
50201/50202 Switch Panel Kit should contain the following items:
• The 50201 Switch Panel (to be mounted in-dash) or the 50202 Switch Box (for exterior mounting).
• 4 mounting screws
• 2 (3-pin) connector housings: 1 male (plug) and 1 female (jack)
• 2 (9-pin) connector housings: 1 male (plug) and 1 female (jack)
• 12 mating female electrical contacts for the connectors. The male contacts are pre-installed.
• 1 grommet (50202 ONLY)
• 3 cap plugs (50202 ONLY) to fill unused holes.
• Race Car Wire Harness Installation Instructions P/N 90502 (This booklet)
8.2 INSTALLATION AND CONNECTIONS (Refer to Table 8.1)
If you have not already done so, read Sections 4.0 and 5.0 of these instructions and think through the installation of the harness kit before securing or cutting any wires.
8.2.1 50201 Switch Panel. See Figure 8.1.
A. Mount the Switch Panel in the desired location by drilling holes in the dash to suit your needs. Four (4) mounting screws are provided.
B. Insert the terminated wires into the two (2) Connector Jacks provided according to Table 8.1.
Be sure you have threaded the wires through any holes and grommets before installing the connectors. The electrical contacts are almost impossible to remove without damage once they have been inserted into the connector body.
C. Using the proper crimping tool, install the receptacle contacts onto the wires of the main harness according to Table 8.1 and insert the contacts into the two (2) Connector Plugs provided.
D. Connect the Switch Panel to the main harness and perform an operational check. Refer to
Section 5.5.
18
8.2.2 50202 Switch Box. See Figure 8.1.
A. Mount the Switch Box in the desired location. Bolts or heavy screws are recommended.
Note: The box is pre-punched to allow the Switch Box wires to exit from any chosen side. The
rubber grommet is provided to protect the wires as they exit from the box. Cap plugs are
included to plug the remaining unused holes for a finished look.
B. Attach the Switch Panel to the box with the four (4) screws provided, routing the wires out the hole.
C. Insert the terminated wires into the two (2) Connector Jacks provided according to Table 8.1.
Be sure you have threaded the wires through any holes and grommets before installing the connectors.
Note: The electrical contacts are almost impossible to remove without damage once they
have been inserted into the connector body.
D. Using the proper crimping tool, install the receptacle contacts onto the wires of the main harness according to Table 8.1 and insert the contacts into the two (2) Connector Plugs provided.
E. Connect the Switch Panel to the main harness and perform an operational check. Refer to
Section 5.5.
Figure 8.1 50201/50202 Switch Panel Connectors
19
8.2.3 If you are using the 50001 8-Circuit Competition Wire Harness
A. 18 ga. wire #732 (brn) is not used, and should be capped and stowed.
B. All of the 14 gauge wires of the Switch Panel connect to and match color-for-color (but not
number-for-number) to the wires of the 50001 INSTRUMENT PANEL SECTION.
8.2.4 Connecting the 50002 12-Circuit Pro-Street Harness and The 50201/50202 8-Switch Race
Car Control Centers
Before connecting the 50002 harness and the 50201/50202 switch panel together, both the
50002 fuse panel and the 50201/50202 control panel should be mounted in their permanent locations.
See Instruction Manual #90502, Sections 4.0 and 5.0 for general mounting and harness routing instructions.
Note: The dimmer switch harness and the turn signal harness may need to be routed at this time.
The “ignition switch section” jumper harness white 6-pin connector must be plugged into the main harness and the jumper harness routed to the switch panel before that harness can be terminated to the 60101/60102. Failure to do this could result in wires being cut too short.
The wires in the two sections below must be removed from the designated section of the 50002 harness, routed to the 50201/50202 panel, re-terminated, and installed in the white 9-pin connector as per the diagram.
