Painless Performance 60520, 90543, 60521 User Manual
P/N 60520 & 60521
2005-06 GM LS2 FUEL INJECTION WIRE
HARNESS INSTALLATION INSTRUCTIONS
Manual P/N 90543
First Edition June 12, 2006
PAINLESS PERFORMANCE PRODUCTS
2501 Ludelle Street - Fort Worth, Texas 76105-1036 - (800) 423-9696
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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............................................................................................... 4
5.3 HARNESS ATTACHMENT........................................................................................... 5
5.4 TERMINAL INSTALLATION INSTRUCTIONS.......................................................... 5
6.0 GM LS2 SYSTEM WIRE HARNESS INSTALLATION...................................................... 6
6.1 DASH SECTION CONNECTIONS…………................................................................ 10
6.2 ENGINE GROUP INSTALLATIONS........................................................................... 11
6.3 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 ............................................................................................... 8
Figure 6.3 Brake Switch Relay......................................................................................................... 8
Figure 6.4 Gear Indicator Switch ..................................................................................................... 9
Figure 6.5 Fuel Pump Relay ............................................................................................................ 9
Figure 6.6 Cruise Control Switch ................................................................................................. 10
Figure 6.7 Alternator…………….................................................................................................... 12
Figure 6.8 Knock Sensor Driver Side........................................................................................ 12
Figure 6.9 Oxygen Sensor…............................................................................................................ 12
Figure 6.10 MAP Sensor …………………............................................................................................. 12
Figure 6.11 Cam Position Sensor............................................................................................................ 12
Figure 6.12 Crank Position Sensor.................................................................................................. 12
Figure 6.13 Injectors 1, 3, 5, 7................................................................................................................ 13
Figure 6.14 Injectors 2, 4, 6, 8................................................................................................................ 13
Figure 6.15 Throttle Body………....................................................................................................... 13
Figure 6.16 Accelerator Pedal........................................................................................................... 13
Figure 6.17 MAF and IAT............................................................................................................. 13
Figure 6.18 Driver Side Coil Connector................................................................................................. 13
Figure 6.19 Passenger Side Coil Connector........................................................................................ 14
Figure 6.20 ECT Sensor...................................................................................................................... 14
Figure 6.21 Oil Pressure Sensor .......................................................................................................... 14
Figure 6.22 TAC Module………………............................................................................................. 14
Figure 6.23 Passenger Side Knock Sensor……………………………………………………………….14
Figure 6.24 VSS (4L60E)…………………......................................................................................... 15
Figure 6.25 Transmission Connection (4L60E)................................................................................... 15
Figure 6.26 Transmission Connections (T56 manual)......................................................................... 16
Figure 7.1 Fuse Identification............................................................................................................. 16
Figure 7.2 Engine Code Sticker…………………………………………………………………………18
Figure 7.3-7.9 Diagnostic trouble codes…………………....................................................................... 19-25
LIST OF TABLES
Table 4.1 Compatible Parts.............................................................................................................. 3
Table 6.1 Dash Section Connections................................................................................................ 10
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. Please read entire manual before installation.
The 60520-21 harnesses are complete wiring systems for the fuel injection systems on General Motors throttle-by-
wire LS2 fuel injected engines and to control the 4L60E/4L65E automatic or T56 manual transmission. Engines
with codes ZJA, ZJB, 5MC, YTA and 6MC are supported by this harness (see page 18). Factory 2002-03 LS6
computers with service number 12200411 are to be used with this harness. The computer must have 2002-03 ZO6
Corvette programming. The factory accelerator pedal and TAC module from the 2003 Corvette must also be used.
If the pedal and TAC module are not taken from the donor vehicle they can be purchased new. See page three for
correct part numbers. Factory Corvette computers have an anti-theft feature programmed into them. Before the
engine will run this anti-theft feature must be programmed out. These harnesses include all wiring that is needed by
the computer to run and control the fuel injection system and transmission. 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. Good examples of possible unused computer functions are rear O2
sensors, anti-theft (removal required) and emissions (if not using the optional emissions harness and equipment).
NOTE: If you have purchased an LS2 with an engine code other than those listed above, you can still utilize this
fuel injection wire harness after these engine modifications are made. Contact your local engine machinist
shop for help with these modifications.
1. The 58X crank shaft sensor reluctor wheel must be replaced with part number 12559353. This
replacement part number is a 24X crank shaft reluctor wheel from a 2005 Corvette LS2.
