Painless Performance 60506, 60507 User Manual
P/N 60506 & 60507
1997-98 GM LS1 FUEL INJECTION WIRE
HARNESS INSTALLATION INSTRUCTIONS
P/N 60508 & 60509
1999-02 GM LS1 FUEL INJECTION WIRE
HARNESS INSTALLATION INSTRUCTIONS
Sixth Edition November 17, 2005
PAINLESS PERFORMANCE PRODUCTS
2501 Ludelle Street - Fort Worth, Texas 76105-1036 - (800) 423-9696
Manual P/N 90520
Copyright © Oct. 2001
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........................................... 3
5.0 GENERAL INSTALLATION INSTRUCTIONS.......................................................................... 4
5.1 GROUNDING THE VEHICLE....................................................................................... 4
5.2 ROUGH INSTALLATION............................................................................................... 5
5.3 HARNESS ATTACHMENT........................................................................................... 5
5.4 TERMINAL INSTALLATION INSTRUCTIONS.......................................................... 5
6.0 GM LS1 SYSTEM WIRE HARNESS INSTALLATION.............................................................. 6
6.1 CONTENTS OF THE WIRE HARNESS KIT................................................................ 6
6.2 SPECIFIC CIRCUIT CONNECTIONS........................................................................... 5
6.3 ENGINE GROUP INSTALLATIONS............................................................................... 10
6.4 TAIL SECTION INSTALLATIONS................................................................................. 15
7.0 TROUBLE-SHOOTING INSTRUCTIONS................................................................................... 16
7.1 THE "CHECK ENGINE" LIGHT................................................................................... 16
7.2 RETRIEVING TROUBLE CODES FROM THE COMPUTER..................................... 17
7.3 WHEN TO CALL "PAINLESS WIRING" TECH LINE................................................ 17
LIST OF FIGURES
Figure 6.1 Diagnostic Link Connector (DLC) & Check Engine Light ............................................. 6
Figure 6.2 Brake Switch Connection ............................................................................................... 7
Figure 6.3 Brake Switch Relay......................................................................................................... 8
Figure 6.4 Gear Indicator Switch ..................................................................................................... 8
Figure 6.5 Air Pump & Air Solenoid Relays .................................................................................. 10
Figure 6.6 Canister Purge Solenoid ................................................................................................. 10
Figure 6.7 Canister Vent Solenoid ................................................................................................... 10
Figure 6.8 Air Pump Connection ..................................................................................................... 10
Figure 6.9 Air Bleed Solenoid.......................................................................................................... 10
Figure 6.10 Fuel Pump Relay Connector............................................................................................ 10
Figure 6.11 EGR Valve....................................................................................................................... 12
Figure 6.12 Knock Sensor Connector.................................................................................................. 12
Figure 6.13 Oxygen Sensors ................................................................................................................ 13
Figure 6.14 MAP Sensor .................................................................................................................... 13
Figure 6.15 CMP Sensor .................................................................................................................... 13
Figure 6.16 CKP Sensor .................................................................................................................... 13
Figure 6.17 Injectors 1, 3, 5, 7............................................................................................................. 13
Figure 6.18 Injectors 2, 4, 6, 8 ............................................................................................................ 13
Figure 6.19 TPS Sensor ...................................................................................................................... 14
Figure 6.20 IAC................................................................................................................................... 14
Figure 6.21 MAF Sensor .................................................................................................................... 14
Figure 6.22 Driver Side Coil Connector.............................................................................................. 14
Figure 6.23 Passenger Side Coil Connector......................................................................................... 14
Figure 6.24 ECT Sensor....................................................................................................................... 14
Figure 6.25 IAT Sensor........................................................................................................................ 15
Figure 6.26 VSS (4L60E)...................................................................................................................... 16
Figure 6.27 Transmission Connection (4L60E)………........................................................................ 16
Figure 6.28 Transmission Connections (T56 manual).....…................................................................. 16
Figure 7.1 Fuse Identification.............................................................................................................. 16
LIST OF TABLES
Table 4.1 Compatible Parts.............................................................................................................. 3
Table 6.1 Dash Section Connections................................................................................................ 9
Table 6.2 Engine Section Connections............................................................................................. 11
Table 6.3 Tail Section Connections.................................................................................................. 15
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1.0 INTRODUCTION
We at Painless Performance Products believe you have purchased the most up-to-date and easiest to install
automotive fuel injection harness on the market. All components to this harness are new. All harnesses are tested
for faults before they leave the factory floor. This harness is designed for easy installation, even if you have no
electrical experience.
The 60506-7 harness is designed to be a complete wiring system for the fuel injection system on General Motors
1997-98 LS1 injected engines and to control the 4L60E automatic or T56 manual transmission using the 1998
computer Service #16238212. The 60508-9 harness is designed to be a complete wiring system for the fuel injection
system on a 1999-02 LS1 with a T56 manual or a 4L60E automatic transmission. Factory computers from 1999-02
Camaros or Firebirds, equipped with the LS1, may be used with this harness. These computers were service number
9354896 or 12200411. These harnesses include all wiring that is needed by the computer to run and control the fuel
injection system and transmission. A module has been included to bypass the vehicle anti theft system (VATS)
incorporated in the computer from the factory. This harness along with the VATS module included in the kit will get
the LS1 engine and transmission up and operating. It is recommended that you 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 recommend 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. You cannot run a 4L60E
transmission with a computer programmed for a T56.
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.
