Painless Performance 60211 User Manual
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
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........................................... 2
4.1 TRANSMISSION FUNCTION...................................................................................... 2
4.2 GET TO KNOW THE ENGINE THAT YOU ARE USING........................................... 2
5.0 GENERAL INSTALLATION INSTRUCTIONS............................................................ 3
5.1 GROUNDING THE VEHICLE....................................................................................... 4
5.2 ROUGH INSTALLATION............................................................................................... 4
5.3 HARNESS ATTACHMENT........................................................................................... 4
5.4 TERMINAL INSTALLATION INSTRUCTIONS.......................................................... 4
6.0 GM 96-00 VORTEC SYSTEM WIRE HARNESS INSTALLATION............................ 5
6.1 CONTENTS OF THE 60211 & 60216 WIRE HARNESS KIT...................................... 5
6.2 SPECIFIC CIRCUIT CONNECTIONS........................................................................... 5
6.3 ENGINE GROUP INSTALLATION............................................................................... 7
6.4 TAIL SECTION INSTALLATION................................................................................. 11
7.0 TROUBLE-SHOOTING INSTRUCTIONS.................................................................... 12
7.1 THE "CHECK ENGINE" LIGHT................................................................................... 12
7.2 RETRIEVING TROUBLE CODES FROM THE COMPUTER..................................... 13
7.3 WHEN TO CALL "PAINLESS WIRING" TECH LINE................................................ 13
LIST OF FIGURES
Figure 6.1 Diagnostic Link Connector (DLC) & Check Engine Light ........................................ 5
Figure 6.2 Brake Switch Connection ........................................................................................... 6
Figure 6.3 Brake Switch Relay..................................................................................................... 6
Figure 6.5 Fuel Pump Relay Connector ...................................................................................... 7
Figure 6.6 Knock Sensor Connector ............................................................................................ 9
Figure 6.7 Oxygen Sensors........................................................................................................... 9
Figure 6.8 MAP Sensor................................................................................................................. 9
Figure 6.9 CMP Sensor................................................................................................................. 9
Figure 6.10 CKP Sensor.................................................................................................................. 9
Figure 6.11 Injector Connector ...................................................................................................... 10
Figure 6.12 Coil Driver Connector………………………………………………………………… 10
Figure 6.13 TPS Sensor and IAC Valve ......................................................................................... 10
Figure 6.14 Ignition Coil Connector................................................................................................. 10
Figure 6.15 MAF Sensor ................................................................................................................. 10
Figure 6.16 ECT Sensor ................................................................................................................... 10
Figure 6.17 IAT Sensor..................................................................................................................... 11
Figure 6.18 Fuel Pump/Oil Press. Switch.......................................................................................... 11
Figure 6.19 VSS/Output Speed Sensor (4L80E)................................................................................ 12
Figure 6.20 Fuse Identification........................................................................................................... 13
LIST OF TABLES
Table 4.1 Compatible Parts V8 Engines........................................................................................... 3
Table 6.1 Dash Section Connections................................................................................................ 7
Table 6.2 Engine Section Connections............................................................................................. 8
Table 6.3 Injector Wire Colors........................................................................................................ 8
Table 6.4 Tail Section Connections.................................................................................................. 11
i
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.
: Most remanufactured computers come without any programming in them and must be programmed before
NOTE
they can be used.
: The program in your computer must match the transmission that you plan on using. The 60211 & 60216, require the
NOTE
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 Includes wiring for the fuel injectors, ignition system, and sensors.
DASH GROUP 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 INTRODUCTION
2.0 ABOUT THESE INSTRUCTIONS
3.0 TOOLS NEEDED
4.0 PRE-INSTALLATION AND HARNESS ROUTING GUIDELINES
5.0 GENERAL INSTALLATION INSTRUCTIONS
6.0 60211 VORTEC FUEL INJECTION HARNESS KIT
7.0 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 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 HARNESS ROUTING GUIDELINES
The installation of your harness kit will consist of two parts:
~ 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 Familiarize yourself with the harness by locating each of the harness groups and by looking at the
connectors on the wire ends.
4.2.3 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 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 7.4 Fuel Injection Harness- Part # 60211
Main Computer Service # 16229684 Idle Air Control Motor Delco #217-435
Service # 16244210 Knock Sensor Delco #213-324
Brake Switch Delco #D1565E Coil Delco #D577
Intake Air Temperature Delco #213-243 Cam Position Sensor Delco #213-920
Mass Air Flow Sensor Delco #213-252 Crankshaft Position Sensor Delco #213-946
Engine Coolant Temperature Delco #213-310 VSS (4L80E) GM #24203876
Oxygen Sensor (Drv. Side) Delco #AFS93 Oil Pressure Switch GM #12553175
Oxygen Sensor (Pass. Side) Delco #AFS 93 Manifold Absolute
Throttle Position Sensor Delco #213-912 Pressure Sensor Delco #213-351
Ignition Module Delco #D579
Table 4.1 Compatible Parts For V8 Engines
5.0 GENERAL INSTALLATION INSTRUCTIONS
~ 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!
~ 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:
~ 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
the computer are or become bent.
~ The fuel pump and pressure regulator MUST
CAUTION:
(pounds per square inch).
PSI
to make sure none of the pins in
maintain a constant pressure of 56-62
3
Loading...