Painless Performance Products 20110 User manual

Wire Harness Installation
Instructions
For Installing:
#20110 Classic Customizable Chevy II/Nova
1966-67 Harness 21 Circuit
Manual #90522

Painless Performance Products, LLC
2501 Ludelle Street
Fort Worth, TX 76105-1036
800-423-9696 phone –817-244-4024 fax
Web Site: www.painlessperformance.com
E-Mail: [e-mail]
If you have any questions concerning the installation of this product,
feel free to call Painless Performance Products' tech line at 1-800-423-
9696. Calls are answered from 8am to 5pm central time, Monday thru
Thursday, 8am-4:30pm Friday, except holidays.
Here we have provided you with accurate instructions for the
installation of this product. However, if you have comments/suggestions
concerning these instructions, please call or email us (our contact
information can be found at the top of this page or online at
www.painlessperformance.com).We sincerely appreciate your business.
Painless 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, 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.
Should you damage or lose part of your manual, a full color copy of
these instructions can be found online at www.painlessperformance.com
Installation Manual: 90522
1st Edition: January 14, 2014
Copyright 2002 by Painless Performance Products, LLC

NOTE :
If your vehicle has an existing harness, you will want to retain it for the
possible re-use of various Pigtails & Connector housings, particular to your
application.
Included in this kit is a sheet of pre-printed labels, to assist in
identifying of connections as the existing harness is removed from
the vehicle.
If you do not have an existing harness, there is a package of terminals
included with the harness that will enable you to make most of the connections
needed. Replacement lighting pigtails & sockets can be readily obtained from
your local parts distributor

TABLE OF CONTENTS
List of Figures.………………………………………………………………………… ii
List of Tables.…………………………………………………………………………. ii
1.0 Introduction…………………………………………………………………………………………………….. 1
2.0 About These Instructions…………………………………………………………………………………... 1
3.0 Contents Of The Painless Performance Wire Harness Kit (Part #20110)…………………. 2
4.0 Tools Needed…………………………………………………………………………………………………… 3
5.0 Removal of Original Wire Harness………………………………………………………………………. 3
6.0 Pre-installation and General Harness Routing Guidelines………………………………………. 4
7.0 General Harness Installation Instructions…………………………………………………………….. 4
7.1 Rough Installation…………………………………………………………………………………. 4
7.2 Terminal Installation and Making Connections …………………………………………. 5
7.3 Grounding The Automobile…………………………………………………………………….. 5
8.0 Harness Attachment by Section…………………………………………………………..……………… 6
8.1 Fuseblock Mounting……………………………………………..……………………………….. 6
8.2 Tail/Dome Section Connections………………………….…………………………………… 7
8.3 Engine Section Connections……………………………………………………………………. 11
8.4 Headlight Section Connections………………………………………………………………… 14
8.5 Dash Section Connections…………………...………………………………………………… 15
9.0 Testing the System……………………………………………………………………………………………. 19
10.0 Wire Connection Index and Fuse Requirements……………………………………………………. 19
10.1 Fuse Requirements………………………………………………………………………………… 19
10.2 Wire Connection Index…………………………………………………………………………… 20
i

LIST OF FIGURES
Figure 3.1 The Painless Performance Wire Harness Kit (Part #20110)………………………. 2
Figure 5.1 Engine and Front Harness…………………………………………………………………….. 3
Figure 5.2 Original Fuseblock………………………………………………………………………………… 3
Figure 8.1 Pre-Routing Engine and Headlight Sections…………………………………………….. 6
Figure 8.2 Screws Securing Adapter Bracket…………………………………………………………… 6
Figure 8.3 Fuseblock Mounted……………………………………………………………………………….. 7
Figure 8.4 Routing Dome Light Wires……………………………………………………………………… 7
Figure 8.5 Door Jamb Switch…………………………………………………………………………………. 8
Figure 8.6 Driver Kick Panel and Jamb Routing………………………………………………………… 8
Figure 8.7 Wire Routing in Trunk……………………………………………………………………………. 9
Figure 8.8 Fuel Sender Wire Routing……………………………………………………………………….. 9
Figure 8.9 License Plate Wire Routing……………………………………………………………………… 10
Figure 8.10 Backup and Brake/Tail Sockets……………………………………………………………….. 10
Figure 8.11 Wiper Motor and Engine Wire Routing……………………………………………………... 11
Figure 8.12 Wiper Motor Connections………………………………………………………………………… 11
Figure 8.13 Maxi Fuse………………………………………………………………………………………………. 12
Figure 8.14 Electric Choke Connections……………………………………………………………………… 12
Figure 8.15 Alternator Connections……………………………………………………………………………. 13
Figure 8.16 Brake Pressure Warning Switch Connection………………………………………………. 13
Figure 8.17 Typical Fan Relay installation…………………………………………………………………… 14
Figure 8.18 Headlight and Park/Turn Light Wire Routing……………………………………………… 14
Figure 8.19 Passenger Side headlight Wire Routing…………………………………………………….. 15
Figure 8.20 Dimmer Switch Connection……………………………………………………………………… 15
Figure 8.21 Turn Switch Connector Removal………………………………………………………………. 16
Figure 8.22 Turn Switch Connector Pin-out…………………………………………………………………. 16
Figure 8.23 Steering Column Covered for Protection………………………………………………….... 17
Figure 8.24 Instrument Panel Connections………………………………………………………………….. 17
Figure 8.25 Ignition Switch Connector………………………………………………………………………… 18
LIST OF TABLES
Table 10.1 Fuse Requirements…………………………………………………………………………………. 19
Table 10.2 Wire Connection Index……………………………………………………………………………. 20
ii

