Painless Performance Products Streetrod Universal, Universal, Universal, Universal, Pickup Universal, Universal, Universal, Universal, Muscle Car Universal, Universal Wire Harness Instructions
Wire Harness Streetrod Universal, Wire Harness Streetrod Universal, Wire Harness Pickup Universal, Wire Harness Pickup Universal, Wire Harness Streetrod Universal, Wire Harness Streetrod Universal, Wire Harness Pickup Universal, Wire Harness Pickup Universal, Wire Harness Muscle Car Universal, Wire Harness Muscle Car Universal are 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.
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Wire Harness Installation
Instructions
For Installing:
Part #10101 – Universal Streetrod Harness (12 circuit/GM column)
Part #10102 – Universal Streetrod Harness (12 circuit/Non-GM column)
Part #10103 – Pickup Harness (12 circuit/GM column)
Part #10104 – Pickup Harness (12 circuit/Non-GM column)
Part #10201 – Universal Streetrod Harness (18 circuit/GM column)
Part #10202 – Universal Streetrod Harness (18 circuit/Non-GM column)
Part #10203 – Pickup Harness (18 circuit/GM column)
Part # 10204 - Pickup Harness (18 circuit/Non-GM column)
Part #20103 – Universal Muscle Car Harness (12 circuit/ Non-GM column)
Part #20104 – Universal Muscle Car Harness (18 circuit/ Non-GM column)
Manual #90501
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.
P/N 90501 Painless Wiring Manual February 1993
13 th
Edition September 15, 2008
Copyright
© 1994 by Perfect Performance Products, LLC
NOTE :
If your vehicle has an existing harness, you will want to retain it for the possible reuse 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
20101-20104 Harnesses
Painless Performance has included 20 extra male and female bulkhead terminals in these harness kits. Use these extra terminals to run wires through the firewall using the male and female bulkhead connectors on the harness. See below for instructions on how to use these terminals. The terminals we have provided you are designed for wire gauges 18-14. Strip
¼” of the insulation from the wire and then crimp it to the terminal using the correct terminal crimping tool. These terminals are roll crimp style. You can purchase this type of terminal crimper from your local Radio Shack. See below for a picture of the correct terminal crimping tool and how to use them. Take a look at how the terminals we inserted into the bulkhead connector here at the factory. Notice they are orientated a certain direction. Insert the blade (male) terminal into the engine compartment side bulkhead connector. Insert the female terminal into the passenger compartment side of the bulkhead connector.
TABLE OF CONTENTS
List
List of Tables…………………………………………………………………………………………. ii
List of Diagrams…………………………………………………………………………………….. ii
1.0 Introduction………………………………………………………………………………………….. 1
2.0 About These Instructions……………………………………………………………………….. 1
3.0 Contents Of The Painless Wire Harness Kit……………………………………………….. 2
4.0 Tools
5.0 Pre-Installation and General Harness Routing Guidelines……………………………. 2
6.0 Harness General Installation Instructions………………………………………………….. 4
6.1
6.2
6.3 The
6.4 Terminal Installation and Making Connections………………………………….. 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 Ignition System (Start/Run)……………….……………………………………. 8
7.4 Steering Column Wiring - Turn Signal & Ignition Switch Connections… 9
8.0 Ford - Specific Circuit Connections…………………………………………………………… 10
8.1
8.2
8.3
8.4
Ignition 12
Steering Column Wiring - Turn Signal Connections…………………………... 14
Steering Column Wiring - Ignition Switch Connections……………………… 14
9.0 Mopar - Specific Circuit Connections…………………………………………………………. 17
9.1
9.3
Mopar
9.2 Ignition
Steering Column Wiring - Turn Signal Connections……………………………. 20
9.4 Steering Column Wiring - Ignition Switch Connections………………………. 20