2. The crank shaft position sensor must be replaced with the part number 12560228.
3. The 4X camshaft sprocket must be replaced with part number 12576407. This is a 2X sprocket from a
2005 Corvette.
4. The cam shaft position sensor must be replaced with part number 12568983.
NOTE: Most remanufactured computers come without any programming and must be programmed before they can
be used.
NOTE: The program in your computer must match the transmission that you plan on using. For instance, 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 and charging system, and engine 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, fuse block, ECM connectors, TAC module connector, fuel pump relay
connector, cruise control wiring, accelerator pedal position to TAC module wiring.
TAIL GROUP Includes transmission wiring and a power wire for the fuel pump
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2.0 ABOUT THESE INSTRUCTIONS
These instructions provide information for the installation of the 60520 & 60521 LS2 throttle-by-wire 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
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5.0 GENERAL INSTALLATION INSTRUCTIONS
6.0 GM LS2 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.
3.0 TOOLS NEEDED
In addition to your regular tools you will need 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:
NOTE: Emission devices
The 60520-21 harnesses have no emission wiring included. The emissions kits are sold
separately. If you are planning on connecting the factory emissions it is recommended to
purchase the emissions harness and install it at the same time as the main harness.
4.1 TRANSMISSION FUNCTION
4.1.1 T-56
4.1.2 4L60E
If you are using a T56 transmission, tape off and store the orange/black and black/white
(gear indicator switch) wires in the dash group and the 13-position (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.
If you are using 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.
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4.2 YOU SHOULD GET TO KNOW THE PARTICULAR ENGINE YOU ARE USING:
NOTE: The 2005-2006 LS2 engines 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.
4.2.1 PPPI recommends the use of the following parts. See Table 4.1 for 60520-21. These will meet all
requirements and are compatible with PPPI harnesses. The numbers given are GM and AC Delco
part numbers.
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, TAC module, accelerator pedal and fuel pump
relay 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 and covered for protection. Use nylon ties, poly
split loom or POWERBRAID.
LS2 Fuel Injection Harness (‘05-‘06) Part # 60520 & 60521
Main Computer…………………Service #12200411
Fuel Pump Relay………………..Delco# 15-8240
Brake Switch…………………….Delco# D850A
Gear Indicator Switch…………...Delco# D2286A
MAF/IAT Sensor………………..Delco# 213-364
GM# 25318411
Engine Coolant Temperature……Delco# 213-953
GM# 15326388
Oxygen Sensor (Pass&Drvr Side) Delco# AFS75
GM# 25312184
MAP Sensor…………………..…Delco# 213-331
GM# 16212460
Oil Pressure………………………GM# 12573107
Table 4.1 60520-21 Compatible Parts
Knock Sensors (Pass&Drvr Side) Delco# 213-362
GM #10456603
Coils…………………….…..…....GM #12570616
GM# 12573190
Cam Position Sensor……………..GM #12568983
Crankshaft Position Sensor………GM #12560228
Delco# 213-354
Throttle Body………………....….GM# 12570790
TAC Module……………….….....GM# 12578953
Cruise Control Switch………....…GM# 25111262
Accelerator Pedal………….……..GM# 12565643
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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.
~ 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
(pounds per square inch). If using a higher pressure pump you must add an inline regulator to
PSI
bring the pressure down to the 55-60 range since the LS2 fuel system does not have a built-in
regulator on the fuel rail. AC Delco part #GF822 is a fuel filter with a built in regulator set at the
stock fuel pressure for these LS2 engines.
to make sure none of the pins in
maintain a constant pressure of 55-60
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.
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 Position the computer and TAC module in their intended locations.
5.2.2 Drill a 1-5/8" hole for the firewall grommet near the computer for the engine group and tail section
to pass through.
5.2.3 Route the engine group and transmission section through the hole. Push the grommet (already
installed on the harness) into the hole until it is seated.
5.2.4 Route the dash group over to the driver's side of the car.
5.2.5 Route the fuse block and relays to the place they will be mounted.
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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 Permanently mount your computer. You should mount the fuse block, TAC Module and fuel pump
relay at this time. Mount the accelerator pedal. Note the pigtail that plugs into the accelerator
pedal and then to the TAC module is either 8ft or 12ft long depending on the harness purchased.
Make sure the pigtail wires are not routed near any moving parts of the brake, clutch or accelerator
pedal.
5.3.2 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.
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
CHECKING
These directions are for the wires, which do not have a connector already, installed on them.
