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P/N 60211, 60216 1996-2000
GM VORTEC 7.4 FUEL INJECTION
WIRE HARNESS INSTALLATION
INSTRUCTIONS
Manual P/N 90541
Copyright © 2005
First Edition AUG 2005
PAINLESS PERFORMANCE PRODUCTS
2501 Ludelle Street, Fort Worth, Texas 76105-1036 (800) 423-9696
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TABLE OF CONTENTS 1.0 INTRODUCTION.......................................................................................................................... 1 2.0 ABOUT THESE INSTRUCTIONS............................................................................................... 1 3.0 TOOLS NEEDED.......................................................................................................................... 2 4.0 PRE-INSTALLATION AND HARNESS ROUTING GUIDELINES.................
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1.0 INTRODUCTION You have purchased what we at Painless Performance Products believe to be the most up-to-date and easiest-to-install automotive fuel injection harness on the market. It is designed for easy installation, even if you have no electrical experience. This harness is designed to be a complete wiring system for the fuel injection system on General Motors 1996-2000 7.4 engines. Also, to control the 4L80E automatic transmission using the 1996-1997 computer Service #16229684 an
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3.0 TOOLS NEEDED In addition to your regular tools, you will need, at least, the following: Crimping tool NOTE: USE A QUALITY TOOL TO AVOID OVER-CRIMPING. Wire stripper Continuity tester CAUTION: DO NOT USE A TEST LIGHT TO TEST THE COMPUTER OR SENSOR WIRING OR YOU WILL DAMAGE THE COMPUTER. Electric drill 1 5/8" Hole saw (for the rubber grommet in the firewall) 4.0 PRE-INSTALLATION AND HARNE
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4.2.6 Route the harness away from sharp edges, exhaust pipes, and the hood, trunk and door hinges. 4.2.7 Plan where harness supports will be located. Use a support approximately every 6 inches unless the harness routes under the floor carpet. 4.2.8 Allow enough slack in the harness at places where movement could possibly occur (body to frame, frame to engine, etc.). 4.2.9 The wires should be bundled into harness groups. Use tape, nylon ties or poly split loom. (96-00) Vortec 7.
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5.1 GROUNDING THE VEHICLE A perfectly and beautifully wired automobile will never the less have problems if everything is not properly grounded. Don't go to the effort to installing a quality wire harness only to neglect proper grounding. Note: The installer of this harness is responsible for all ground wires not provided with this part. 5.1.1 Connect a ground strap or cable (minimum of a 4 Ga. wire) from the negative battery terminal to the chassis (frame). 5.1
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5.4.4 Strip insulation away from wire. Only strip as much insulation off as necessary for the type of terminal lug you are using. Note: In the following step, make sure that the terminal is crimped with 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 wires and connectors throughout the harness is a simple process. Make sure that each wire is properly routed and then a
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A. Find a suitable location to mount the DLC connector (using the bracket that the light is mounted in) that will allow access to the front of the connector and still allow you to see the light while driving. B. Mount the DLC connector using the bracket containing the check engine light in the place selected. C. Locate the white ignition hot activation wire, labeled FUSE BLOCK IGNITION (18 Ga.) and attach it to a 12V fused power source where there is power WHEN THE KE
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F. If your vehicle has a pressure type brake switch, you may use a relay as shown in Figure 6.3. The relay must be a SPDT Relay and wired correctly or it could result in a dangerous situation with the vehicle. The torque converter may not unlock. G. The wire labeled FUEL TEST is a test point for the fuel pump. After the vehicle has been wired and tested OK, tape off this wire and store it in the harness. H. The wire labeled TACH (white) is the signal wire for a tachometer if u
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6.3.5 Engine Section Connections WIRE COLOR # OF POSITIONS LABELED CONNECT TO: IN CONNECTOR Blue 1 Knock Knock Sensor Connector Tan/White, Purple/White, Black, Pink 4 O2 SENSOR Driver Side Oxygen Sensor Tan, Purple, Black, Pink 4 O2 SENSOR Passenger Side Oxygen Sensor Black, Lt.Green, Gray 3 MAP MAP Sensor Brown/White, Pink, Pink/Black 3 Dist. Cam Position Sensor Yellow, P
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FIGURE 6.6 Knock Sensor Connector FIGURE 6.7 Oxygen Sensors FIGURE 6.8 MAP Sensor FIGURE 6.10 CPS Sensor FIGURE 6.9 Cam Sensor (Dist.) 9
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FIGURE 6.11 Injectors 1 - 8 FIGURE 6.12 Coil Driver (Component is pictured on a 5.7. This image is used to show connector plug in, not component location) FIGURE 6.14 Ignition Coil FIGURE 6.13 TPS Sensor and IAC Valve FIGURE 6.15 MAF Sensor FIGURE 6.16 ECT Sensor 10
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FIGURE 6.17 IAT Sensor FIGURE 6.18 Fuel Pump/Oil PressureSwitch 6.4 TAIL SECTION INSTALLATION 6.4.1 Locate the tail section that you earlier separated from the engine group. Begin routing it towards the rear of the vehicle. Be sure to avoid all sharp edges, moving or hot parts, or anything else that may damage the harness. 6.4.2 If you are using the 4L80E transmission, route the 13-position connector to the transmission and attach it. Route the i
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FIGURE 6.19 A/T Input Speed & VSS Sensor, Transmission Connection (4L80E) 7.0 TROUBLE- SHOOTING INSTRUCTIONS If you are having trouble with your engine running badly or not running at all, first perform basic trouble-shooting (ensure that you are using the correct parts (Table 4.1), check for faulty connections, blown fuses, spark, timing, fuel pressure, etc.), then see if the computer has stored a trouble code in its memory. FIGURE 6.20
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7.2 RETRIEVING TROUBLE CODES FROM THE COMPUTER 7.2.1 In order to retrieve the trouble codes stored in the computer, a scanner must be connected to the Assembly Diagnostic Link (DLC) connector (installed and connected in Paragraph 6.2.1). Follow the instructions provided with the scanner to read the codes set in the computer. 7.2.2 After you have read any codes, write them down for reference. Remove the connector from the DLC connector. 7.2.3 Take the codes one at a time and match the
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We have attempted to provide you with the most accurate instructions 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. Painless Perform
