Painless performance 60217 User manual

P/N 60217 & 60218

1999 - 2002 GM VORTEC FUEL INJECTION

4.8L, 5.3L & 6.0L

WIRE HARNESS INSTALLATION

INSTRUCTIONS

Manual P/N 90530

Third Edition July 2014

PAINLESS PERFORMANCE PRODUCTS

2501 Ludelle Street Fort Worth, Texas 76105 (800) 423-9696

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

6.0 GM 99-02 VORTEC SYSTEM WIRE HARNESS INSTALLATION..................................................................... 5

6.1 CONTENTS OF THE 60217 & 60218 WIRE HARNESS KIT............................................................ 5

6.2 DASH SECTION INSTALLATION................................................................................................ 5

6.3 ENGINE SECTION INSTALLATION............................................................................................. 9

6.4 TAIL SECTION INSTALLATION.................................................................................................. 14

7.0 TROUBLE-SHOOTING INSTRUCTIONS...................................................................................................... 16

7.1 THE "CHECK ENGINE" LIGHT.................................................................................................... 16

7.2 RETRIEVING TROUBLE CODES FROM THE COMPUTER............................................................... 16

7.3 IDLE LEARN PROCEDURE......................................................................................................... 17

LIST OF FIGURES

Figure 6.1 Diagnostic Link Connector (DLC) & Check Engine Light ............................................................. 7

Figure 6.2 Brake Switch Connection ......................................................................................................... 7

Figure 6.3 Brake Switch Relay.................................................................................................................. 8

Figure 6.4 Air Pump Relay ...................................................................................................................... 8

Figure 6.5 Canister Purge Solenoid .......................................................................................................... 8

Figure 6.6 Canister Vent Solenoid ............................................................................................................ 9

Figure 6.7 Air Pump Connections .............................................................................................................. 9

Figure 6.8 Air Bleed Solenoid.................................................................................................................... 9

Figure 6.9 Fuel Pump Relay Connector...................................................................................................... 9

Figure 6.10 EGR Valve............................................................................................................................... 12

Figure 6.11 Knock Sensor Connector.......................................................................................................... 12

Figure 6.12 Oxygen Sensors ..................................................................................................................... 12

Figure 6.13 MAP Sensor ........................................................................................................................... 12

Figure 6.14 CMP Sensor ........................................................................................................................... 12

Figure 6.15 CKP Sensor ............................................................................................................................ 12

Figure 6.16 Injectors 1, 3, 5, 7................................................................................................................... 13

Figure 6.17 Injectors 2, 4, 6, 8 .................................................................................................................. 13

Figure 6.18 TPS Sensor ............................................................................................................................ 13

Figure 6.19 IAC......................................................................................................................................... 13

Figure 6.20 MAF Sensor ........................................................................................................................... 13

Figure 6.21 Driver Side Coil Connector....................................................................................................... 13

Figure 6.22 Passenger Side Coil Connector................................................................................................. 14

Figure 6.23 ECT Sensor............................................................................................................................. 14

Figure 6.24 VSS Output............................................................................................................................. 15

Figure 6.25 Transmission Sensor ............................................................................................................... 15

Figure 6.26 Park Neutral Position Sensor.................................................................................................... 16

Figure 6.27 Transmission Connector……………………………………………………………………………………………………… 16

Figure 7.1 Fuse Identification................................................................................................................... 16

LIST OF TABLES

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

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

Table 6.2 Engine Section Connections..................................................................................................... 11

Table 6.3 Tail Section Connections.......................................................................................................... 15

1.0 INTRODUCTION

You have purchased what we at Painless Performance Products believe to be the most up-to-date

and easiest-to-install automotive fuel injection harness on the market. It is designed for easy

installation, even if you have no electrical experience.

This harness is designed to be a complete wiring system for the fuel injection system on General

Motors 1999 - 2002 4.8L, 5.3L, & 6.0L Vortec injected engines and to control the 4L60E, 4L65E,

4L80E, 4L85E automatic or manual transmissions using the computer Service #12200411. This

includes all wiring that is needed by the computer to run and control the injection system and

transmission.