1.0 INTRODUCTION
You have purchased what we at Perfect Performance Products, LLC, believe to be the easiest to install
automotive wire harness on the market. It is designed for easy installation, even if you have no electrical
experience.
All kits have a built in anti-theft feature. Remove the fuse labeled "coil" from the fuse block; this will
prevent the vehicle from starting.
The fuse block and fuses have been updated. The proper fuses have been pre-installed in the fuse block.
In addition, all wires have been color-coded and printed. This will help you to identify the different
circuits during installation and later if additions to the overall system are necessary. For fuse
specifications and color designations, see Section 10.0.
In addition, all of our kits have "accessory" terminals at the front of the fuse block for your convenience.
These terminals may be constantly hot or "switched" hot but all are non-fused.
This Painless Performance wire harness is designed to be used with a 1966-67 Chevy II/Nova. All of the
wire in this kit is 600 volt, 125˚c, TXL. Standard automotive wire is 300 volt, 80˚c, GPT with PVC
insulation.
This complete automobile wiring system has been designed with three major groups incorporated into it:
TAIL/DOME GROUP Includes taillights, right and left turn signals, brake light, fuel
tank sender and the dome light.
ENGINE GROUP Includes starter solenoid, battery feed, alternator, voltage
regulator, distributor, water temperature, oil pressure, and air
conditioning.
HEADLIGHT GROUP Includes high beam, low beam, park, right turn, electric fan,
horn.
DASH GROUP Includes wires to connect to indicator lights and switches to their
proper sources.
2.0 ABOUT THESE INSTRUCTIONS
The contents of these instructions are divided into major Sections, as follows
1.0 Introduction
2.0 About These Instructions
3.0 Contents Of The Painless Performance Wire Harness Kit (Part #20110)
4.0 Tools Needed
5.0 Removal of Original Wire Harness
6.0 Pre-installation and General Harness Routing Guidelines
7.0 General Harness Installation Instructions
8.0 Harness Attachment by Section
9.0 Testing the System
10.0 Wire Connection Index and Fuse Requirements
Sections are divided into subsections and Paragraphs. Throughout these instructions, the Figure
numbers refer to illustrations and the Table numbers refer to information in table form. These are
located in Section and Paragraphs corresponding to the number. Always pay special and careful attention
to any Notes, especially those in Tables, and any text marked CAUTION .
1

3.0 CONTENTS OF THE PAINLESS PERFORMANCE WIRE HARNESS KIT (PART #20110)
Refer to Figure 3.1 to take inventory. See that you have all the parts you are suppose to have in this kit.
If anything is missing, contact the dealer where you obtained the kit or Perfect Performance Products,
L.L.C. at [phone]. This wire harness kit should contain the following items:
The Main Wire Harness (with the fuseblock wired in and fuses installed)
Tail Light Harness (plugged into main harness)
Dome Light Harness (plugged into main harness)
Fuseblock Mounting Plate
Parts Kit (contains terminals, splices, and extra fuses)
High Output Alternator Kit PP-662
Maxi Fuse with holder and cover (in Bag Kit)
Rubber Grommet (in Bag Kit)
2 packages of Nylon Tie Wraps (in Bag Kit)
2 Door Jamb Switches (in Bag Kit)
12 Instrument Panel Light Bulbs (in Bag Kit)
8 Harness Mounting Clamps (in Bag Kit)
Figure 3.1 The Painless Performance Wire Harness Kit (Part #20110)
2
Main Wire
Harness
Tail & Dome
Harnesses
Mounting
Plate
Parts
Kit
Bag Kit
PP-662