10.0 All Makes - Specific Circuit Connections……………………………………………………… 21
10.1 Generator Charging System…………………………………………………………….. 21
10.2 Generator to Alternator Conversion………………………………………………….. 22
10.3 Connecting to Ammeter and the Maxi-Fuse……………………………………….. 22
Lighting……………………………………………………..……………………… 23
10.5 Headlight Section "A"………………………………………………………………………. 24
10.6 Headlight Section "B"………………………………………………………………………. 25
10.7 Instrument Panel Wiring………………………………………………………………….. 26
10.8 Brake Light Switch…………………………………………………………………………… 26
10.9 Tail Section Wiring…………………………………………………………………………… 26
10.10 Helpful Hints for Tail Section Wiring………………………………………………….. 28
11.0 Wire Connection Index and Fuse Requirements…………………………………………… 28 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…………………………………………….. 6
Figure 7.2B High Output Wire…………………………………………………………………………….. 7
Figure 7.2C GM CS-130 External Fan Alternator……………………………………………………….8
Figure 7.2D GM CS-130 Connector and Pin Out………………………………………………………..8
Figure 7.2E GM CS-130D Internal Fan Alternator……………………………………………….… …8
Figure 7.2F GM CS-130D Connector and Pin Out………………………………………………………8
Figure 7.3 Maxi-Fuse……………………………………………………………………………………….. 8
Figure 7.4 GM Ignition System………………………………………………………………………….. 9
Figure 7.5 GM Turn Signal Connectors……………………………………………………………….. 9
Figure 8.1A Ford Alternator…………………………………………………………………………………. 11
Figure 8.1B High Output Wire……………………………………………………………………………… 11
Figure 8.1C Ford Internal Regulator Alternator…………………………………………………………11
Figure 8.1D Ford 3G Alternator…………………………………………………………………………….. 12
Figure 8.2 Ford Ignition System (Start/Run)……………………………………………………… 13
Figure 8.3 Ford Electronic Ignition (Motorcraft)……………………………………………… 13
Figure 8.4 Ford Ignition Diagram (Duraspark II Systems)…………………………………… 15
Figure 8.5 Ford Ignition Switch Connectors………………………………………………………. 16
Figure 9.1A Mopar Alternator……………………………………………………………………………… 17
Figure 9.1B High Output Wire…………………………………………………………………………….. 18
Figure 9.2A Mopar Ignition System……………………………………………………………………… 19
Figure 9.2B Mopar Electronic Ignition with Dual Ballast Resistor…………………………………19
Figure 10.1 Generator Charging System………………………………………………………………. 21
Figure 10.2 Ammeter and Maxi-Fuse…………………………………………………………………… 22
Figure 10.3 Interior Lighting……………………………………………………………………………….. 23
Figure 10.4A Typical Fan Relay Installation……………………………………………………………. 23
Figure 10.4B Headlight Section "A" Wiring…………………………………………………………….. 24
Figure 10.5 Dimmer Switches…………………………………………………………………………….. 25
Figure 10.6 Headlight Section "B" Wiring…………………………………………………………….. 25
Figure 10.7 Integrated Brake Light and Separate Turn/Brake Lights………………………. 27
LIST OF TABLES
Table 7.1 GM Ignition and Turn Signal Wiring…………………………………………………… 10
Table 8.1 Ford Ignition and Turn Signal Wiring…………………………………………………. 15
Table 9.1 Mopar Ignition and Turn Signal Wiring (1 of 2)…………………………………… 20
Table 9.1 Mopar Ignition and Turn Signal Wiring (2 of 2)…………………………………… 21
Table 11-1 Fuse Requirements………………………………………………………………………….. 28
Table 11-2 Wire Connection Index (1 of 3)…………………………………………………………. 29
Table 11-2 Wire Connection Index (2 of 3)…………………………………………………………. 30
Table 11-2 Wire Connection Index (3 of 3)…………………………………………………………. 31
LIST OF DIAGRAMS
Diagram 1 Instrument Panel Section Wiring……………………………………………………….. 32
Diagram 2 Engine Wiring………………………………………………………………………………….. 33 ii
1.0
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.
In addition all of our kits have "accessory" terminals at the front of the fuse block for your convenience. These terminals may be constantly hot or "switched" hot but all are un-fused. If you plug into one of these terminals you must provide your own in-line fuse or circuit breaker.
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. Trunk accessory, door locks, power windows, and electric fuel pump are included in the 18-circuit kit.