NOTE: This harness is not emissions legal unless used with kit #60322 or 60323.

To overcome the Passlock system in the 12200411 programming, the PCM will need to

have this feature removed.Contact Painless Performance with your proof of purchase for this

harness and we will flash your PCM for free. This harness along with the removal of the Passlock

software will get the Vortec engine and transmission up and operating but it is recommended that

you also 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: This harness has no provision for operating cooling fans. If you wish to operate the fans

automatically, painless kit #30106 is available. This kit will turn the fans on at 205 degrees, and off

at 195. This kit is also available in a weatherproof version, part # 30127

NOTE: If you need your GEN III Vortec to be emission legal, the computers program must match the

emissions package to that specific engine.

NOTE: Most likely the check engine light will come on and stay on when using a computer without

removing the programming for any unused devises.

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, the

manual, 4L60E, 4L65E, 4L80E, or 4L85E.

Usually the computer, relays and fuse block can easily be mounted under the dash. Most of the

wiring in the harness has been pre-terminated to the proper connector and all wire has been GM

color-coded. All wiring is TXL, 600 volt, and 125 degree centigrade with cross-link insulation.

This fuel injection system harness has been divided into three major groups:

ENGINE GROUP Includes wiring for the fuel injectors, ignition & charging systems, power/ ground

and sensors.

DASH GROUP Includes wiring for the ignition feed, assembly line diagnostic link (DLC)

connector, check engine light, computer connectors, brake switch, tachometer,

electric speedometer, fuse block, fuel pump relay connector and emissions

devises.

TAIL GROUP Include wiring for the VSS, park neutral position sensor, transmission and power

wire for fuel pump.

2.0 ABOUT THESE INSTRUCTIONS

These instructions provide information for the installation of the 60217 & 60218 Vortec Fuel Injection

Harness Kit. The contents of these instructions are divided into major Sections, as follows:

1.0 INTRODUCTION

2.0 ABOUT THESE INSTRUCTIONS

3.0 TOOLS NEEDED

4.0 PRE-INSTALLATION AND HARNESS ROUTING GUIDELINES

5.0 GENERAL INSTALLATION INSTRUCTIONS

6.0 60217 or 60218 VORTEC FUEL INJECTION HARNESS KIT

8.0 TROUBLE-SHOOTING INSTRUCTIONS

Sections are further divided into Paragraphs and Steps. Throughout, the Figure numbers refer to

illustration and the Table numbers refer to information in table form. These are located in or near

the sections or paragraphs to which they correspond. Always pay careful attention to any notes or

any text labeled CAUTION.

3.0 TOOLS NEEDED

In addition to your regular tools, you will need, at least, the following:

Crimping tool NOTE: USE A QUALITY TOOL TO AVOID OVER-CRIMPING.

Wire stripper

Continuity tester CAUTION: DO NOT USE A TEST LIGHT TO TEST THE COMPUTER OR

SENSOR WIRING OR YOU WILL DAMAGE THE COMPUTER.

Tech II or equivalent scanner (for presetting and diagnostic purposes)

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, securing, group/ 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 a manual transmission, read Paragraph 4.1.1, then skip to the note

at the end of the section. If you are using the 4L60E, 4L65E, 4L80E, or 4L85E, then skip

Paragraph 4.1.1, and start at paragraph 4.1.2.

4.1.1 If you are using a manual transmission, tape off and store the purple and pink

(brake switch) wires, the park neutral position plugs/ wires and the 13-position

(transmission) round connector in the tail section.

4.1.2 If you ARE going to use a 4L60E, 4L65E, 4L80E, or 4L85E transmission,

you must use the vehicle speed sensor (VSS), transmission connector, park neutral

position connectors and correct brake switch. These are necessary to make the

transmission work correctly. The brake switch should be closed (electrically connected)

when the brakes ARE NOT being applied and open (not electrically connected) when

the brakes ARE being applied. This is the opposite of a standard brake light switch. If

you are using a pressure brake switch, a SPDT relay must be installed to unlock the

converter when the brakes are applied. The vehicle speed sensor lets the computer

know how fast the wheels are turning. The park neutral position sensor tells the PCM if

the transmission is in park or neutral.

