Painless Performance 60505 User Manual

P/N 60502 & 60505

1994/1995 GM LT1 FUEL INJECTION

WIRE HARNESS INSTALLATION

INSTRUCTIONS

Manual P/N 90517

Copyright © May 2002

PAINLESS PERFORMANCE PRODUCTS

2501 Ludelle Street - Fort Worth, Texas 76105-1036 - [phone]

E-Mail: [e-mail]

Web: [e-mail]

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 [phone] or e-mail us at
[e-mail]. 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 90517 Painless Wiring Manual

March 16, 2005

Copyright  1994 by Perfect Performance Products, LLC

TABLE OF CONTENTS

1.0 INTRODUCTION.......................................................................................................................... ii

2.0 ABOUT THESE INSTRUCTIONS............................................................................................... ii

3.0 TOOLS NEEDED.......................................................................................................................... 1

4.0 PRE-INSTALLATION AND HARNESS ROUTING GUIDELINES........................................... 1

4.1 TRANSMISSION FUNCTION...................................................................................... 1

4.2 GET TO KNOW THE ENGINE THAT YOU ARE USING........................................... 2

5.0 GENERAL INSTALLATION INSTRUCTIONS.......................................................................... 3

5.1 GROUNDING THE VEHICLE....................................................................................... 3

5.2 ROUGH INSTALLATION............................................................................................... 4

5.3 HARNESS ATTACHMENT........................................................................................... 4

5.4 TERMINAL INSTALLATION INSTRUCTIONS.......................................................... 4

6.0 GM 94 & 95 LT1 SYSTEM WIRE HARNESS INSTALLATION............................................... 5

6.1 CONTENTS OF THE 60502 OR 60505 WIRE HARNESS KIT..................................... 5

6.2 SPECIFIC CIRCUIT CONNECTIONS........................................................................... 5

6.3 ENGINE GROUP INSTALLATION............................................................................... 9

6.4 TAIL SECTION INSTALLATION................................................................................. 13

7.0 TROUBLE-SHOOTING INSTRUCTIONS................................................................................... 13

7.1 THE "CHECK ENGINE" LIGHT................................................................................... 14

7.2 RETRIEVING TROUBLE CODES FROM THE COMPUTER..................................... 14

7.3 WHEN TO CALL "PAINLESS WIRING" TECH LINE................................................ 16

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......................................................................................................... 7

Figure 6.4 Gear Indicator Switch ..................................................................................................... 7

Figure 6.5 Air Pump Relay Connector ............................................................................................. 8

Figure 6.6 Canister Purge Solenoid ................................................................................................. 8

Figure 6.7 Air Pump Connection ..................................................................................................... 9

Figure 6.8 Fuel Pump Relay Connector............................................................................................ 9

Figure 6.9 EGR Solenoid ................................................................................................................. 10

Figure 6.10 Knock Sensor .................................................................................................................. 10

Figure 6.11 Oxygen Sensor ................................................................................................................ 11

Figure 6.12 MAP Sensor .................................................................................................................... 11

Figure 6.13 Injectors 1, 3, 5, 7............................................................................................................. 11

Figure 6.14 Injectors 2, 4, 6, 8 ............................................................................................................ 11

Figure 6.15 TPS Sensor ...................................................................................................................... 11

Figure 6.16 IAC................................................................................................................................... 11

Figure 6.17 MAF Sensor .................................................................................................................... 12

Figure 6.18 Distributor Connection..................................................................................................... 12

Figure 6.19 Ignition Module................................................................................................................ 12

Figure 6.20 Coil................................................................................................................................... 12

Figure 6.21 ECT Sensor....................................................................................................................... 12

Figure 6.22 IAT Sensor........................................................................................................................ 12

Figure 6.23 VSS.................................................................................................................................... 13

Figure 6.24 Transmission Connection ................................................................................... .............. 13

Figure 7.1 Fuse Identification.............................................................................................................. 14

i

LIST OF TABLES

Table 4.1 Compatible Parts.............................................................................................................. 3

Table 6.1 Dash Section Connections................................................................................................ 8

Table 6.2 Engine Section Connections............................................................................................. 10

Table 6.3 Tail Section Connections.................................................................................................. 13

Table 7.1 Diagnostic Trouble Codes................................................................................................ 14 & 15

1.0 INTRODUCTION

You have purchased what we at Painless Performance Products believe to be the most up-to-date and easiest-to­install 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 1994 and
newer LT1 injected engines and to control the 4L60E transmission. This includes all wiring that is needed by the
computer to run and control the injection system and transmission. A module has been included to bypass the vehicle
anti theft system (VATS) incorporated in the computer. When using this harness on a '96 or '97 engine you must
replace the coil, coil output wire and knock sensor with the parts from a '92 - '95 engine.

