Painless Performance 60219, 60220 User Manual
P/N 60219 & 60220
2000 - 2002 GM VORTEC THROTTLE BY WIRE
FUEL INJECTION 4.8L, 5.3L & 6.0L
WIRE HARNESS INSTALLATION
INSTRUCTIONS
Manual P/N 90559
FIRST EDITION MARCH 2008
Copyright © MARCH 2008
PAINLESS PERFORMANCE PRODUCTS
2501 Ludelle Street Fort Worth, Texas 76105 (800) 423-9696
TABLE OF CONTENTS
1.0 INTRODUCTION........................................................................................................................ 1
2.0 ABOUT THESE INSTRUCTIONS.................................................................................................. 2
3.0 TOOLS NEEDED........................................................................................................................ 2
4.0 CONTENTS OF THE 60219 & 60220 WIRE HARNESS KIT............................................................ 2
5.0 PRE-INSTALLATION AND HARNESS ROUTING GUIDELINES........................................................ 2
5.1 TRANSMISSION FUNCTION...................................................................................................... 3
5.2 GET TO KNOW THE ENGINE THAT YOU ARE USING.................................................................. 3
6.0 GENERAL INSTALLATION INSTRUCTIONS................................................................................. 4
6.1 GROUNDING THE VEHICLE...................................................................................................... 4
6.2 ROUGH INSTALLATION............................................................................................................ 5
6.3 HARNESS ATTACHMENT........................................................................................................... 5
6.4 TERMINAL INSTALLATION INSTRUCTIONS................................................................................ 5
7.0 GM 00-02 VORTEC SYSTEM WIRE HARNESS INSTALLATION...................................................... 7
7.1 DASH SECTION INSTALLATION................................................................................................ 7
7.2 ENGINE SECTION INSTALLATION............................................................................................. 10
7.3 TAIL/TRANSMISSION SECTION INSTALLATION.......................................................................... 15
8.0 TROUBLE-SHOOTING INSTRUCTIONS........................................................................................ 18
8.1 THE "CHECK ENGINE" LIGHT.................................................................................................... 18
8.2 RETRIEVING TROUBLE CODES FROM THE COMPUTER............................................................... 18
LIST OF FIGURES
Figure 6.1 Accelerator Pedal............................................................................................. 6
Figure 6.2 TAC Module Connections................................................................................. 6
Figure 7.1 Diagnostic Link Connector (DLC) & Check Engine Light ..................................... 8
Figure 7.2 Brake Switch Connection ................................................................................ 8
Figure 7.3 Brake Switch Relay......................................................................................... 9
Figure 7.4 Cruise Control................................................................................................ 9
Figure 7.5 Fuel Pump Relay Connector............................................................................ 9
Figure 7.6 Alternator...................................................................................................... 9
Figure 7.7 Knock Sensor Connector................................................................................. 12
Figure 7.8 Oxygen Sensors ............................................................................................ 13
Figure 7.9 MAP Sensor .................................................................................................. 13
Figure 7.10 CMP Sensor .................................................................................................. 13
Figure 7.11 CKP Sensor ................................................................................................... 13
Figure 7.12 Injectors 1, 3, 5, 7......................................................................................... 13
Figure 7.13 Injectors 2, 4, 6, 8 ........................................................................................ 13
Figure 7.14 TPS Sensor ................................................................................................... 14
Figure 7.15 TAC Motor..................................................................................................... 14
Figure 7.16 MAF Sensor .................................................................................................. 14
Figure 7.17 Driver Side Coil Connector.............................................................................. 14
Figure 7.18 Passenger Side Coil Connector........................................................................ 14
Figure 7.19 ECT Sensor................................................................................................... 14
Figure 7.20 VSS Output................................................................................................... 16
Figure 7.21 Transmission Sensor .................................................................................... 16
Figure 7.22 Transmission Connection .............................................................................. 16
Figure 7.23 Park Neutral Position Sensor.......................................................................... 16
Figure 7.24 Transmission Connector…………………………………………………………………………….. 17
Figure 8.1 Fuse Identification......................................................................................... 18
LIST OF TABLES
Table 5.1 Compatible Parts.............................................................................................. 4
Table 7.1 Dash Section Connections.................................................................................. 10
Table 7.2 Engine Section Connections ............................................................................. 12
Table 7.3 Tail Section Connections................................................................................... 16
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 2000 - 2002 4.8L, 5.3L, & 6.0L Electronic Throttle, also known as Throttle By Wire or Fly By
Wire, Vortec injected engines and to control the 4L60E, 4L65E, 4L80E, 4L85E automatic
transmissions using the computer Service #12200411. This includes all wiring that is needed by the
computer to run and control the injection system and transmission.
NOTE: This harness is not emissions legal unless used with emission harness #60328 or 60329. Also,
the computer’s program must match the emissions package to that specific engine.
To overcome the Passlock system in the 12200411 programming, the PCM will need to
have this feature removed. Contact the Painless Performance Tech Dept. for information on PCM
programming. This harness along with the removal of the Passlock software 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: This harness has no provision for operating cooling fans. If you wish to operate the fans
automatically, painless kit #30106 is available. This kit will turn the fans on at 205 degrees, and off
at 195. This kit is also available in a weatherproof version, part # 30127
NOTE: Most likely the check engine light will come on and stay on when using a computer without
removing the programming for any unused devises.
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
4L60E, 4L65E, 4L80E, or 4L85E.
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 & charging systems, power/ ground
and sensors.
DASH GROUP Includes wiring for the ignition feed, assembly line diagnostic link (DLC)
connector, check engine light, computer connectors, brake switch, tachometer,
electric speedometer, fuse block, fuel pump relay connector and emissions
devises.
