Painless Performance LS2 User's Manual
Contents
1. 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 Ifyou 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 4 1 2 4L60E 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 relay2. harness and wires at places where movement could occur DOUBLE CHECK YOUR CALCULATIONS Strip insulation away from wire Only strip as much insulation off as necessary for the type of terminal lug you are using 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 OVER CRIMP THE TERMINAL Crimp the terminal onto the wire 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 When all the wires are attached tighten the mounts and ties to secure the harness permanently Attach the connectors to the computer BE VERY CAREFUL NOT TO BEND ANY PINS After all connections have been made throughout the harness connect the battery to the vehicle BE SURE THE IGNITION IS OFF WHEN YOU RECONNECT THE BATTERY OR YOU CAN DAMAGE THE COMPUTER 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 amp
3. If your vehicle has a pressure type brake switch you may use a relay as shown in Figure 6 3 The relay must be a SPDT Relay and wired correctly or it could result in a dangerous situation with the vehicle The torque converter may not unlock 10 ILLUSTRATION A Bik Wht Orn Bik PE e RSX Xx K ING ILLUSTRATION B To Reverse Lamps Power for Reverse Lamps 12V IGN From Ignition Switch Bik Wht wire is capped off and stowed FIGURE 6 4 Gear Indicator Switch CAUTION FAILURE TO WIRE THIS SWITCH CORRECTLY WILL RESULT IN A DANGEROUS SITUATION ON THE VEHICLE Illustration A is for Park Neutral only Illustration B is for Park Neutral Reverse and Gear Indicator H Plug in the fuel pump relay to the fuel pump relay connector The wire labeled FUEL TEST is a test point for the fuel pump After the vehicle has been wired and tested tape off this wire and store it in the harness FIGURE 6 5 Fuel Pump Relay Connector 11 I Fan 1 relay wire green and fan 2 relay wire blue are relay ground wires activated by the computer The factory cooling fan settings are listed below Note Fan 1 will come ON at 226 f and go OFF at 217 f Fan 2 will come ON at 235 f and go OFF at 226 f J The wire labeled TACH white is the signal wire for a tachometer if used A tachometer filter might need to be purchased depending on the brand of tachometer used The VSS output wire green white sends out a signal to operate a
4. Light Skip Shift Light Clutch Pedal Pos CPP Switch Cruise Control Cruise Switch Pink Purple Lt Blu Pink Green Blue White Black Gry Pnk Pnk Blu Wht Gry Blk Gry BNR ole VIN a BR Table 6 1 Dash Section 12 6 3 ENGINE GROUP INSTALLATIONS The engine group is designed to be separated into left side driver and right side passenger sections Each side is tie wrapped separately BUT NOT LABELED The left side of the engine has the connectors for the cam position sensor alternator and engine coolant sensor all of which ARE labeled When you begin routing FIRST separate the engine group into left and right sections and place them accordingly 6 3 1 Before you connect any wires separate the tail section from the engine group and place it out of the way 6 3 2 Connect the two ring terminals labeled STARTER B with Red wires to the large battery terminal on the starter solenoid 6 3 3 Locate the three large ring terminals with Black and BIk Wht wires and ground them to the engine 6 3 4 Using Figure 6 7 6 25 and the specific connections indicated in Table 6 2 connect the wiring as directed 6 3 5 Engine Section Connections WIRE COLOR OF WIRES LABELED CONNECT TO Lt Blue Blue Tan White Purple White Black Pink Tan Purple Black Pink Orange Black Lt Green Gray Brown White Red Pink Black Blue White Yellow Black Lt Green Pink Black Pink Lt Green Black Pink Pink Black Pink