4.0 TOOLS NEEDED
In addition to your regular tools, you will need, at least, the following tools:
Crimper tool Note: Use a quality tool to avoid over crimping
Wire stripper
Test light or volt meter
Small ( 10 amp or less) battery charger
5.0 REMOVAL OF ORIGINAL WIRE HARNESS
5.0.1 Locate the engine and front harness and unplug them from the bulk head connector at
the firewall. Disconnect the the other end of each of the wires and remove the harness
from the vehicle.
5.0.2 Locate the two screws that secure the fuse block to the firewall and remove. Disconnect
the wires from the dash cluster, switches and lights. Remove the door sill plate and kick
panel on the driver’s side floor for access to the wires going to the rear. Remove the rear
light sockets and retain for reuse. Remove the rear harness from the vehicle.
3
Figure 5.1 Engine and Front Harness
Figure 5.2 Original Fuseblock

6.0 PRE-INSTALLATION AND GENERAL HARNESS ROUTING GUIDELINES
The installation mainly constists in two parts:
•The physical routing and securing of the wire harness, wires, and groups.
•The proper connection of the individual circuits.
These two major tasks are not separate steps, but are intergated together. That is, you will route wire
and make some connections, route some more wires and make some more connections.
We can not tell you how to route your harness, but we can offer some guidelines. Pre-installation and
general harness routing guidelines starting in Section 6.0, GENERAL installation instructions in Section
7.0, and precise instructions concerning the electrical connections you have to make, beginning in Section
8.0. Remember this harness was designed to be routed in the original manner.
To help you begin thinking through the installation of your new harness, read the following sections.
6.0.1 Famiarlize yourself with your harness by locating each of the sections as listed in Table
10.2 Wire Connection Index on pages 20-22.
(whenever a particular section is referred to in these instructions it is shown in “ all
caps”: ENGINE SECTION A)
6.0.2 A good exercise is to lay out the wire harness on the floor next to your vehicle and
indentify all the SECTIONS. You will want to route the harness through and around open
areas. Inside edges provide extra protection from hazards and also provides places for tie
wraps, clips, and other supports.
6.0.3 Route the harness away from sharp edges, exhaust pipes, and hood, trunk, and door
hinges.
6.0.4 Plan where harness will be located. Always allow enough slack at places where
movement could occur (body to frame, frame to engine, ect.). Use a support every 12
inches unless the harness routes under the floor carpet.
6.0.5At the wire ends don’t depend on the terminals to support the harness. The weight could
cause terminals to disconnect or copper wire strand to break.
6.0.6The wire should be bundled in groups. Use tie wraps, convoluted split loom, or electrical
tape for harness coverings.
7.0 GENERAL HARNESS INSTALLATION INSTRUCTIONS
7.1 ROUGH INSTALLATION
Note: Harness routing and shaping is a time consuming task. Taking your
time will enhance the beauty of your installation. Please be patient and
TAKE YOUR TIME.
7.1.1 Mold harness groups to the coutour of the floor pans, firewall, fender panels,and
any other areas where wire or harness groups are routed. Remember to always
route the harness away from sharp edges, exhaust pipes, hood and door hinges.
Note: Do not tighten tie wraps and mounting devices at this time. Make all
harness attachments LOOSELY.
4