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
2.0
ABOUT THESE INSTRUCTIONS
The contents of these instructions are divided into major Sections, as follows:
1.0 Introduction
2.0
3.0
4.0
About These Instructions
Tools Needed
Contents of Painless Wire Harness Kit
5.0
6.0
7.0
Pre-Installation and General Harness Routing Guidelines
General Harness Installation Instructions
GM - Specific Circuit Connection Details
8.0
9.0
Ford - Specific Circuit Connection Details
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
Notes
, especially those in the Tables, corresponding to the number. Always pay special and careful attention to any and any text marked
Caution
.
1
3.0
CONTENTS OF THE PAINLESS WIRE HARNESS KIT
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:
A The Main Wire Harness, with the Fuse Block wired in and fuses installed.
E
F
G
B
C
D
H
Headlamp Connector Cables. (Extra Headlamp Cables are available separately under P/N 80300.)
Maxi Fuse
Firewall Grommet (large) [NOT INCLUDED IN 20103 AND 20104 KITS]
2 Fender Well Grommets (for Headlamps)
2 packages of Nylon Tie Wraps
2 GM Turn Signal Connectors (if applicable)
Parts Box, containing a GM Alternator Connector, Terminals, Splices, etc. This booklet, P/N 90501 Painless
Wiring Manual.
Figure 3-1 The Painless Wire Harness Kit
Note: This drawing shows some parts found only in the GM column kits.
4.0
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.
Stripper
Test Light or Volt Meter
Electric
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 have to make in 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
DOOR SECTION A
DOOR SECTION B
ENGINE SECTION
ENGINE SECTION (Single, 10 ga. red wire)
ENGINE SECTION A
HEADLIGHT SECTION A
HEADLIGHT SECTION B
IGNITION SWITCH SECTION
INSTRUMENT PANEL SECTION
RADIO SECTION
SPEAKER SECTION
TAIL SECTION
TURN SIGNAL 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
Power Windows*
Power Door Locks*
Cigarette Lighter*
Wipers
Electric Fuel Pump*
Air Conditioner
Electric Cooling Fan
Coil
Trunk Light*
Turn Signals
Radio Ignition Switched Power
Radio Constant Power
Power Antenna*
Gauges
Accessories
Backup Lights*
Cruise Control*
*These circuits are included in the 18-circuit kit only.
3
5.4
Where will the following harness groups be routed?
Headlights
Engine
Dash
Tail Lights
Doors and Speakers
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.
5.6
5.7
5.8
Route the harness away from sharp edges, exhaust pipes, and hood, trunk and door hinges.
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.
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, Powerbraid, or tape.
5.9
HARNESS GENERAL INSTALLATION INSTRUCTIONS
6.0
6.1
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 If using the 20103 / 20104 harness, check the opening in your firewall with the template on pg.
32. Some modification may be necessary.
6.1.3 If installing a grommet style pass thru harness, 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, SINGLE
10 GA. (Red wire #916), and HEADLIGHT SECTION A).
6.1.4 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.
6.1.5 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.
6.1.6 Position rear group, consisting of DOOR SECTIONS A & B and SPEAKER SECTION (both in 18-
6.2
circuit kits only) and TAIL SECTION, on 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 itself does not have to be grounded.)
6.2.2 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.
6.2.3 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 cowl vent, air conditioning, radio, etc.
Note: Do not tighten tie wraps and mounting devices at this time. Make all harness attachments
LOOSELY.
6.2.4 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!
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 ( 2 GA Minimum ) from the negative terminal of the battery to the engine block
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 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 - External Regulator. See Figure 7-1.
7.1.1 With a short 16-gauge jumper wire, connect Voltage Regulator terminals 3 & 4 together. Connect
ENGINE SECTION wire #914 (wht) to Voltage Regulator terminal 3 or 4.
7.1.2 Connect ENGINE 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 - Internal Regulator. See Figure 7-2A.
7.2.1 Connect ENGINE SECTION wire #914 (wht) to Alternator terminal 1. Connect ENGINE 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.
#914 Alternator
Figure 7-2A Late GM Alternator - Internal Regulator
6
GM One-Wire Alternator.
