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
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 and
#16244210. This includes all wiring that is needed by the computer to run and control the injection system and transmission.
This harness will get the Vortec engine and transmission up and operating but it is recommended that you also have the
computer reprogrammed to remove anything in the original factory programming that relates to a device or devices that are
not being used in your particular vehicle.
NOTE: Most likely the check engine light will come on and stay on when using a computer with the original factory
programming this is normal and is why we recommended that the computer be reprogrammed.
NOTE: Most remanufactured computers come without any programming in them and must be programmed before
they can be used.
NOTE: The program in your computer must match the transmission that you plan on using. The 60211 & 60216, require the
use of a 4L80E transmission. If any other electronic transmission is used, a stand alone control system is required.
Usually, the computer, relays and fuse block can easily be mounted under the dash. Most of the wiring in the harness has
been pre-terminated to the proper connector and all wire has been GM color-coded. All wiring is TXL, 600 volt, and 125
degree centigrade with cross-link insulation.
This fuel injection system harness has been divided into three major groups:
ENGINE GROUP
DASH GROUP
Includes wiring for the fuel injectors, ignition system, and sensors.
Includes ignition feed wire, assembly line diagnostic link (DLC) connector,
check engine light, computer connectors, brake switch wiring, tachometer wiring, VSS Signal
wire, fuse block, and fuel pump relay connector.
TAIL GROUP
Include VSS wiring, transmission wiring and power wire for fuel pump.
2.0
ABOUT THESE INSTRUCTIONS
These instructions provide information for the installation of the 60211& 60216 Vortec Fuel Injection Harness Kit. The
contents of these instructions are divided into major Sections, as follows:
1.0
2.0
3.0
4.0
5.0
6.0
7.0
INTRODUCTION
ABOUT THESE INSTRUCTIONS
TOOLS NEEDED
PRE-INSTALLATION AND HARNESS ROUTING GUIDELINES
GENERAL INSTALLATION INSTRUCTIONS
60211 VORTEC FUEL INJECTION HARNESS KIT
TROUBLE-SHOOTING INSTRUCTIONS AND TROUBLE CODES
Sections are further divided into Paragraphs and Steps. Throughout, the Figure numbers refer to illustration 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 careful attention to any notes or any text labeled CAUTION.
1
3.0
TOOLS NEEDED
In addition to your regular tools, you will need, at least, the following:
Crimping tool
Wire stripper
NOTE: USE A QUALITY TOOL TO AVOID OVER-CRIMPING.
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 HARNESS ROUTING GUIDELINES
The installation of your harness kit will consist of two parts:
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The physical routing, positioning, and securing of the harness, wire groups, and individual wires and
connectors.
The proper electrical connection of the individual circuits.
We cannot tell you how to route the harness in your automobile. That depends a great deal upon the particular make of the
automobile and what extent you want to secure and conceal the harness. We do offer some general guidelines and routing
practices starting in Paragraph 5.3, general installation instructions in Section 5.0, and precise instruction concerning the
electrical connections you will have to make beginning in Section 6.0. To help you begin thinking through the installation of
your wire harness, read the following sections:
4.1
TRANSMISSION FUNCTION
4.1.1
If you are using the 4L80E transmission, you must use the vehicle speed sensor (VSS), and the correct
brake switch. These are necessary to make the transmission work correctly. The vehicle speed sensor lets
the computer know how fast the wheels are turning. The brake switch should be closed (electrically
connected) when the brakes ARE NOT being applied and open (not electrically connected) when the
brakes ARE being applied. This is the opposite of a standard brake light switch. If you are using a pressure
brake switch, a SPDT relay must be installed to unlock the converter when the brakes are applied. See
Figure 6.3
4.2
YOU SHOULD GET TO KNOW THE PARTICULAR ENGINE YOU ARE USING:
NOTE: The 96-00 7.4 had four oxygen sensors from the factory, but the harness has provisions for only two,
one on the driver side and one on the passenger side of the engine. We removed the rear oxygen
sensors since they originally were behind the catalytic converters and most people don’t want to run
more than two oxygen sensors. This system has four rectangular connectors at the computer. A
#16229684 computer is required for proper operation.