7.1.2 Attach harness groups to your vehicle with clips or ties (provided with this kit)
starting at the fuse block and working your way out to the front and rear groups.
The dash wires should be routed out of the way of any under dash obstacles,
such air conditioning, radio, etc.
7.1.3 When used every 1-1/2” or so on the visible areas of the harness, the plastic
wire ties make a very attractive assembly. A tie wrap in other areas every 6” or
so will hold the wires nicely. Convoluted loom also makes for an attractive
assembly.
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!!!
7.2 TERMINAL INSTALLATION AND MAKING CONNECTIONS
Note: In the following steps you will be making circuit connections. Before
you start, you should carefully read Section 8 as appropriate, and
continually refer to Section 10, DOUBLE-CHECKING your routing and
length calculations before cutting any wires and making connections.
Giving special attention to all switches.
7.2.1 Have all needed tools and connectors handy.
7.2.2 Select the correct size for the wire and stud application.
7.2.3 Determine the correct wire length and cut the wire. Remember to always allow
enough slack in the harness and wires at places where movement could possibly
occur, such as automobile body to frame, frame to engine, ect. Double-check
your calculations.
7.2.4 Strip insulation away from wire. Strip only enough nessessory for the type of
terminal lug you are using.
7.2.5 Crimp the terminal onto the wire.
Note: Make sure the terminal is crimped with the proper crimping tool. An
improper crimp will NOT make a good conection.
CAUTION: DO NOT OVER CRIMP
7.2.6 Connecting the harness throughout the groups is a redundant process. Make
sure that each wire is first properly routed and then attach. DO NOT ATTACH
FIRST THEN ROUTE AFTERWARD.
7.2.7 When all wires are attached, tighten the mounts and ties to secure the harness
permanently.
7.3 GROUNDING THE AUTOMOBILE
A perfectly and beautifully wired automobile will neverless have bugs and problems if
everything is not properly grounded. Do not go to the careful effort of installing a quality
harness only to neglect proper grounding.
7.3.1 Connect a Ground strap or Cable (even a 10-gauge is too small) from the
Negitive Battery terminal to the vehicle chassis (frame).
7.3.2 Connect a Ground Strap from the Engine to the Chassis. DO NOT RELY UPON
THE MOTOR MOUNTS TO MAKE THIS CONNECTION.
7.3.3 Connect a Ground Strap from the Engine to the Body.
5
7.3.4 If you have a fiberglass body you should install a terminal black to ground all

your gauges and accessories. Ground the Terminal Block and everything will be
grounded.
Note: Grounding straps may be purchased from most auto supply stores.
8.0 HARNESS ATTACHMENT BY SECTION
8.1 FUSEBLOCK MOUNTING
8.1.1 Take the grommet provided and install into the hole in the adapter plate. Route
the ENGINE and HEADLIGHT SECTIONS through the adaptor plate hole and
firewall while bolting the fuseblock to the adapter plate, allowing the assembly to
hang free.
8.1.2 Route the DASH SECTION (ignition, instrument panel, headlight switch,
etc)around the kick panel, over the steering column and the along the bottom
the dash.
8.1.3 Position the fuseblock assembly so that the grommet is centered in the bulkhead
hole. Using the 2 screws provided attach the fuseblock adapter plate to the
firewall. See FIGURE 8.2 & 8.3
NOTE: The fuseblock itself does not have to be grounded.
6
Figure 8.1 Pre-Routing Engine and Headlight Sections
Figure 8.2 Screws Securing Adapter Bracket

8.2 TAIL/DOME SECTION CONNECTIONS
8.2.1 Take the DOME LIGHT SECTION and route it up from behind the drivers side kick
panel, up through the A-Pillar over to the dome light. NOTE: If your dome
light wires are in good condition you can splice the new wires to the
original ones in the kick panel area.
8.2.2 Take the White wire on the Dome Light Harness and route it from the door jamb
switch on the drivers side along the bottom of the dash to the passenger side
door jamb switch. Connecting the white wires at the jamb switches and
connecting the headlight switch connector (wire at headlight switch connector
installed at factory) allows the dome light to be turned on when either of the
doors are opened or the headlight switch knob is turned. Note: New door
jamb switches have been provided with the kit.
7
Figure 8.3 Fuseblock Mounted
Figure 8.4 Routing Dome Light Wires

8.2.3 Take the Tail Harness and route it from the drivers kick panel down the door
jamb toward the rear of the vehicle. Routing the harness in between the rear
seat and the body into the trunk. Once in the truck route the fuel sender wire to
the fuel sender. Route the remaining harness over the fender and under the
trunk opening. SEE FIGURE 8.7
8
Figure 8.5 Door Jamb Switch
Figure 8.6 Driver Kick Panel and Jamb Routing

8.2.4 Locate the wire for the fuel sending unit and route it as shown in Figure 8.8.
Connect the wire to the sending unit.
9
Figure 8.7 Wire Routing in Trunk
Figure 8.8 Fuel Sender Wire Routing
Back of Rear
Seat

8.2.5 Locate the wire for the license plate light in the harness and route it through the
grommet going out of the trunk. Connect the wire to the light.
8.2.6 Figure 8.10 shows the backup and brake/tail light sockets. You can remove the
terminals from the sockets and solder the new wires to them or you can cut off
the wire coming out of the sockets and splice to them using the supplied butt
connectors.
10
Figure 8.10 Backup and Brake/Tail Sockets
Figure 8.9 License Plate Light Wire Routing