5. after the engine starts running If it reappears or stays on while the engine is running the computer has detected a problem and a trouble code has been set NOTE The engine will not run unless the computer has been reprogrammed to remove the antitheft functions The computer will set codes for all unused emissions devices and the check engine light will stay on unless the emission functions are removed RETRIEVING TROUBLE CODES FROM THE COMPUTER 7 2 1 7 2 2 7 2 3 Note 7 2 4 7 2 5 In order to retrieve the trouble codes stored in the computer a scanner must be connected to the Assembly Diagnostic Link DLC connector installed and connected in Paragraph 6 2 1 Follow the instructions provided with the scanner to read the codes set in the computer After you have read any codes write them down for reference Remove the cover from the DLC connector Take the codes one at a time and match them to the codes in a Corvette factory repair manual or to the list at the end of this manual This will tell you what circuit the computer has detected a problem in A code indicates a problem in a specific circuit NOT THAT A PARTICULAR PART IS BAD Before taking more extensive corrective actions for any trouble codes make sure that all connections on the indicated circuit INCLUDING THE COMPUTER are clean and tight Inspect the wiring in the circuit for any broken shorted or exposed wires Finally insure all ground wires are clean a
6. aio 8 Figure 6 3 Brake Switch Relay nsnsi sikers rioto reee r saya ERIN ORE POLIA gina Asti ch ES e ais ri 8 Figure 6 4 Gear Mee ge EE 9 Figure 6 5 Foel Pump Relay ica ALn Alina 9 Figure 6 6 Cruise Control Switch a rostro eil ola aerei 10 Figure 6 7 Alternator conio edi ALA sora Aia 12 Figure 6 8 Knock Sensor Driver Side ener leende bereg Seoses 12 Figure 6 9 Oxygen Sensor ita ARR E eE SE JR Sa rei eb like 12 Figure 6 10 MAP ENSOT siti SERA RONA asa 12 Figure 6 11 Cam Position Sensor visi isti sie ei SEENEN 12 Figure 6 12 Crank Position Sensor 12 Figure 6 13 Injectors T 3 3 E 13 Figure 6 14 Injectors 2 4 E 13 Figure 6 15 Throttle E 13 Figure 6 16 Accelerator Pedal i pla sta lalla Giara lilolane ai ei NA nisi 13 Figure 6 17 ERR E E 13 Figure 6 18 Driver Side Coll Connectot vir ie ssa ani iene 13 Figure 6 19 Passenger Side Coil Connector aliena a a iene 14 Figure 6 20 PC SOEN aio kA bika Rane ian nai dana 14 Figure 6 21 Oil TEE 14 Figure 6 22 Re EE 14 Figure 6 23 Passenger Side Knock Sensor 14 Figure 6 24 KK ei acilia se ie degen eer 15 Figure 6 25 Transmission Connection GL GE 15 Figure 6 26 Transmission Connections T56 manual 16 Figure 7 1 Fuse Identificationi i ae ae NASA AE 16 Figure 7 2 Engine Code Stucke si rari n li EE 18 Figure 7 3 7 9 Diagnostic trouble codes a re renere reen renere r ener nerne rnnee 19 25 LIST OF TABLES Table 4 1 Compatible Parts un sirene
7. 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 amp 60521 Main Computer Service 1220041 1 Knock Sensors Pass amp Drvr Side Delco 213 362 Fuel Pump Relay Delco 15 8240 GM 10456603 Brake Switch Delco D850A i GM 12570616 Gear Indicator Switch Delco D2286A GM 12573190 MAF IAT Sensor Delco 213 364 Cam Position Sensor GM 12568983 GM 25318411 Engine Coolant Temperature Delco 213 953 Crankshaft Position Sensor GM 12560228 GM 15326388 Delco 213 354 Oxygen Sensor Pass amp Drvr Side Delco AFS75 Throttle Body GM 12570790 GM 25312184 MAP Sensor Delco 213 331 TAC Module GM 12578953 GM 16212460 Cruise Control Switch GM 25111262 Oil Pressure GM 12573107 Accelerator Pedal GM 12565643 Table 4 1 60520 21 Compatible Parts 5 0 5 1 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 HARNE
8. are covered under a lifetime warranty All other products manufactured and or sold by Painless Performance are warranted to the original purchaser to be free from defects in material and workmanship under normal use Painless Performance will repair or replace defective products without charge during the first 12 months from the purchase date No products will be considered for warranty without a copy of the purchase receipt showing the sellers name address and date of purchase You must return the product to the dealer you purchased it from to initiate warranty procedures 20 DTC C1277 or P1571 Powertrain Indicated Traction Control Malfunction DTC C1278 TCS Temporarily Inhibited By PCM DTC C1281 C1283 or C1286 VSES Sensors Uncorrected DTC C1292 C1293 or C1296 Master Cylinder Pressure Sensor Circuit FIGURE 7 3 Diagnostic Trouble Codes 21 DTC P0118 Engine Coolant Temperature ECT Sensor Circuit High Voltage Engine Coolant Temperature ECT Insufficient for Closed Loop Fuel DTC P0125 Control Engine Coolant Temperature ECT Below Thermostat Regulating DTC P0128 Temperature DTC P0135 P0141 P0155 or P0161 HO2S Heater Performance DTC P0137 or P0157 HO2S Circuit Low Voltage DTC P0138 or P0158 HO2S Circuit High Voltage Crankshaft Position CKP Sensor Circuit FIGURE 7 4 Diagnostic Trouble Codes 22 FIGURE 7 5 Diagnostic Trouble Codes 23 DTC P0601 P0607 P1600 P1621 P1627 P1680 P1681 P16