7.2.4 Connect ENGINE SECTION wire #915 (red) to the Alternator Output lug (Bat).
Insulate and stow ENGINE 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 on page 6.
7.2.5 When using a 1-wire alternator you must 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
P/N 30707 GM “CS 130 (External Fan)
Alternator Pigtail
To #914
Alternator Exciter
NOTE; If not using a charge light, an 82 ohm,
5 watt resistor must be used to prevent premature
Regulator failure
Figure 7-2C CS-130 External Fan Alternator Figure 7-2D CS-130 Connector and Pin Out
P/N 30705 GM “CS 130D” (Internal Fan)
Alternator Pigtail
To #914
Alternator Exciter
NOTE : If not using a charge light, an 82 ohm
5 watt resistor must be used to prevent premature
Regulator failure.
Figure 7-2E CS-130D internal Fan Alternator Figure 7-2F CS 130D Connector and Pinout
7.3
GM Ignition (Start/Run) System. See Figure 7-4.
Note: If you are going to install an ammeter, see Section 10.3 first.
7.3.1 With crimping tool, attach Maxi Fuse (Figure 7-3) onto end of ENGINE SECTION (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!
7.3.2 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.
Figure 7-3 Maxi Fuse
7.3.3 Connect ENGINE SECTION A wire #919 (pur) to the Starter Solenoid Start (S) terminal. (See illustration on page 31)
8
7.3.4 If you are using a 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.
Figure 7-4 GM Ignition (Start-Run) System
7.4
7.3.5 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.
7.3.6 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.
Steering Column Wiring - Turn Signal & Ignition Switch Connectors
7.4.1 There are two different 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.
The TURN SIGNAL SECTION wires may have already been terminated for you. If not, cut wires to length and install the 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
9
7.4.2 Some harness’ come with the GM ignition switch connectors pre-wired. See Table 7-1 and Figure 7-5 for color codes, wire numbers, and wire designations for the Ignition Switch Connectors.
7.4.3 IGNITION SWITCH SECTION wire #919 (pur) has been cut and spade lugs installed on the GM keyed steering column harnesses. These spade lugs 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 two purple wires with the yellow spade lugs must be connected together and the (pur) #919 needs to be routed to the neutral safety switch, cut and connected to it, then continued on to the starter solenoid.
7.4.4 The harness does not support seat belt buzzers or key alarms.
7.4.5 To supply power to a fuel injection system, use ENGINE SECTION A wire #920 (pnk) as the fused ignition power source.
TURN SIGNAL SECTION
Designation
Color
Blk
LF
Dk.Blu
Brn
Turn
Ylw
RR
Wht
IGNITION SWITCH SECTION
Brn
Orn
Ignition
Pnk
Accessory
Ignition Switched Fuse Panel
Painless Painless
Wire No. Color
933 Orn
Battery
Red*
* See note 8 on page 28
Table 7-1 GM Ignition & Turn Signal Wiring
8 FORD - SPECIFIC CIRCUIT CONNECTIONS
8.1
Ford Alternator. See Figure 8-1.
Note: Your Alternator may not appear exactly as represented in Figure 8-1. however the circuits are wired the same manor..
8.1.1 Connect ENGINE SECTION wire #915 (red) to the Alternator Output lug (Bat). Connect ENGINE
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.
8.1.2 Connect a 14-gauge jumper from the Voltage Regulator A terminal to the Alternator Output lug
(Bat).
10
8.1.3 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.
8.1.4 The Alternator case must be clean, and free from corrosion where it contacts the block. An
additional connection, form the ground stud on the rear of the alternator to the engine ground
may be needed
8.1.5 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
NOTE: The base of the Voltage Regulator MUST be grounded in order for it to function correctly. connected. Install ground wires as in Paragraph 8.1.4. This alternate configuration is illustrated in dashed lines in Figure 8-1A.
Figure 8-1A Ford Alternator (2 configurations) Figure 8-1B High Output Wire
Figure 8-1C Ford 2G Alternator
8.1.6 Connect ENGINE SECTION wire #915 RED to both wires as noted in Figure 8-1C.
8.1.7 Connect ENGINE SECTION wire #914 WHT to the Light Green/Red stripe wire as noted in Figure
8-1C.