ACCESSORY SECTION SWITCHES
Color Ga. No. Connect To
Grn
Blu
14
14
863 Fuel Pump #2
862 Elec. Water Pump
Ylw/Wht 14 847 Fuel Pump #1
Gry/Wht 14 801 Cooling Fan
Grn
Blu
14
14
763
762
Fuel Pump #2
Elec. Water Pump
Ylw/Wht 14 747 Fuel Pump #1
Gry/Wht 14 701 Cooling Fan
HEADLIGHT SECTION B+
Blu/Ylw 14 807 Headlights
Brn 14 829 Tail Lights
Blu/Ylw 14 707 Headlights
Brn 14 729 Tail Lights
IGNITION SWITCH SECTION
Pnk
Brn
Orn
Red
Pur
Blk
14 831 Ign. Switch RUN
18 832 Fuse Block Relay
14 833 Ign. Switch Accy.
12 834 Switch Panel B+
12 819 Ign. Switch START
14 860 Ground
Pnk 14 731 Ign. Switch RUN
Brown 18 732 Fuse Block Relay
Orn 14 769 Ign. Switch Accy.
Red
Pur
Blk
10 770 Switch Panel B+
14 719 Ign. Switch START
12 771 Ground
Note: 1. Circuit numbers are for ID purposes only.
2. There is a 14-gauge and an 18-gauge brown wire.
Table 8.1 50002 and 50201/50202 Wire Connection Index
20
As noted in the diagram, there is one 9-pin connector and one 3-pin connector. The easiest way to assure proper connection is to carefully study the connector diagram. The pin locations for each wire in the connectors is listed there.
Note: The pins and the white connectors can be installed improperly. They are difficult to change once installed. The female white connectors are used with the male terminals on the 50201/50202 side, and the male white connectors are used with the female terminals on the 50002. the wire
Terminals are already installed on the 50201/50202, and all you have to do is cut the wires coming from the 50002 harness to match up. Install the female white connectors on the male numbers on the terminals of the 50201/50202 harness as per the pin locations in the diagram. Match up colors and ID numbers in the 50201/50202 connector with the colors and wire ID the 14 and 18-gauge brown wires. Terminate and install them in the proper pin locations of the male in the corresponding connector. Make sure the
8.3 50201/50202 Wire Connection Index
50002 harness, double-checking the locations of the female terminals on the 50002 harness
9-pin and 3-pin connectors, and install them connectors are properly seated.
Color Ga. No. Connected To Color Ga. No.
Connected To
Red 12 770 Panel Input (B+)
Blk 12 771
Blu/Ylw 14 707
Ground
Ylw/Wht 14 747 Fuel Pump #1
Brn
Headlamps/Dimmer Sw. Grn
14 729 Tail/Park Lights
14 763 Fuel Pump #2
Blu 14 762 Water Pump
Pnk 14 731 Ignition Coil
Pur 14 719 St.Solenoid START
Gry/Wht 14 701 Cooling Fan
Orn
Brn
14 769 Accessory
18 732 Fuse Block Relay
(Used w/50002 only)
Table 8.2 50201/50202 Wire Connection Index
9.0 50101 REPLACEMENT FUSE BLOCK
The 50101 is a replacement Fuse Block for individuals wanting to update their current fuse block to increase current capabilities and provide the fused circuits needed for racing applications. This is the ideal unit for the vehicle owner who races but wants to stay street legal.
9.1 CONTENTS OF THE 50101 REPLACEMENT FUSE BLOCK KIT
Take an inventory to see that you have everything you're supposed to have in this kit. If anything is missing, go to the dealer where you obtained the kit or contact Perfect Performance Products, Inc. at
(817) 244-6898. The 50101 Replacement Fuse Block Kit should contain the following items:
• The 50101 12-Circuit Fuse Block, with fuses installed.
• 2 Flashers
• 1 Fusible Link (See Figure 6.3)
• Assorted terminals
• Race Car Wire Harness Installation Instructions P/N 90502 (This booklet)
9.2 INSTALLATION AND CONNECTIONS
A. Find a suitable location (possibly where previous fuse block was located) and attach Fuse Block
Mounting Bracket using the holes provided.