4.2.1
PPPI recommends the use of the following parts. See Table 4.1. These will meet all requirements and are
compatible with PPPI harnesses. The numbers given are GM and AC Delco part numbers. You must use
the computer listed on table 4.1 with our harness.
4.2.2
4.2.3
Familiarize yourself with the harness by locating each of the harness groups and by looking at the
connectors on the wire ends.
Decide where and how the computer, fuse block and relays will be mounted. PPPI wire harness kits are
designed to mount the computer either under the dash or in the kick panel on the right side. They must be
no further apart than the wiring will allow (approx. 18 inches).
4.2.4
A good exercise is to lay out the wire harness on the floor beside your vehicle and identify all the
connectors and wires.
4.2.5
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.
2
4.2.6
4.2.7
Route the harness away from sharp edges, exhaust pipes, and the hood, trunk and door hinges.
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
4.2.9
Allow enough slack in the harness at places where movement could possibly occur (body to frame, frame to
engine, etc.).
The wires should be bundled into harness groups. Use tape, nylon ties or poly split loom.
(96-00) Vortec 7.4 Fuel Injection Harness- Part # 60211
Main Computer
Service # 16229684
Service # 16244210
Delco #D1565E
Delco #213-243
Delco #213-252
Delco #213-310
Delco #AFS93
Delco #AFS 93
Delco #213-912
Delco #D579
Idle Air Control Motor
Knock Sensor
Coil
Cam Position Sensor
Crankshaft Position Sensor
VSS (4L80E)
Oil Pressure Switch
Manifold Absolute
Pressure Sensor
Delco #217-435
Delco #213-324
Delco #D577
Delco #213-920
Delco #213-946
GM #24203876
GM #12553175
Brake Switch
Intake Air Temperature
Mass Air Flow Sensor
Engine Coolant Temperature
Oxygen Sensor (Drv. Side)
Oxygen Sensor (Pass. Side)
Throttle Position Sensor
Ignition Module
Delco #213-351
Table 4.1 Compatible Parts For V8 Engines
5.0
GENERAL INSTALLATION INSTRUCTIONS
CAUTION:
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DO NOT DISCONNECT THE BATTERY OR THE COMPUTER CONNECTORS WHILE THE
IGNITION IS ON.
DO NOT SHORT ANY WIRES IN THIS HARNESS TO GROUND (WITH THE EXCEPTION OF
LABELED GROUND WIRES) OR DAMAGE TO THE COMPUTER WILL RESULT.
GIVING OR RECEIVING A "JUMP START" MAY DAMAGE THE COMPUTER.
DO NOT USE A TEST LIGHT WHEN TESTING COMPUTER SENSORS OR COMPUTER
CIRCUITS. DAMAGE TO THE COMPUTER WILL RESULT!
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WHEN ROUTING THE WIRES FOR THE VEHICLE SPEED SENSOR (IF USED) MAKE
CERTAIN THAT THEY ARE AT LEAST 12 INCHES AWAY FROM ANY IGNITION WIRING
(SPARK PLUG WIRES, ETC.).
Notes:
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There is a normal, small current drain on these fuel injected systems.
NEVER FORCE ANY CONNECTOR.
When connecting the plugs to the computer USE EXTREME CARE to make sure none of the pins in
the computer are or become bent.
~
The fuel pump and pressure regulator MUST maintain a constant pressure of 56-62
PSI (pounds per square inch).
3
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).
5.1.2
Connect a ground strap (minimum of a 4 Ga. wire) from the engine to the chassis (frame). DO
NOT RELY UPON THE MOTOR MOUNTS TO MAKE THIS CONNECTION.