11
Figure 8-1D Ford 3G ALternator
8.1.8 Connect ENGINE SECTION wires #915 Red to charge post of alternator, #914 wht to the
“I” terminal of the regulator, and # 916 to the B+ side of the solenoid. You will have to run a
separate wire (not provided), from the “A” terminal of the regulator to either the charge post at
back of the alternator, or to the B+ side of the solenoid.
NOTE: When using a 3G alternator, a large (6 Ga Min.) auxiliary charge wire MUST be run as
Shown in Figure 8-1D. This wire is in addition to the #’s 915 and 916. While not shown in
The above illustration, an inline fuse of AT LEAST 135 amps. Is strongly recommended.
8.2
Ford Ignition (Start/Run) System. See Figure 8-2.
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.
8.2.1 With crimping tool, attach the Maxi Fuse (Figure 7-3) onto end of ENGINE SECTION (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.
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.
12
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.
Figure 8-2 Ford Ignition (Start/Run) System
Figure 8.3 Motorcraft Electronic Ignition System
13
Figure 8-4 Ford Ignition Diagram (Duraspark II Systems)
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 a length of wire to reach it.
FOR SAFETY, PLEASE USE A NEUTRAL SAFETY SWITCH!
14
TURN SIGNAL SECTION
Ford
Color
Designation
IGNITION SWITCH SECTION
Wire No. Color
Stop
RF
Grn/Wht
RR
Grn/Orn
Wht/Red
Turn
Ylw
Dk.Blu
Horn
Horn Ground Gnd ----
Brn/Pur or Wht/Blu
¹
Red/Grn, Ignition
Wht/Blu or Brn/Pur
Red/Blu Ignition Coil (start) ² ----
Blk/Grn or Blk/Ylw
Gry, Gry/Ylw, or Blk
Accessory Fuse Panel
Ignition Switched Fuse Panel
932
933
Brn
Orn
NOTES:
1.
2.
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
15
Figure 8-5 Ford Ignition Switch Connectors (See note on Page 10, Section 8.2)
16
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.
9.1.2 The Mechanical regulator is connected as follows: The #914(wht) is connected to the “ign” terminal of the regulator. The “fld terminal of the regulator is connected the field terminal of the alternator The #914 wire left from the first connection should have sufficient length for this.
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 For an Electronic regulator, Connect ENGINE SECTION wire #914 (wht) to the Alternator Field (F) terminal. Connect ENGINE SECTION wire #915 (red) to the Alternator Output lug (Figure 9-1)
9.1.4 Connect a 14-gauge wire from the Alternator terminal where wire #914 is connected to center terminal of the ELECTRONIC Voltage Regulator.
9.1.5 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.
9.1.6 Finally, make sure BOTH the alternator and the voltage regulator housing are grounded.
Figure 9-1 Mopar Alternator w/ Electronic Regulator
17
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 (single) 10-gauge red wire #916 (with or without ammeter) to the
Starter Relay Battery Terminal. Retain excess 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 The # 920 (pnk) wire serves as a ballast resistor BYPASS during engine starting. 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).
18
Figure 9-2A Mopar Ignition (Start/Run) System
Figure 9-2B Mopar Electronic Ignition with Dual Ballast Resistor
9.2.11 Connect #914 (wht) to both dark blue wires as labeled in Figure 9-2B. Connect a ballast bypass wire as labeled in Figure 9-2B. NOTE: This ballast bypass wire will only provide 12 volts when cranking the engine. This is done for ease of starting the engine.
19
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.
9.3.3 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.
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 neutral safety switch is mounted on a floor shifter, see note 11 in wire connection index.
Wht
Grn
Grn
Pnk
Ylw¹
Blk
Blu
Red
1970-74 WITHOUT TILT COLUMN
TURN SIGNAL CONNECTOR
Designation
Color
RF
RR
Turn
Blk
IGNITION SWITCH CONNECTOR
Ignition
Ignition Switched Fuse Panel
B+
933 Orn
Red
Ylw²
Ylw²
Orn
Buzzer Switch
Buzzer Switch
Gear Shift Lamp
³
³
³
NOTES:
1.