NOTE: Emission devices. This harness has provisions for the emission devices. We

have rolled up the canister purge and canister vent, air pump, and air bleed solenoid

wiring in the dash section. It may be left there if these items are not to be used. If you

plan on using these items route these wires out to the engine compartment.

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

NOTE: The 99–02 4.8L, 5.3L & 6.0L Vortec engines had four oxygen sensors

from the factory, but we have provisions for only two, one on the driver side

and one on the passenger side of the engine. We 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. A 12200411

computer is required for proper operation.

4.2.1 PPPI recommends the use of the following parts. See Table 4.1. 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 part #12200411.

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 right side.

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.

Table 4.1 Compatible Parts

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.

5.0 GENERAL INSTALLATION INSTRUCTIONS

~ 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) MAKING

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.

~ When connecting the plugs to the computer

NEVER

FORCE ANY CONNECTOR. USE EXTREME CARE

~ The fuel pump you are using

to make sure none

of the pins in the computer are or become bent.

MUST maintain a constant pressure of 55-62 P.S.I.

(pounds per square inch). The Vortec fuel system does 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.

4.8L, 5.3L & 6.0L Vortec Fuel Injection Harness (99 - 02) Part # 60217 & 60218

Main Computer…………………Service#12200411

Fuel Pump Relay………………..Painless #80130

Brake Switch……………………Painless# 80176

MAF/ IAT Sensor……………….Delco# 213-364

Engine Coolant Temperature……Delco# 213-953

Oxygen Sensor (Pass. Side)……..Delco# AFS106

Oxygen Sensor (Drvr. Side)……..Delco# AFS106

TPS Sensor………………………Delco# 213-912

MAP Sensor…………………..…Delco# 213-796

Idle Air Control Motor…………..GM# 17113598

Knock Sensor………………….....Delco# 213-362

EGR Valve……………………….GM# 17113575

Coils………………………….…..GM# 10457730

Cam Position Sensor……………..GM# 12561211

Crankshaft Position Sensor………Delco# 213-354

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 sensors in their intend 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 tail 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: 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 and relays

at this time.

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, 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.

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

proper die in the crimping tool. An improper crimp will not make a good

connection. DO NOT OVER-CRIMP

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.

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.

CAUTION: BE SURE THE IGNITION IS OFF WHEN YOU RECONNECT THE

BATTERY OR YOU WILL DAMAGE THE COMPUTER.

6.0 GM 99 – 02 4.8L, 5.3L & 6.0L VORTEC SYSTEM WIRE HARNESS INSTALLATION

INSTRUCTIONS

6.1 CONTENTS OF THE 60217 & 60218 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 (800) 423-9696 or (817) 244-6898.

The kit should contain the following items:

~ The main wire harness with the connectors already on the ends of most of the wires

~ Fuel Injection Installation Instructions P/N 90530 (This Booklet)

~ 4” & 7” tie wraps

6.2 DASH SECTION INSTALLATION

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.

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), fuel pump relay, emissions devises

(optional) and 6 other wires.

CAUTION: DO NOT MAKE ANY CONNECTIONS WHILE THE COMPUTER IS PLUGGED

INTO THE HARNESS.

Note: Wire color (Example: Blk/Wht) is one wire with a stripe. The second color

(the stripe) may not be bold. Observe all two-color wires closely.

A. AC REQUEST –

This circuit is used to inform the PCM that the AC compressor has been turned on. This

wire is to be spliced into the circuit from the AC switch to the AC compressor.

This is not a power supply for the compressor

B. The secondary Air Injection (AIR) system helps reduce hydrocarbon (HC), carbon

monoxide (CO), and oxides of nitrogen (NOx) exhaust emissions.