9. 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 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 Attach harness groups to your automobile with clips or ties starting at the computer and working your way outward Do not tighten tie wraps or mounting devices at this time Make all harness attachments LOOSELY 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 5 4 1 5 4 2 5 4 3 5 4 4 Note 5 4 5 5 4 6 5 4 7 5 4 8 5 4 9 CAUTION In the following steps you will be making the circuit connections Before you start you should carefully read Sections 6 0 and continually refer to the wire charts DOUBLE CHECKING your length calculations before cutting any wire or making any connections These directions are for the wires which do not have a connector already installed on them Have all tools and connectors handy Select the correct terminal for the wire and application Determine the correct wire length and cut the wire Remember to allow enough slack in the
10. lil ses Anali asta line 3 Table 6 1 Dash Section Connections iii 10 Table 6 2 Engine Section Connections iii 11 Table 6 3 Fail Section Connections vi iaia Reit 15 TABLE OF CONTENTS 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 SMC 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 i
11. must be installed to unlock the converter when the brakes are applied 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 24 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
12. speedometer The wire labeled SKIP SHIFT LIGHT white black is only used with the T56 manual transmission The computer grounds this wire to turn on the skip shift light if used M Cruise Control There are four cruise control wires in this harness Most late model GM steering columns years 1983 1993 already have or can be retrofitted with a cruise control switch See Figure 6 6 for the proper connection of these wires to a factory GM cruise control switch part number 25111262 This harness kit does not include the connector needed because it has been discontinued by Delphi The Pink wire is power connector pin A The Gray wire is the cruise control on switch signal connector pin B The Blu Wht wire is the cruise control set coast switch signal connector pin D The Gry Blk wire is the cruise control resume accel switch signal connector pin C PA nez gt CRUISE pON OFF ON RJA WIPER E SS he LJ A Y FIGURE 6 6 Cruise Control N Connect the TAC Module Pigtail to the TAC Module and the Accelerator Pedal 6 2 2 Dash Section Connections WIRE COLOR OF WIRES LABELED CONNECT TO Grn Blk BIk Wht Orn DLC Gray Grn Wht Black Orange Fuel Relay Fuel Pump Relay Green White VSS Output Speedometer White Tach Tachometer Orange Black Black White Gear Indicator Gear Indicator Switch Brake Switch Brake Switch Fuse Block Ignition Ignition Power Fan 1 Relay Coolant Fan 1 Relay Fan 2 Relay Coolant Fan 2 Relay Skip Shift
13. 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 BIk 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 amp Check Engine Light DL D 2 D 3 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 Mount the DLC connector using the bracket containing the check engine light in the place selected Locate the 18 gauge pink ig
14. 83 or P2610 ECU Malfunction FIGURE 7 6 Diagnostic Trouble Codes 24 Engine Coolant Temperature ECT Sensor Circuit Intermittent High DTC P1115 Voltage FIGURE 7 7 Diagnostic Trouble Codes 25 FIGURE 7 8 Diagnostic Trouble Codes 26 DTC P1514 Throttle Body Performance DTC P1515 Control Module Throttle Actuator Position Performance Throttle Actuator Control TAC Module Throttle Actuator Position DTC P1516 Performance DTC U1300 U1301 or U1305 Class 2 Data Link Shorted FIGURE 7 9 Diagnostic Trouble Codes 27