5.1.3
Connect a ground strap from the engine to the body.
5.2
ROUGH INSTALLATION
CAUTION:
DISCONNECT THE POWER FROM YOUR VEHICLE BY REMOVING THE
NEGATIVE BATTERY CABLE FROM THE BATTERY.
Note: Make no wire connections or permanent mounting of any kind at this time.
5.2.1
5.2.2
Position the computer and sensors in their intended locations.
Drill a 1-5/8" hole for the firewall grommet near the computer for the engine group and tail section to pass
through.
5.2.3
Route the engine group and tail section through the hole. Push the grommet (already installed on
the harness) into the hole until it is seated.
5.2.4
5.2.5
Route the dash group over to the driver's side of the car.
Route the fuse block and relays to the place they will be mounted.
5.3
HARNESS ATTACHMENT
Note: Harness routing and shaping will be a time-consuming task. Taking your time will enhance
the beauty of your vehicle. Please take your time and be patient.
5.3.1
5.3.2
Permanently mount your computer. You should mount the fuse block and relays at this time.
Mold harness groups to the contour of the dash, engine, frame, etc. Remember to route harness
away from sharp edges, exhaust pipes, hinges, and moving parts.
5.3.3 Attach harness groups to your automobile with clips or ties starting at the computer and working
your way outward.
Note: Do not tighten tie wraps or 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, colored plastic wire ties make a very
attractive assembly. Otherwise, a tie installed in other areas every 6" or so will hold the wires in place
securely. REMEMBER TO TAKE YOUR TIME.
5.4
TERMINAL INSTALLATION INSTRUCTION
Note: In the following steps you will be making the circuit connections. Before you start, you
should carefully read Sections 6.0, and continually refer to the wire charts, DOUBLE
CHECKING your length calculations before cutting any wire or making any connections.
These directions are for the wires, which do not have a connector already, installed on them.
5.4.1
5.4.2
5.4.3
Have all tools and connectors handy.
Select the correct terminal for the wire and application.
Determine the correct wire length and cut the wire. Remember to allow enough slack in the
harness and wires at places where movement could occur. DOUBLE CHECK YOUR
CALCULATIONS.
4
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
5.4.6
Crimp the terminal onto the wire.
Connecting the wires and connectors throughout the harness is a simple process. Make sure that each wire
is properly routed and then attached. DO NOT ATTACH THEN ROUTE AFTERWARD.
5.4.7
5.4.8
5.4.9
When all the wires are attached, tighten the mounts and ties to secure the harness permanently.
Attach the connectors to the computer. BEING VERY CAREFUL NOT TO BEND ANY PINS.
After all connections have been made throughout the harness, connect the battery to the vehicle.
CAUTION:
BE SURE THE IGNITION IS OFF WHEN YOU RECONNECT THE BATTERY
OR YOU WILL DAMAGE THE COMPUTER.
6.0
6.1
96-00 7.4 VORTEC SYSTEM WIRE HARNESS INSTALLATION INSTRUCTIONS
CONTENTS OF THE 60211 & 60216 WIRE HARNESS KIT
Take inventory to see that you have everything you are supposed to have in this kit. If anything is missing, contact the dealer
where you obtained the kit or contact Painless Performance at 800-423-9696. The kit should contain the following items:
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The main wire harness with the connectors already on the ends of most of the wires.
Fuel Injection Installation Instructions P/N 90541 (This Booklet).
4” & 7” tie wraps.
6.2
SPECIFIC CIRCUIT CONNECTIONS
Note: 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 before securing or cutting any wires. Wire color (Example: Blk/Wht) is
one wire with a stripe. The second color (the stripe) may not be bold. Observe all two-color wires closely.
6.2.1 DASH SECTION INSTALLATION
The wires in this group consist of the diagnostic link connector (DLC) (SEE FIGURE 6.1), the check engine light
(pre-mounted into a mounting bracket), fuseblock/w fuses and relays, fuel pump relay connector/w relay and 7 other
wires.