These fuel injection system harnesses have been divided into the following 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, gear shift indicator wiring,
tachometer wiring, VATS, fuse block, fuel pump relay connector
(These emission sections are not included in the 60508-9 harnesses) air pump, air bleed,
canister purge, canister vent, air pump and air solenoid relays.
TAIL GROUP Includes VSS wiring, transmission wiring and a power wire for the fuel pump
.
2.0 ABOUT THESE INSTRUCTIONS
These instructions provide information for the installation of the 60506, 60507, 60508 & 60509 LS1 fuel injection
harness kits. The contents of these instructions are divided into the following major sections:
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 GM LS1 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 illustrations and
the Table numbers refer to information in tables. 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. 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 using the T56 transmission, read Paragraph 4.1.1, then skip to the note at the end of the page. If you are
using the 4L60E, then skip Paragraph 4.1.1, and start at paragraph 4.1.2.
4.1.1 If you are using a T56 transmission, tape off and store the purple and pink (brake switch) wires,
the orange/black and black/white (gear indicator switch) wires in the dash group and the 13position (transmission) round connector in the tail section. Plug in the skip shift solenoid, reverse
lockout solenoid and vehicle speed sensor connector to the transmission as shown in Figure 6.28.
We have included a wire to turn on a skip shift light if you are planning on using one. This wire is
white/black and provides a ground to the skip shift light. You must connect power to the other side
of the light.
4.1.2 If you ARE going to use a 4L60E transmission, tape off and store the skip shift light wire, skip
shift solenoid and reverse lockout solenoid connectors. You must use the vehicle speed sensor
(VSS), correct brake switch and a gear indicator 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.
NOTE: Emission devices
The 60506-7 harnesses have provisions for the emission devices. We have rolled up the canister
purge, canister vent, air pump and air bleed solenoid wiring in the dash section and it may be left
there if these items are not to be used. If you plan on using these items you will need to route these
wires out to the engine compartment. Secure the wires to the main harness using the tie wraps
supplied.
The 60508-9 harnesses have no emission wiring included.
2
4.2 YOU SHOULD GET TO KNOW THE PARTICULAR ENGINE YOU ARE USING:
NOTE: The 1997-02 LS1 engine had four oxygen sensors from the factory. We have included
provisions for only two oxygen sensors, which include one on the driver side and one on the
passenger side of the engine. We have 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. This system has two rectangular connectors at the computer.
4.2.1 PPPI recommends the use of the following parts. See Table 4.1A for 60506-7 or 4.1B for 60508-
9. 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 either under the dash or in the kick panel on the passenger 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.
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.
LS1 Fuel Injection Harness (97 - 98) Part # 60506 & 60507
Main Computer…………………Service #16238212
Fuel Pump Relay………………..Delco# 15-8240
Brake Switch…………………….Delco# D850A
Gear Indicator Switch…………...Delco# D2286A
Intake Air Temperature………….Delco# 213-243
MAF Sensor……………………..Delco# 213-353
Engine Coolant Temperature……GM# 12551708
Oxygen Sensor (Pass. Side)……..Delco# AFS97
Oxygen Sensor (Drvr. Side)……..Delco# AFS98
TPS Sensor………………………Delco# 213-912
MAP Sensor…………………..…Delco# 213-331
Idle Air Control Motor…………..GM# 17113391
Table 4.1A 60506-7 Compatible Parts
Knock Sensors…………………...Delco# 213-362
EGR Valve……………………….Delco# 214-5597
Coils………………………….…..Delco# D580
Cam Position Sensor……………..Delco# 213-355
Crankshaft Position Sensor………Delco# 213-354
Air Pump…………………………Delco# 215-353
Air Pump Relay………..………...Delco# 15-8426
Air Solenoid Relay………………Delco# 15-8426
Air Bleed Solenoid………………GM# 1997201
Canister Purge Solenoid…………GM# 1997278
Canister Vent Solenoid…………..GM# 24574755
VSS(4L60E Only)……………….Delco# 213-328
3
LS1 Fuel Injection Harness (99 - 02) Part # 60508 & 60509
Main Computer…………………Service #9354896
Service #12200411
Fuel Pump Relay………………..Delco #15-8240
Brake Switch…………………….Delco #D850A
Gear Indicator Switch…………...Delco #D2286A
Intake Air Temperature………….GM #12160244
Delco #213-243
MAF Sensor……………………..GM #25179711
Engine Coolant Temperature……GM #5326388
Delco #213-953
Oxygen Sensor (Pass. Side)……..GM #25312196
Delco #AFS97
Oxygen Sensor (Drvr. Side)……..GM #25312197
Delco #AFS98
TPS Sensor………………………GM #17123852
Delco #213-912
MAP Sensor…………………..…GM #16212460
Delco #213-331
Idle Air Control Motor…………..GM #17113391
Knock Sensors…………………...GM #10456603
Delco# 213-362
Coils………………………….…..GM #12558948
Delco# D580
Cam Position Sensor……………..GM #12561211
Delco# 213-363
Crankshaft Position Sensor………GM #12560228
Delco# 213-354
VSS(4L60E Only)……………….Delco# 213-328
Table 4.1B 60508-9 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 and pressure regulator you are using MUST
PSI
(pounds per square inch). If using a higher pressure pump you must add an inline regulator to
bring the pressure down to the 55-60 range since the LS1 fuel system does not have a built-in
regulator on the fuel rail as in many earlier GM fuel injection systems.
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.
to make sure none of the pins in
maintain a constant pressure of 55-60
4
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