8.3 ENGINE SECTION CONNECTIONS
8.3.1 Route the wiper motor, coil, choke, temp sender, oil sender, starter, alternator
and a/c compressor wires across the firewall to the wiper motor and to the
engine.
NOTE: Included in the kit are 6 large harness securing clamps for the firewall and inner
fender routing and 2 small clamp for headlight crossover wires.
8.3.2 Cut wiper motor wires to length, terminate and connect wires as shown in Figure
8.12
11
8.3.3 Locate the maxi fuse holder and mount it to the passenger side inner fender
Figure 8.11 Wiper Motor and Engine Wire Routing
NOT
USED
YELLOW
LT.BLUE
BLACK
YELLOW
BLUE
Figure 8.12 Wiper Motor Connections

panel as shown in figure 8.13. Take the starter Red wire (916) and route it to the
maxi fuse holder. Cut the wire, crimp on a ring terminal and connect it to a fuse
holder terminal. Take the remaining wire that was cut off and crimp on a ring
terminal, connect it to the other side of the fuse holder. Take the other end and
route it to the starter solenoid and connect it to the large battery terminal.
NOTE: If using an alternator larger than 65 Amps, you will need to review the
instructions in the PP-662 ALTERNATOR WIRE KIT (supplied in bag in with this
harness) before you make any maxi fuse or starter connections.
CAUTION: TO PROTECT THE ENTIRE SYSTEM THE MAXI FUSE MUST BE
INSTALLED AS INSTRUCTED.
8.3.4 Route and connect the starter, coil, oil sender, choke, temp sender, a/c
compressor and alternator wires.
12
Figure 8.14 Electric Choke Connections
Figure 8.13 Maxi Fuse

Figure 8.15 Alternator Connections
Note: In with the kit you should find a connector with a Blue and a White wire labeled
“Alternator pigtail”, this connector will be used as shown when using an external
regulator system. If you have converted to a internal regulated system you will not
need the alternator pigtail but will use the connector and terminals provided.
CAUTION : If using an alternator larger than 65 amps, you will need to use the PP-662
ALTERNATOR WIRE KIT supplied in a bag in the box. with this harness.
Note: This will be used along with the alternator wires in the main harness.
8.3.5 If you have a `67 model vehicle you will connect the brake pressure warning
switch as shown below. The `66 model vehicle did not have a brake warning
switch, you will tape and stow the wire.
13
Figure 8.16 Brake Pressure Warning Switch Connection
Internal Regulator
External Regulator

8.4 HEADLIGHT SECTION CONNECTIONS
8.4.1 Route the headlight, park light, horn and electric fan wires down the inner fender
panel to the horn area. Secure the wires to the inner fender panel using the
supplied clamps.
8.4.2 Connect the horn wires.
8.4.3 Take and route the headlight, park/turn and electric fan wires thru the core
support and connect to the driver side lights and fan relay (if a electric fan is
being used).
8.4.4 Take the headlight ground ring terminal and ground it using one of the bolts in
the core support.
8.4.5 Route the passenger headlight and park/turn wires across the front of the core
support as shown. Use the two small clamps supplied to secure the wires.
8.4.6 On the Passenger-side of the core support you will find a hole (see arrow -
Figure 8.19) in which you will route the park/turn signal wires through. Once you
have routed the wires back through the core support, then route them down the
side of the radiator to the park/turn signal light and connect. Route the headlight
wires and connect.
14
Figure 8.18 Headlight and Park/Turn Signal Wire Routing
Figure 8.17 Typical Fan Relay Installation (Painless Part #30101 Fan Relay Kit)

8.4.7 Take the headlight ground ring terminal and ground it using one of the bolts in
the core support.
8.5 DASH SECTION CONNECTIONS
8.5.1 Locate the connector for the dimmer switch and connect the switch.
8.5.2 If wiring a `67 model vehicle you will take the Tan wire labeled “Park Brake Swt”
and connect it to the terminal on the parking brake assembly. This wire will not
be used on the `66 model vehicle, you will tape and stow it.
8.5.3 On the base of the steering column you will find the backup switch. Take the
backup switch connector and plug it into the switch.
15
8.5.4 You will need to remove and use the turn signal switch connector from the
Figure 8.19 Passenger Side Headlight Wire Routing
Figure 8.20 Dimmer Switch Connection (Dimmer Switch –Painless
Part #80150)