2.
3.
12 gauge wire
20 gauge wire
The Painless harness does not support these.
Table
----
----
----
20
TURN SIGNAL CONNECTOR
Designation 79 w/tilt
Light Wht
RR
LR
Signal
Hazard
RF
Turn
Horn
Not supported by the Painless wire harness:
----
Horn
Key
Alarm Blk
R
Lamp
Corner
79 w/o tilt 82 RWD w/o tilt 82 RWD w/tilt
Table 9-1A Mopar Ignition and Turn Signal Wiring 2 of 2
10 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 ENGINE SECTION wire #915 (red) to Voltage Regulator terminal B.
10.1.4 Insulate and stow ENGINE SECTION wire #914 (wht).
Figure 10-1 Generator Charging System
21
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
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 (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 45PS).
22
Figure
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).
NOTE: This is a GROUND Activated Circuit.
Figure 10-4A Typical Fan Relay Installation (Painless Part #30101)
23
Figure 10-4B Typical Fan Relay with Thermostat (Painless Part # 30102 )
Figure 10-4C HEADLIGHT SECTION A Wiring
10.5 HEADLIGHT SECTION A. See Figure 10-4C.
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 thread them onto the wires BEFORE you connect the wires.
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.
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.
Connect 906 (gry/wht) from ACCESSORY SECTION B+ to the other side of the fan switch. Figure
10-4A shows a typical fan relay installation.
24
10.5.5 If you are using a thermostatic switch in the engine to control the ground for the fan relay, you
will then connect the 901 (gry/wht) from ACCESSORY SECTION SWITCHES directly to the 906
(gry/wht) from ACCESSORY SECTION B+.
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.
Figure 10-6 HEADLIGHT SECTION B Wiring (Painless Part #80152)
25
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.
10.8 Brake Light Switch
10.8.1 Connect wires #917 (orn) and #918 (wht) to the Brake Light Switch wherever it may be mounted.
These wires may be in ENGINE SECTION A or with the TURN SIGNAL SECTION wires, depending on the harness purchased.
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 BELOW. 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:
Note B:
Note C:
If you have Integrated Brake Lights you must use bulbs that have two (2) filaments in them such as in an 1157 bulb.
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.
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.
26
Figure 10-7A Integrated Brake Lights
Figure
Separate Turn/Brake Lights
27
10.10 Helpful Hints for Tail Section Wiring
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.
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.
10.10.3 If you are using Halogen brake/tail light bulbs a relay kit (Painless 30105) MUST be used to prevent damage to your turn signal & brake light switch
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.X
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.
Requirements
Switch…………………………………………………
Emergency
Turn 15
10
AC/Heat Relay…………………………………………………… 5
Radio 10
20
Lock…………………………………………………………..
Wipers……………………………………………………………….
Brake
Dome/Trunk……………………………………………………….
Electric Fan Relay………………………………………………… 5
Antenna……………………………………………………
Power
15
Switch………………………………………………………
Electric Fuel Pump………………………………………………. 15
Table 11-1 Fuse Requirements
28
30
Radio Ignition (Switched)…………………………………….. 10
Ga.
18
No.