NOTE: The use of a 40 pulse Vehicle Speed Sensor, such as the one that comes
standard in the 4L60E transmission, is required when using a 1994 or newer
computer for operation of emission devices. The use of any other style transmission,
such as a 350 or 400 Turbo, which cannot operate a 40-pulse sensor, will require the
use of an earlier style computer. The use of a 4L60E will also require the use of an
electronic speedometer because of the absence of a cable drive in the transmission.

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 have been divided into three major groups:

ENGINE GROUP Includes wiring for the fuel injectors, distributor, and sensors.
DASH GROUP Includes ignition feed wires, assembly line diagnostic link (DLC) connector,
check engine light, computer wiring and connectors, brake switch wiring, gear
shift indicator wiring, tachometer wiring, air pump, canister purge, VATS and

fuse block.

TAIL GROUP Include VSS wiring, transmission wiring (if applicable) and power wire for fuel

pump.

2.0 ABOUT THESE INSTRUCTIONS

These instructions provide information for the installation of the 60502 LT1 (94 & 95) 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 60502 LT1 (94 & 95) FUEL INJECTION HARNESS KIT

8.0 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.

ii

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

If you are not using the 4L60E transmission, read Paragraph 4.1.1, then skip to Paragraph 4.1.3. If you ARE
going to use 4L60E, then skip Paragraph 4.1.1, and start at paragraph 4.1.2.

4.1.1 If you ARE NOT using a 4L60E transmission, tape off and store the light blue/black and pink

(brake switch) wires in the dash group and the 13-position (transmission) round connector in the
tail section.

4.1.2 If you ARE going to use a 4L60E transmission then you MUST have a two-position vehicle speed

sensor (VSS), and the 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.

4.1.3 Regardless of whether you use the 4L60E or not, the vehicle speed sensor (VSS) and park/neutral

indicator switch must be used and is needed by the computer so it can command the emissions
control devices on the engine. This part is necessary if you want your car to be street-legal.

NOTE; Emission devices

This harness has provisions for 3 emission devices, which are EGR solenoid, Air Pump relay and a

Canister Purge solenoid.

We have rolled up the canister purge solenoid wiring and air pump
wiring in the dash section and may be left there if these items are not to be used. If you
plan on using the canister purge solenoid and air pump you will need to route these wires
out to the engine compartment and install an air pump relay. Secure the wires to the main
harness using the tie wraps supplied.

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To keep the check engine light from coming on you will need to plug in a canister purge
solenoid and air pump relay to the wires in the dash section. (The computer looks for
signals from these controls and does not care if the actual devices are installed.)

4.2 YOU SHOULD GET TO KNOW THE PARTICULAR ENGINE YOU ARE
USING:

NOTE: The 94 & 95 LT1 engine has two oxygen sensors, one on the right side and one on the left side

4.2.1 PPPI recommends the use of the following parts. See Table 4.1. These will meet all requirements

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

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.

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,

4.2.9 The wires should be bundled into harness groups. Use tape, nylon ties or poly split loom.

of the engine. This system has four rectangular connectors at the computer. A 16188051
computer is required for proper operation.

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.

kits are designed to mount 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. 16 inches).

frame to engine, etc.).

2

LT1 Fuel Injection Harness (94 & 95) Part # 60502 or 60505

Main Computer............................Service#16188051 EGR. Solenoid................................ Delco# 214-396

Brake Switch.....................................GM# 25524845 Gear Indicator Switch..................GM# 15705308 or

Intake Air Temperature.....................GM# 12110319 Delco #D2286A

Ignition Module.............................Delco# D-1986-A MAP Sensor ....................................GM# 16137039

Fuel Pump Relay...GM# 14089936 Delco# 15-8240 Idle Air Control ................................GM# 17113099

Coolant Temperature Sensor ..........GM# 25036979 Knock Sensor ...................................Delco# 213-96

Coil.......................................................Delco# D-573 Air Pump Relay....GM# 14100455 Delco# 15-8426

Oxygen Sensors...GM# 25312184 or Delco# AFS 75 Air Pump......................................Delco# 2604-4885

TPS Sensor.........................................GM# 17106680 MAF Sensor.....................................Delco# 213-252

Canister Purge Solenoid GM# 1997201 Delco# 214-565

NOTE: Components with part numbers other then the ones listed may plug into the 60502 or 60505

harness, but the part numbers MUST match the ones on this list for proper operation. An adapter is
included to adapt the 4-pin square IAC connector to the '94-'96 flat 4-pin connector.

Table 4-1 Compatible Parts

5.0 GENERAL INSTALLATION INSTRUCTIONS

CAUTION:

~ 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.
~ Each connector in this harness is different and will not fit in the wrong place. NEVER FORCE ANY
CONNECTOR.
~ When connecting the plugs to the computer USE EXTREME CARE
the computer are or become bent.
~ The fuel pump you are using MUST

be rated at a minimum of 45 PSI (pounds per square inch).

to make sure none of the pins in

5.1 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.

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.

3