15. Lt Blue Black Pink Black White Pink Yellow Black Pink Red Black Pink Blue White Blue Grn Ppl Brn Pnk Ylw Yellow Black White Pink Purple Tan Black Yellow Purple Red Green Lt Blue Brown Black Pink Red White Purple White Lt Blu Wht Grn Wht Brn Wht Blk Pnk Black 3 Black White 3 Red 2 Red Grey Tn Wht Blk Gry Knock 2 Passenger Side Knock Sensor Knock 1 Driver Side Knock Sensor Drvr Side Oxy Driver Side Oxygen Sensor Pass Side Oxy Pass Side Oxygen Sensor MAP MAP Sensor CMP Cam Position Sensor CKP Crankshaft Position Sensor Inj 1 Driver Side Front Injector Inj 2 Passenger Side Front Injector Inj 3 Driver Side 2 Injector Inj 4 Passenger Side 2 Injector Inj 5 Driver Side 3 Injector Inj 6 Passenger Side 3 Injector Inj 7 Driver Side Rear Injector Inj 8 Passenger Side Rear Injector Throttle Body Throttle Body MAF IAT MAF IAT Sensor ECT Engine Coolant Temp Sensor Drvr Coils Driver Side Coil Connector NNIAISSNNNNNNNN WND BB Se Pass Coils Pass Side Coil Connector a Ground Engine Ground Starter B Starter Solenoid Batt Term Alt Alternator Oil Pressure Oil Pressure Sensor LA AM Ch 1 Knock sensors will thread into the extra mounting holes on each side of the engine block See Figure 6 8 and Figure 6 23 for the correct location to install the knock sensors TABLE 6 2 60520 21 Engine Section Connections 13 CAM POSITION SENSOR i LE
16. PERFORMANCE PRODUCTS P N 60520 amp 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 1 0 INTRODUCTION usa RE eck EE Ee 1 2 0 ABOUT THESE INSTRUCTIONS rire 1 3 0 TOOLS NEEDED tn lib Wai chek ed ee EURI a lee 2 4 0 PRE INSTALLATION AND HARNESS ROUTING GUIDELINES in 2 4 1 TRANSMISSION FUNCTION 2 4 2 GET TO KNOW THE ENGINE THAT YOU ARE USING 3 5 0 GENERAL INSTALLATION INSTRUCTIONS ene 4 5 1 GROUNDING THE VEHICLE rosende 4 5 2 ROUGH INSTALLA TIONG ss si ara SpA a Lelio 4 5 3 HARNESS ATTACHMENTS RIA anale 5 5 4 TERMINAL INSTALLATION INSTRUCTIONS i 5 6 0 GM LS2 SYSTEM WIRE HARNESS INSTALLATION eee renerne renerne rene nnnee 6 6 1 DASH SECTION CONNECTIONS igc5 ira iaia 10 6 2 ENGINE GROUP INSTALLATIONS ren ane 11 6 3 TAIL SECTION INSTALLATIONS a annenenennna 15 7 0 TROUBLE SHOOTING INSTRUCTIONS nena 16 7 1 THE CHECK ENGINE LIGH Donci eios aa id Ea Rioni 16 7 2 RETRIEVING TROUBLE CODES FROM THE COMPUTER 17 7 3 WHEN TO CALL PAINLESS WIRING TECH LIN renere ene 17 LIST OF FIGURES Figure 6 1 Diagnostic Link Connector DLC amp Check Engine Light 1 W u u senseeeererrersere erne rnnee 6 Figure 6 2 Brake Switch Connection session a pa ite
17. SS 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 to make sure none of the pins in the computer are or become bent The fuel pump and pressure regulator you are using MUST maintain a constant pressure of 55 60 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 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 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 5 2 Note The installer of this harness is responsible for all ground wires not provided with this part 5 1 1 Connect a ground s
18. a FIGURE 6 11 Cam Position Sensor FIGURE 6 12 Crank Position Sensor 14 EN INJ 8 INJ 6 INJ 4 INT 2 5 INI 7 E j THROTTLE d o FIGURE 6 15 Throttle body FIGURE 6 16 Accelerator Pedal Connector plugs in here FIGURE 6 17 MAF AT Sensor FIGURE 6 18 Driver Side Coil Connector 15 PASSENGER COILS FIGURE 6 19 Passenger Side Coil Connector FIGURE 6 20 ECT Sensor FIGURE 6 23 Passenger Side Knock Sensor This knock sensor threads into the engine block behind the starter 16 6 4 TAILS 6 4 1 6 4 2 6 4 3 6 4 4 6 4 5 6 4 6 ECTION INSTALLATION Locate the tail section that you earlier separated from the engine group Begin routing it towards the rear of the vehicle Be sure to avoid all sharp edges moving or hot parts or anything else that may damage the harness If you ARE using the 4L60E transmission route the 13 position connector to the transmission and plug it in Tape up the reverse lockout and skip shift solenoid connectors and store them in the harness If you ARE using the T56 manual transmission route the reverse lockout and skip shift solenoid connectors to the transmission and attach them Tape up the 13 position connector labeled TRANS and store it in the harness Take the connector for the Vehicle Speed Sensor VSS and connect to the Vehicle Speed Sensor Take the gray wire labeled FUEL PUMP and route it to the fuel pump This is the power wire for the
19. agraphs 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