901
Connect to Color
Gry/Wht
ACCESSORY SECTION
SWITCHES
Cooling Fan Switch
Tan
1
Blk/Wht
Blu
Gry/Wht
Blu/Ylw
2
Lt.Grn
Tan
Ylw/Blk
1
Ylw
1
Ylw/Blk
1
Ylw
1
Wht
Red
Blk/Wht
Red
3
14
14
16
18
14
10
14
14
14
14
14
14
14
14
10
903
904
905
906
907
908
909
910
911
912
913
914
915
902
916
ACCESSORY SECTION B+
Cigarette Lighter B+
AC/Heat Switch B+
Wiper Switch B+
Cooling Fan Switch B+
DIMMER SWITCH SECTION
Dimmer Switch
Dimmer Switch
Dimmer Switch
DOOR SECTION A
Right Door Lock B+
Right Power Window B+
DOOR SECTION B
Left Door Lock B+
Left Power Window B+
ENGINE SECTION
Alternator Exciter
Alternator B+
A/C Compressor
ENGINE SECTION
(SINGLE WIRE)
Battery Positive or Starter Solenoid
(Large Terminal)
ENGINE SECTION A
Brake Switch B+ Orn
4, 12
Wht
12
Pur
11
Pnk
Lt.Grn
Lt.Blu/Blk
Pur/Wht
Red
Grn
Blu
Lt.Blu
Brn
Lt.Grn
Tan
Gry/Wht
14 917
12
14
18
18
18
18
14
18
18
18
16
16
18
919
920
921
922
923
954
924
925
926
927
908
909
901
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
Table 11-2 Wire Connection Index, 1 of 3
29
Wire Starting Point Section of Starting
Point
Fan Relay
A/C Compressor
Fuse Panel*
Fuse Panel*
Fuse Panel*
Fuse Panel*
Headlight Switch
High Beam
Low Beam
Fuse Panel*
Fuse Panel*
Fuse Panel*
Fuse Panel*
Fuse Panel*
Fuse Panel*
A/C Central Switch
Fuse Panel*
Headlight Section A
Engine Section A
Fuse Panel
Fuse Panel
Fuse Panel
Fuse Panel
Headlight Section B
Headlight Section A
Headlight Section A
Fuse Panel
Fuse Panel
Fuse Panel
Fuse Panel
Fuse Panel
Fuse Panel
Accy. Section Switches
Fuse Panel
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
Fuse Panel
Turn Signal Section
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
9
Ga.
12
No.
928
18
18
20
20
18
18
18
18
18
18
18
18
18
18
12
12
12
18
14
12
14
18
18
14
Grn
Lt.Blu
Blu
Brn
Pnk
Lt. Grn
Lt.Blu/Blk
Pur/Wht
Orn/Blk
Red
Red/Blk
Pur/Blk
Clear
1,6
Clear
1,6
Brn
Brn
Brn
Orn
7
10
Pnk
Brn
Orn
Red
8
Pur
5
Red/Wht
929
927
930
959
931
932
933
934
919
935
936
937
938
930
939
921
922
923
955
940
941
942
943
944
Clear
1,6
Clear
1,6
Wht
Grn/Blk
1
Ylw/Wht
1
Grn
Ylw
Pnk
Brn
Pur/Blk
1
Orn
Lt.Grn
1
Blk
20
20
18
16
14
14
14
18
14
18
18
18
18
943
944
945
946
947
948
949
939
929
942
950
956
961
SPEAKER SECTION
Right Rear Speaker
Left Rear Speaker
TAIL SECTION
Dome Lights B+
Trunk Accessory Light B+
Electric Fuel Pump B+
Right Rear Turn Signal
Left Rear Turn Signal
Fuel Sending Unit
Tail Lights
Power Antenna
Third Brake Light
Backup Lights
Dome Light Ground
Table 11-2 Wire Connection Index, 2 of 3
30
Connect to Wire Starting Point
HEADLIGHT SECTION B
Headlight Switch B+
Headlight Switch
Headlight Switch
Headlight Switch
Headlight Switch B+
Fuse Panel*
Dimmer Switch
Tail Lights
Park Lights
Instr. Panel Lighting
Fuse Panel*
IGNITION SWITCH SECTION
Ignition Switch (Coil Ignition) Fuse Panel*
Ignition Switch Accessory
Ignition Switch Ignition
Fuse Panel*
Fuse Panel*
Ignition Switch B+
Ignition Switch Start
INSTRUMENT PANEL SECTION
Voltmeter Source & Gauges B+
Fuse Panel*
Starter Solenoid
Fuse Panel*
High Beam Indicator
Left Turn Indicator
Right Turn Indicator
Instrument Panel Lighting
Fuel Gauge
Temperature Gauge
Oil Pressure Gauge
Tachometer
Accessory Power (Switched)
RADIO SECTION
Radio B+ Unswitched (Constant)
Radio B+ Switched
Radio: Power Antenna
Radio Right Rear Speaker Out
Radio Left Rear Speaker Out
Dimmer Switch*
Section of Starting
Point
Fuse Panel
Dimmer Switch Section
Tail Section
Headlight Section A
Instrument Panel Section
Fuse Panel
Fuse Panel
Fuse Panel
Fuse Panel
Fuse Panel
Engine Section A
Fuse Panel
Left Front Turn Signal* Turn Signal Section
Right Front Turn Sig.*