TAIL GROUP Include wiring for the VSS, park neutral position sensor, transmission and power
wire for fuel pump.
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2.0 ABOUT THESE INSTRUCTIONS
These instructions provide information for the installation of the 60219 & 60220 TBW 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 60219 or 60220 VORTEC FUEL INJECTION HARNESS KIT
7.0 GM 00-02 VORTEC SYSTEM WIRE HARNESS INSTALLATION
8.0 TROUBLE-SHOOTING INSTRUCTIONS
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.
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.
Tech II or equivalent scanner (for presetting and diagnostic purposes)
Electric drill
1 5/8" Hole saw (for the rubber grommet in the firewall)
4.0 CONTENTS OF THE 60219 & 60220 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 or (817) 244-6898.
The kit should contain the following items:
~ The main wire harness with the connectors already on the ends of most of the wires
~ Fuel Injection Installation Instructions P/N 90559 (This Booklet)
~ 4” & 7” tie wraps
~ TAC Module to Accelerator Pedal Pigtail
5.0 PRE-INSTALLATION AND HARNESS ROUTING GUIDELINES
The installation of your harness kit will consist of two parts:
~ The physical routing, positioning, securing, group/ 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.
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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:
5.1 TRANSMISSION FUNCTION
5.1.1 Which ever transmission you are using ,4L60E, 4L65E, 4L80E, or 4L85E
transmission, you must ensure the following components are connected correctly:
vehicle speed sensor(VSS), transmission connector, park neutral position connectors
and correct brake switch. These are necessary to make the transmission work correctly.
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. The vehicle speed sensor lets the computer know how fast the
wheels are turning. The park neutral position sensor tells the PCM if the transmission is
in park or neutral.
5.2 YOU SHOULD GET TO KNOW THE PARTICULAR ENGINE YOU ARE USING:
NOTE: The 00–02 4.8L, 5.3L & 6.0L TBW Vortec engines had four oxygen
sensors from the factory, but we have provisions for only two, one on the
driver side and one on the passenger side of the engine. We removed the two
rear oxygen sensors since they originally where behind the catalytic
converters and most people don’t want to run more than two oxygen
sensors.
5.2.1 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 part #12200411.
5.2.2 Familiarize yourself with the harness by locating each of the harness groups and
by looking at the connectors on the wire ends.
5.2.3 Decide where and how the computer, TAC Module, fuse block, and relays will be
mounted. PPPI wire harness kits are designed to mount either under the dash or in the
kick panel on the right side.
5.2.4 A good exercise is to lay out the wire harness on the floor beside your vehicle
and identify all the connectors and wires.
5.2.5 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.
5.2.6 Route the harness away from sharp edges, exhaust pipes, and the hood, trunk,
and door hinges.
5.2.7 Plan where harness supports will be located. Use a support approximately every
6 inches unless the harness routes under the floor carpet.
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4.8L, 5.3L & 6.0L TBW Vortec Fuel Injection Harness (00 - 02) Part # 60219 & 60220
Main Computer…………………Service#12200411
Fuel Pump Relay………………..Delco# 15-8571
Brake Switch…………………….PPI# 80176
MAF/ IAT Sensor……………….Delco# 213-364
Engine Coolant Temperature……Delco# 213-953
Oxygen Sensor (Pass. Side)……..Delco# AFS106
Oxygen Sensor (Drvr. Side)……..Delco# AFS106
Throttle Body……………………Delco# 17113659
MAP Sensor…………………..…Delco# 213-796
Idle Air Control Motor…………..GM# 17113598
Knock Sensor………………….....Delco# 213-362
TAC Module……………………..Delco#12574221
Coils………………………….…..GM# 10457730
Cam Position Sensor……………..GM# 12561211
Crankshaft Position Sensor………Delco# 213-354
Accelerator Pedal………………...Delco#15177923
Table 5.1 Compatible Parts
5.2.8 Allow enough slack in the harness at places where movement could possibly
occur (body to frame, frame to engine, etc.).
5.2.9 The wires should be bundled into harness groups. Use tape, nylon ties, or poly
split loom.
6.0 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 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.
~ Each connector in this harness is different and will not fit in the wrong place, with
the exception of the Crank and Cam position sensors. 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 you are using MUST
maintain a constant pressure of 55-62 P.S.I.
(pounds per square inch). The Vortec fuel system does have a built-in regulator on
the fuel rail as in many earlier GM fuel injection systems.
6.1 GROUNDING THE VEHICLE
A perfectly and beautifully wired automobile will nevertheless 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.
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6.1.1 Connect a ground strap or cable (minimum of a 4 Ga. wire) from the negative
battery terminal to the chassis (frame).
6.1.2 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.
6.1.3 Connect a ground strap from the engine to the body.
6.2 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.
6.2.1 Position the computer and TAC Module in their intended locations.
6.2.2 Drill a 1-5/8" hole for the firewall grommet near the computer for the engine
group and tail section to pass through.
6.2.3 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.
6.2.4 Route the dash group over to the driver's side of the car.
6.2.5 Route the fuse block and relays to the place they will be mounted.
6.3 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.
6.3.1 Permanently mount your computer and TAC Module. You should also mount the
fuse block and relays at this time.
6.3.2 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.
6.3.3 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.
6.3.4 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.
6.4 TERMINAL INSTALLATION INSTRUCTION
Note: In the following steps you will be making the circuit connections. Before you
start, you should carefully read Section 7.0
charts, DOUBLE CHECKING
your length calculations before cutting any wire or
, and continually refer to the wire
making any connections. These directions are for the wires, which do not have a
connector already, installed on them.
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