Note: You may need to connect the check engine light wires to their mates in the wire harness.
CAUTION:
DO NOT MAKE ANY CONNECTIONS WHILE THE COMPUTER IS
PLUGGED INTO THE HARNESS.
FIGURE 6.1 DLC Connector & Check Engine Light
5
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.
C.
Mount the DLC connector using the bracket containing the check engine light in the place
selected.
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 KEY IS IN THE START AND RUN
POSITION. This wire activates the relays that supply power to all the ignition hot circuits in the fuel
injection harness. If the white wire is connected correctly, the check engine light will come on when the
ignition switch is in the "ON and START" position.
D.
E.
The purple and brown wires labeled BRAKE SWITCH are the wires that connect to the brake
switch to let the computer know when the brake is applied. If you ARE NOT using a 4L80E then you will
tape off and store these wires. If you ARE using the 4L80E transmission, then you will have to install a
brake switch. The brown wire provides power for this switch and the purple wire is the signal going to the
computer.
If you are using the recommended brake switch then you will wire it according to Figure 6.2.
The brown wire to the back of the switch in the illustration is the wire that has power on it whether or not
the brake is being applied.
FIGURE 6.2 Brake Switch Connection
FIGURE 6.3 Brake Switch Relay
CAUTION: FAILURE TO WIRE THIS SWITCH CORRECTLY WILL RESULT IN A
DANGEROUS SITUATION ON THE VEHICLE.
6
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.
I.
The wire labeled TACH (white) is the signal wire for a tachometer if used.
The VSS output wire (green) sends out a signal to operate the electronic cruise control or speedometer if so
equipped.
6.2.2 Dash Section Connections
WIRE COLOR
# OF POSITIONS
IN CONNECTOR
LABELED
Fuel Relay
VSS Output
Tach
CONNECT TO:
Gray, Grn/Wht, Blk/Wht, Org, Red
Green
White
5
Fuel Pump Relay
Speedometer
Tachometer
Purple, Brown
White
Brake Switch
Fuse Block Ignition
Brake Switch
Ignition Power
Table 6.1 Dash Section Connections
FIGURE 6.5 Fuel Pump Relay Connector
6.3
ENGINE GROUP INSTALLATION
The engine group is designed to be separated into left side (passenger) and right side (driver) sections. Each side is
tie-wrapped separately, BUT NOT LABELED. The left side of the engine has the connectors for the idle air control
and throttle position sensor, all of which ARE labeled. When you begin routing, FIRST separate the engine group
into left and right sections and place them accordingly.
6.3.1
6.3.2
Before you connect any wires, separate the tail section from the engine group and place it out of
the way.
Connect the two ring terminals labeled STARTER B+ with Red wires to the large battery terminal on the
starter solenoid.
6.3.3
6.3.4
Locate the two large ring terminals with Black and Blk/Wht wires and ground them to the engine.
Using Figure 6.6-6.18, and the specific connections indicated in Table 6.2, connect the wiring as directed.
7
6.3.5
Engine Section Connections
WIRE COLOR
# OF POSITIONS
IN CONNECTOR
1
LABELED
CONNECT TO:
Blue
Knock
Knock Sensor Connector
Driver Side Oxygen Sensor
Passenger Side Oxygen Sensor
MAP Sensor
Cam Position Sensor
Crankshaft Position Sensor
Central Port Injector
Tan/White, Purple/White, Black, Pink
Tan, Purple, Black, Pink
Black, Lt.Green, Gray
Brown/White, Pink, Pink/Black
Yellow, Purple, Pink
See NOTE: Below For Injector
Wire Colors
4
4
3
3
3
16
O2 SENSOR
O2 SENSOR
MAP
Dist.