Headlight Switch
Fuel Sending Unit
Temp. Sending Unit
Oil Pres. Sending Unit
Tachometer Source
Fuse Panel*
Fuse Panel*
Fuse Panel*
Power Antenna
Right Rear Speaker
Left Rear Speaker
Dimmer Switch Section
Turn Signal Section
Headlight Section B
Tail Section
Engine Section A
Engine Section A
Engine Section A
Fuse Panel
Fuse Panel
Fuse Panel
Tail Section
Speaker Section
Speaker Section
Radio R. Rear Spkr.Out Radio Section
Radio L. Rear Spkr.Out Radio Section
Fuse Panel*
Fuse Panel*
Fuse Panel*
Turn Signal Switch
Turn Signal Switch
Fuel Gauge
Headlight Switch
Fuse Panel
Fuse Panel
Fuse Panel
Turn Signal Section
Turn Signal Section
Instrument Panel Section
Headlight Section B
Radio: Power Antenna Radio Section
Turn Signal Switch* Turn Signal Section
Backup Switch Cruise Control Section
Interior Light Harness Near Fuse Panel
Brn
Pur
Blk
Blu
Wht
Lt.Blu
16
16
18
18
16
18
951
952
953
925
918
926
TURN SIGNAL SECTION
Emergency Flasher Switch B+
Turn Signal Switch Flasher B+
Horn Switch
Turn Signal Switch
Turn Signal Switch
Turn Signal Switch
Emer. Flasher Relay*
Turn Flasher Relay*
Horn Relay*
Fuse Panel
Fuse Panel
Fuse Panel
Right Tail Section
Left Tail Section
Right Front Turn Signal Headlight Section A
Brake Switch Engine Section A
Left Front Turn Signal Headlight Section A
Pnk
1
Lt.Grn
Lt.Grn
1
1
18
18
18
957
958
956
CRUISE CONTROL SECTION
Cruise Control Switch
Backup Switch
Backup Switch
Table 11-2 Wire Connection Index, 3 of 3
Fuse Panel*
Fuse Panel*
Backup Lights
Fuse Panel
Fuse Panel
Tail Section
NOTES:
1. Depending upon the particular wire harness you purchased, you may not have some of these wires.
2.
3. This section consists of only one large (10 gauge) wire.
4. From fuse panel to brake switch.
5. This wire is cut and spade lugs have been installed (GM-keyed kits only) 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.
6. These are two (2) wires, bonded together. One wire is Speaker POSITIVE (+) and the other wire is Speaker
NEGATIVE (-).
7. This wire needs to go from the headlight switch to the instrument panel lights.
8. There are two (2) Red 934 wires that MUST both be connected to the "Batt" terminal of the ignition switch. These wires supply all of the ignition switched power that goes to the fuse panel and both are needed because of the amount of power required to power all of the accessories.
9. This wire is power for the portion of the headlight switch that goes out to the headlights and front parking lights.
10. 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.
11. Non-GM keyed column harnesses have 48” of extra length to accommodate a floor shifter. If a floor shifter is being used, utilize this extra length to route the 919 Purple to the neutral safety switch on the shifter or transmission and then to the starter solenoid. If not using a floor shifter, cut 919 Purple to length needed for starter solenoid and discard extra length.
12. Kit 20104 has these wires located near the turn signal and ignition switch section wires.
31
32
33
Use this firewall opening template for the following part numbers:
Part #20103 – Universal Muscle Car Harness (12 circuit/ Non-GM column)
Part #20104 – Universal Muscle Car Harness (18 circuit/ Non-GM column)
NOTE: The template drawing on this page may not be to scale, double check your measurements with the dimensions on the drawing before cutting the opening.
34
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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Key features
- Easy to install
- Anti-theft feature
- Pre-installed fuses
- Color-coded wires