1. AIR PUMP (not equipped on all models) -The AIR pump assembly is mounted

in the right rear corner of the engine compartment and supplies the air to the AIR

system. The electric air pump sends air to the check valves near the exhaust

manifolds. The AIR pump is controlled by the Powertrain Control Module (PCM)

through the AIR pump solenoid relay. Battery voltage to the AIR pump is controlled

by the AIR pump solenoid relay. A vacuum operated shut off valve prevents air flow

during OFF periods. When the PCM provides a ground circuit for the secondary AIR

pump solenoid relay, battery voltage applies power to the AIR pump and the

solenoid. Intake manifold vacuum is then applied through the solenoid to the

vacuum operated shut off valve. The vacuum operated shut off valve then opens up

and allows air to be delivered to the check valves. See Figure 6.7

2. AIR RELAY (not equipped on all models) -The PCM controls the operation of

the AIR system through the AIR pump solenoid relay. When the PCM provides a

ground circuit for the secondary AIR pump solenoid relay, battery voltage is allowed

to power up the AIR pump and the solenoid. See Figure 6.4

3. AIR SOL (not equipped on all models) -The AIR solenoid is activated by the

AIR pump solenoid relay. The AIR solenoid allows intake manifold vacuum to the

shut off valve. The shut off valve then opens allowing air flow. See Figure 6.8

4. CAN VENT (not equipped on all models) -The Evaporative Emissions (EVAP)

control system used on all vehicles is the charcoal canister storage method. This

method transfers fuel vapor from the fuel tank to an activated carbon, charcoal,

storage device, canister, to hold the vapors when the vehicle is not operating. When

the engine is operating, the fuel vapor is purged from the carbon element by intake

air flow and consumed in the normal combustion process. See Figure 6.6

5. CANISTER PURGE (not equipped on all models) -The Evaporative Emissions

(EVAP)control system is the charcoal canister storage method. This method

transfers fuel vapor from the fuel tank to an activated carbon charcoal storage

canister, to hold the vapors when the vehicle is not operating. When the engine is

operating, the fuel vapor is purged from the carbon element by intake air flow and

consumed in the normal combustion process. See Figure 6.5

C. BRAKE SW (optional) - These circuits are used to provide power to the TCC solenoid in

the automatic transmission. If you are not using the electronic automatic transmission,

you may stow these wires. If you are using the electronic automatic transmission, these

wires will connect to the brake switch terminals that are normally used for cruise control

or TCC solenoid (normally closed). These wires do not connect to the terminals for

the brake lights.

D. DLC -The Data Link Connector (DLC) Figure 6.1 is used to communicate with the PCM.

The Powertrain On Board Diagnostic (OBD) System Check is an organized approach to

identifying a problem created by an electronic powertrain control system malfunction. The

Powertrain OBD System Check is the starting point for any drivability concern diagnosis.

The Powertrain OBD System Check directs the installer to the next logical step in

diagnosing a drivability concern. Understanding and using the Powertrain OBD System

Check correctly will reduce the diagnostic time and prevent the replacement of good parts.

Mount the DLC connector using the bracket that the light is mounted in allowing access to

the front of the connector allowing you to see the light while driving. See Figure 6.1

See table 4.1 for the recommended brake switch. If you are using the

recommended brake switch then you will wire it according to Figure 6.2. The pink wire to

the back of the switch in the illustration is the wire that has power on it whether or not

the brake is being applied. 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.

E. FUEL TEST (use as needed) - This circuit is used to power the electric fuel pump for

test purposes only. Temporarily apply fused positive power to this wire for testing the fuel

pump.

F. FUSE BLOCK IGNITION (mandatory) - This circuit is used to provide power to the

injection system. Connect this wire to a terminal/ wire from the ignition switch that is hot

in the RUN and CRANK

positions. Failure to provide power in the crank position will

result in PCM shutdown while the engine is trying to start.

Note: You will know this circuit

is properly connected if the Check Engine Light is on when the ignition switch is on and

while starting.

G. TACH (optional) - This circuit is used to provide a signal from the PCM to the

tachometer. Connect this wire to the signal input on the tachometer.

H. VSS OUTPUT (optional) - This circuit is used to provide a signal from the PCM to the

electric speedometer. Connect this wire to the signal input on the electric speedometer

(not all aftermarket electric speedometers use the same signal for operation. Consult the

tech dept of the speedometer manufacture for compatibility).

This manual suits for next models

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