5.4.1 Have all tools and connectors handy.
5.4.2 Select the correct terminal for the wire and application.
5.4.3 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.
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 the proper die in the
crimping tool. An improper crimp will not make a good connection. DO NOT OVERCRIMP THE TERMINAL.
5.4.5 Crimp the terminal onto the wire.
5.4.6 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 When all the wires are attached, tighten the mounts and ties to secure the harness permanently.
5.4.8 Attach the connectors to the computer. BE VERY CAREFUL NOT TO BEND ANY PINS.
5.4.9 After all connections have been made throughout the harness, connect the battery to the vehicle.
your length calculations before cutting any wire or making any connections.
, and continually refer to the wire charts, DOUBLE
CAUTION: BE SURE THE IGNITION IS OFF WHEN YOU RECONNECT THE BATTERY
OR YOU CAN DAMAGE THE COMPUTER.
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6.0 GM 2005-06 LS2 SYSTEM WIRE HARNESS INSTALLATION INSTRUCTIONS
6.1 CONTENTS OF THE 60520-21 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 (817) 244-6898. The kit should contain the
following items:
~ The main fuel injection wire harness.
~ Fuel Injection Installation Instructions P/N 90543 (This Booklet).
~ 4” & 7” tie wraps.
~ TAC Module to Accelerator Pedal Pigtail
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.
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), cruise control wires, gear indicator switch wires, clutch
pedal position wires, brake switch wires, fuse block ignition wire and tachometer wires.
Note: You may need to connect the check engine light wires to their mates in the wire harness.
Note: Wire color (Example: Blk/Wht) is a black wire with a white stripe. The second color (the
stripe) may not be bold. Observe all two-color wires closely.
Note: All connectors are labeled on the harness.
Note: All individual components are labeled on the harness.
CAUTION: DO NOT MAKE ANY CONNECTIONS WHILE THE COMPUTER IS PLUGGED
INTO THE HARNESS.
FIGURE 6.1 DLC Connector & Check Engine Light
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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. Mount the DLC connector using the bracket containing the check engine light in the place
selected.
C. Locate the 18 gauge, pink, ignition hot activation wire labeled FUSE BLOCK IGNITION and
attach it to a fused, 12 volt 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 pink wire is connected correctly the check engine light
will come on when the ignition switch is in the ON or START position. Do not connect the
battery to test this until all connections are made.
D. 4L60E only:
the Gear INDICATOR
vehicle is in park or neutral. The Blk/Wht wire is a supplied ground wire for the gear indicator
switch. If you have a GM column then you can use the combination switch Delco P/N D2286A
and wire it as described in paragraph two or three below. The ORN/BLK wire needs to be
grounded in park and neutral and ungrounded in drive. This can also be done with a toggle switch
or a switch on the parking brake. NOTE: The Orn/Blk and Blk/Wht wires are only needed if
using a 4L60E transmission. If you are using a manual transmission then you will tape and
stow these wires.
D.1. The recommended switch is a combination reverse light, gear indicator AND neutral safety switch.
You may use it for all these purposes if you wire it EXACTLY as shown in Figure 6.4
Illustration B
D.2. If you are going to use the recommended switch as a gear indicator for the computers benefit
ONLY, then you will wire it as shown in Figure 6.4 Illustration A.
D.3. You may want to install your own switch. This switch must connect the Orn/Blk wire to ground
only when the car is in PARK OR NEUTRAL. Use the Blk/Wht wire to supply ground to this
switch. The other end of the Blk/Wht wire is already grounded throughout the harness.
E. Manual Transmission only
these wires to a normally closed switch on the clutch pedal assembly. These wires need contact
between them when the clutch pedal is not depressed and loose contact between them when the
clutch pedal is depressed.
F. The Purple, Pink and Lt.Blue wires labeled BRAKE SWITCH are the wires that connect to the
brake switch. The Purple and Pink wires are connected to the normally closed side of the brake
switch. Pink is power and Purple is signal to let the computer know when the brake is applied.
These wires must be connected so the lock up function of the torque converter will operate
correctly. If you are not using a 4L60E then tape off and store these two wires. Connect the Lt.
Blue wire to the normally open brake lamp side of the brake switch regardless of which
transmission you are using. See Figure 6.2.
Locate the Org/Blk and Blk/Wht wires in the dash group. These two wires are for
Switch. The Org/Blk wire is the signal wire for the ECM to know the
: Locate the gray and pink Clutch Pedal Position wires. Connect
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