20. fuel pump Tail Section Connections WIRE COLO R OF WIRES LABELED CONNECT TO Purple White Lt Grn Black 2 VSS Vehicle Speed Sensor 2 Reverse Lockout Sol Reverse Lockout Solenoid 2 Skip Shift Sol Skip Shift Solenoid Pink Lt Green Pink Gray Blue Pink 2 Lt Green Red Brown Yellow Red Orange Black White Transmission Transmission 4L60E Tan Black Lt Yellow Black Gray Blue White Red Black Fuel Pump Fuel Pump Power Term TABLE 6 3 Tail Section Connections FIGURE 6 24 VSS 4L60E FIGURE 6 25 Transmission Connection 4L60E 17 Skip Shift Solenoid Reverse Lockout Solenoid FIGURE 6 26 Transmission Connections T56 7 0 TROUBLE SHOOTING INSTRUCTIONS If you are having trouble with your engine running badly or not running at all first perform basic trouble shooting ensure that you are using the correct parts Table 4 1 check for faulty connections blown fuses spark fuel pressure etc then see if the computer has stored a trouble code in its memory DRIVER SIDE INJECTORS amp COILS TRANSMISSION TAC MODULE PASSENGER SIDE G INJECTORS OXY SENSORS BRAKE SWITCH MAF SENSOR PCM amp MIL LIGHT d KEY ON POWER DLC CONSTANT CONSTANT POWER POWER FIGURE 7 1 60522 23 Fuse Identification 18 7 1 7 2 7 3 THE CHECK ENGINE LIGHT Normally the check engine light should come on when the ignition is turned on and then go out a few moments
21. gear indicator for the computers benefit ONLY then you will wire it as shown in Figure 6 4 Illustration A 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 BIk Wht wire to supply ground to this switch The other end of the Blk Wht wire is already grounded throughout the harness Manual Transmission only Locate the gray and pink Clutch Pedal Position wires Connect 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 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 Power 12V Power 12V Lt Blue PURPLE To Brake Lamps Brake Light 30 Amp SPDT Relay Purple Brake Switch LS1 Harness Brake Switch 12 Volts Wires FIGURE 6 3 Brake Switch Relay
22. nclude 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
23. nd secure If a trouble code is detected and the problem has been fixed clear the codes by first making sure the ignition is off then disconnecting the NEGATIVE battery cable for at least 3 minutes WHEN TO CALL PAINLESS PERFORMANCE PRODUCTS TECH LINE 7 3 1 7 3 2 These harness kits have been built with the highest regard to quality control Before calling us please double check all connections and perform normal basic trouble shooting fuel pressure timing ignition system etc If you have any questions concerning the installation of this harness or having trouble in general feel free to call Painless Performance Products tech line at 817 423 9696 Calls are answered from 8am to 5pm central time Monday thru Friday except holidays Email questions to Tech painlessperformance com 19 The Engine Code Sticker is located at the back of the driver side head Figure 7 2 Engine Code Sticker We have attempted to provide you with the most accurate instructions 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 817 244 4024 We sincerely appreciate your business Painless Performance Limited Warranty and Return Policy Chassis harnesses and fuel injection harnesses
24. nition 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 4L60E only Locate the Org Blk and BIk Wht wires in the dash group These two wires are for the Gear INDICATOR Switch The Org BIk wire is the signal wire for the ECM to know the 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 BIk and BIK 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 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 If you are going to use the recommended switch as a
25. 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 2 0 ABOUT THESE INSTRUCTIONS These instructions provide information for the installation of the 60520 amp 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 3 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 Par
26. trap 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 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 5 3 HARNESS ATTACHMENT Note 5 3 1 5 3 2 5 3 3 Note 5 3 4 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 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
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