CPS
Injector V8
3
3
2
2
4
TPS
MAF
ECT
IAT
Throttle Position Sensor
Mass Airflow Sensor
Engine Coolant Temp Sensor
Intake Air Temp Sensor
Idle Air Control Motor
Black, Blue, Grey
Pink, Yellow, Black/White
Yellow, Black
Tan, Black
IAC
Lt.Green/Black, Lt.Blue/Black,
Lt.Blue/White, Lt.Green/White
Pink, White, Black/White,
White/Black
Pink, White, White/Black
Black/White, Black
4
3
Coil Driver
Coil Driver Connector
Coil
Ground
Starter B+
Coil Connector
Engine Ground
Starter Solenoid Batt. Terminal
Red (2)
TABLE 6.2 Engine Section Connections
Injector Wire Colors
Black
Injector #1
Black/White
Yellow/Black
Red/Black
Injector #5
Injector #6
Injector #7
Injector #8
Lt.Green/Black Injector #2
Pink/Black
Lt.Blue/Black
Injector #3
Injector #4
Blue/White
TABLE 6.3 Injector Wire Colors
8
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
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
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 input shaft speed sensor connector to the transmission and attach it.
6.4.3
6.4.4
Take the connector for the Vehicle Speed Sensor (VSS) and connect to the Vehicle Speed Sensor.
Take the gray wire labeled FUEL PUMP and route it to the fuel pump. This is the power wire for the fuel
pump.
6.4.5
Tail Section Connections
WIRE COLOR
# OF POSITIONS
IN CONNECTOR
2
LABELED
VSS Input
CONNECT TO:
Red/Black, Blue/White
Vehicle Speed Sensor
Vehicle Speed Sensor
VSS Output
Purple/White, Green/Black
2
Lt. Green, Yellow/Black, Yellow,
Red/Black, Lt. Blue/White, Pink,
Pink/Black, Black, Red, Blue,,
Tan/Black, Brown
Trans.
Transmission
13
Fuel Pump
Gray
Fuel Pump Power Terminal
TABLE 6.4 Tail Section Connections
11
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 Fuse Identification
7.1
THE "CHECK ENGINE" LIGHT
Normally, the "check engine" light should come on when the ignition is turned on, then go out a few
moments after the engine starts running. If it reappears, or stays on while the engine is running, the
computer has detected a problem and a trouble code has been set.
NOTE: Most likely the check engine light will come on and stay on when using a computer with the original
factory programming this is normal and is why we recommended that the computer be reprogrammed to
remove any items that the factory vehicle had that aren’t being used in the vehicle you are installing the
engine into.
12
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
7.2.3
After you have read any codes, write them down for reference. Remove the connector from the DLC
connector.
Take the codes one at a time and match them to the codes in the 1997 C/K Truck repair manual. This will
tell you in which circuit the computer has detected a problem.
Note: A code indicates a problem in a specific circuit, NOT THAT A PARTICULAR PART IS
BAD.
7.2.4
Before taking more extensive corrective actions for any trouble codes make sure that all
connections on the indicated circuit, INCLUDING THE COMPUTER, are clean and tight.
Inspect the wiring in the circuit for any broken, shorted, or exposed wires. Finally, insure all
ground wires are clean and secure.
7.2.5
If a trouble code is detected and the problem has been fixed, clear the codes by first making sure the
ignition is off then disconnecting the NEGATIVE battery cable for at least 3 minutes.
7.3
WHEN TO CALL PAINLESS PERFORMANCE PRODUCTS' TECH LINE
7.3.1
These harness kits have been built with the highest regard to quality control. Before calling us
please double check all connections and perform normal basic trouble-shooting (fuel pressure,
timing, ignition system, etc.).
7.3.2
If you have any questions concerning the installation of this harness or having trouble in general, feel free
to call Painless Performance Products' tech line at 1-800-423-9696. Calls are answered from 8am to 5pm
central time, Monday thru Friday, except holidays. Email questions to [email protected]
13
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 Performance Limited Warranty
and Return Policy
Chassis harnesses and fuel injection harnesses 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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