21
B. Connect the Windshield Wiper Switch hot wire to the WIPER B+ terminal (Blu).
Note: The wire color coding noted in each step is the color of the wires at the 50101 Fuse Block.
The color coding of your vehicle's wiring may not be the same. “B+” means "Battery Power.”
C. Connect the Cooling Fan Switch hot wire to the EL FAN B+ terminal (Gry/Wht).
Note: Your vehicle may not have an Cooling Fan Switch. It may instead have a Cooling Fan
Thermostat (usually located on the lower end of the radiator) or be directly wired so that the cooling fan runs whenever the ignition is on.
D. Connect the Alternator Ignition (Exciter) wire to the ALT IGN B+ terminal (Wht). This wire provides power to the alternator when the ignition is on. See Figure 6.1 for externally-regulated alternators Figure 6.2 for internally- regulated "one-wire" alternators.
E. Connect the Alternator Battery Post wire to the ALT BAT POST terminal (Red).
F. Connect the System hot wire to the POSITIVE Battery Post or Starter Solenoid hot terminal (Red).
Note:Be sure to install the Fusible Link (Figure 6.3) between the end of the Red wire and the Battery or Solenoid for overall protection.
G. Connect the Brake Light Switch hot wire to the STOP B+ terminal (Orn).
H. Connect the Ignition Ballast Resistor OR Coil wire to the coil/DIST terminal (Pnk).
Note:This is NOT a choice between two wires. Your vehicle either has an /ignition Ballast Resistor, or it does not.
I. Connect the Water Pump Switch (or, if unswitched, the Water Pump) hot wire to the WATER
PUMP (Orn/BIk).
J. Connect the Horn hot wire to the TO HORN terminal (Grn).
K. Connect the Headlight Switch hot wire to the LIGHT B+ terminal (Red/BIk).
L. Connect the Ignition Switch RUN wire to the IGN SW coil terminal (Pnk).
Note: The wire normally routed from the ignition switch "RUN" terminal to the coil or the ignition ballast resistor has been cut in half to go through the fuse in the Fuse Block. This has been done for two reasons. First, it provides a fused ignition circuit for electronic fuel injection systems. Second, it provides a theft deterrent when the coil fuse is removed, disabling the ignition circuit.
M. Connect the Ignition Switch ACCESSORY wire to the IGN SW B+ terminal (Brn). This wire powers up the accessory side of the fuse block independent of the ignition switch.
N. Connect the Ignition Switch hot wire to the BAT FEED terminal (Red).
O. Connect the Dash Panel Instrument and Warning Light hot wire to the Gauges B+ terminal
(Red/Wht). You may also connect your Radio hot wire to this terminal.
P. Connect the Dome/Interior Light and/or Trunk Light + 12V Feed wire to the DOME B+ terminal
(Wht).
Q. Connect the Fuel Pump Switch (or, if unswitched, the Fuel Pump) hot wire to the FUEL PUMP
(Ylw/Wht).
R. Connect the Hazard Flasher Switch hot wire (from the steering column) to the HAZARD B+ terminal (Brn). The Hazard Flasher is built into the circuit at the 50101 Fuse Block.
S. Connect the Turn Signal Switch Flasher hot wire to the TURN SW B+ terminal (Pur). The Turn
Signal Flasher is built into the circuit at the 50101 Fuse Block.
T. Connect the Horn Switch wire (in steering column or from external button) to the HORN SW terminal (BIk). This wire, when grounded, activates the Horn Relay in the 50101 Fuse Block.
U. The IGN SW ACCY and IGN ACCY 1 terminals are provided for switched power needs such as
Trans Brake, Line Lock, N.O.S., or other fused ignition requirements.
22

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Key features
- Easy Installation
- Color-Coded Wires
- Relay-Activated Wiring
- 12-Circuit and 8-Circuit Options
- Pre-wired Fuse Blocks and Switch Panels
- Compatible with General Motors-Keyed Steering Columns
- Detailed Installation Instructions
- Troubleshooting Tips
- Safety Precautions
- Pre-Installed Fuses