P/N 60502 & 60505

1992-1997 GM LT1 FUEL INJECTION

WIRE HARNESS INSTALLATION
INSTRUCTIONS
Manual P/N 90517
Copyright © May 2002
 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: painless@painlessperformance.com

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: 90517

11th Edition: March 2019

Copyright  1994 by Painless Performance Products, LLC

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 TABLE OF CONTENTS
1.0 INTRODUCTION.......................................................................................................................... 4

2.0 ABOUT THESE INSTRUCTIONS............................................................................................... 4

3.0 TOOLS NEEDED.......................................................................................................................... 5

4.0 PRE-INSTALLATION AND HARNESS ROUTING GUIDELINES........................................... 5

4.1 TRANSMISSION FUNCTION...................................................................................... 5

4.2 GET TO KNOW THE ENGINE THAT YOU ARE USING........................................... 6
4.3 KNOCK SENSORS…………………………………………........................................... 7

5.0 GENERAL INSTALLATION INSTRUCTIONS.......................................................................... 9

5.1 GROUNDING THE VEHICLE....................................................................................... 9

5.2 ROUGH INSTALLATION............................................................................................... 9
5.3 HARNESS ATTACHMENT........................................................................................... 10
5.4 TERMINAL INSTALLATION INSTRUCTIONS.......................................................... 10

6.0 INSTALLATION………………………………………………................................................... 11
6.1 SPECIFIC CIRCUIT CONNECTIONS........................................................................... 11
6.2 ENGINE GROUP INSTALLATION............................................................................... 15
6.3 TAIL SECTION INSTALLATION................................................................................. 18

7.0 TROUBLE-SHOOTING INSTRUCTIONS................................................................................... 19

7.1 THE "CHECK ENGINE" LIGHT................................................................................... 19

7.2 RETRIEVING TROUBLE CODES FROM THE COMPUTER..................................... 20
7.3 WHEN TO CALL "PAINLESS WIRING" TECH LINE................................................ 22

LIST OF FIGURES
Figure 4.1 Knock Module Location............................................................................................... 7
Figure 4.2 ECM Terminal Lock …………………………………………………………………… 8
Figure 4.3 Knock Sensor Add On............................................................................................... 8
Figure 6.1 Diagnostic Link Connector (DLC) & Check Engine Light ............................................. 11
Figure 6.2 Brake Switch Connection ............................................................................................... 12
Figure 6.3 Brake Switch Relay......................................................................................................... 12
Figure 6.4 Gear Indicator Switch ..................................................................................................... 13
Figure 6.5 Air Pump Relay Connector ............................................................................................. 14
Figure 6.6 Canister Purge Solenoid ................................................................................................. 14
Figure 6.7 Air Pump Connection ..................................................................................................... 14
Figure 6.9 EGR Solenoid ................................................................................................................ . 16
Figure 6.10 Knock Sensor .................................................................................................................. 16
Figure 6.11 Oxygen Sensor ................................................................................................................ 16
Figure 6.12 MAP Sensor ....................................................................................... ............................. 16
Figure 6.13 CKP Sensor ......................................................................................... ........................... 16
Figure 6.14 Injectors 1, 3, 5, 7......................................................................................................... .... 17
Figure 6.15 Injectors 2, 4, 6, 8 ............................................................................................................ 17
Figure 6.16 TPS Sensor .................................................................................................................. .... 17
Figure 6.17 IAC................................................................................................................................... 17
Figure 6.18 MAF Sensor .................................................................................................................. .. 17
Figure 6.19 Distributor Connection..................................................................................................... 17
Figure 6.20 Ignition Module................................................................................................................ 18
Figure 6.21 Coil......................................................................................................................... .......... 18
Figure 6.22 ECT Sensor....................................................................................................................... 18
Figure 6.23 IAT Sensor................................................................................................................... ..... 18
Figure 6.24 VSS.................................................................................................................................... 19
Figure 6.25 Transmission Connection .................................................................................................. 19
Figure 7.1 Fuse Identification.......................................................................................................... .... 14
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 LIST OF TABLES
Table 4.1 Compatible Parts.............................................................................................................. 6
Table 4.2 Knock Sensor…………………………………………………………………………… 7
Table 6.1 Dash Section Connections..................................................................................... ........... 14
Table 6.2 Engine Section Connections............................................................................................. 15
Table 6.3 Tail Section Connections............................................................................................. ..... 19
Table 7.1 Diagnostic Trouble Codes................................................................................................ 21 & 22

1.0 INTRODUCTION
This harness is designed to be a complete wiring system for the fuel injection system on General Motors 1992 and newer LT1
injected engines and to control the 4L60E transmission. This harness includes all wiring that is needed by the computer to run and
control the injection system and transmission. A module has been included to bypass the vehicle anti theft system (VATS) incorporated
in the computer. When using this harness on a '96 or '97 engine you must replace the coil, coil output wire
with the parts from a '92 - '95 engine.

NOTE: The use of a 40 pulse Vehicle Speed Sensor, such as the one that comes standard in the 4L60E
transmission, is required when using a 1994 or newer computer for operation of emission devices. If
emission devices are required in your area, the use of any other style transmission, such as a 350 or 400
Turbo, which cannot operate a 40-pulse sensor, cannot be used. The use of a 4L60E will also require the
use of an electronic speedometer because of the absence of a cable drive in the transmission.

Any 1994-1997 LT1 ECM will work with this harness. It will however be up to you, the installer, to
verify you have the right combination of knock sensor module, knock sensor part number, and the
number of knock sensors needed for your application. See Section 4.3 for the correct knock sensor
information.

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.

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

ENGINE GROUP Includes wiring for the fuel injectors, distributor, and sensors.
DASH GROUP Includes ignition feed wires, assembly line diagnostic link (DLC) connector,
check engine light, computer wiring and connectors, brake switch wiring, gear
shift indicator wiring, tachometer wiring, air pump, canister purge, VATS and
fuse block.
TAIL GROUP Include VSS wiring, transmission wiring (if applicable) and power wire for fuel
pump.
2.0 ABOUT THESE INSTRUCTIONS
These instructions provide information for the installation of the 60502 LT1 (92-97) 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 60502 LT1 (94 & 95) FUEL INJECTION HARNESS KIT
8.0 TROUBLE-SHOOTING INSTRUCTIONS AND TROUBLE CODES

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.
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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.
Electric drill
1 5/8" Hole saw (for the rubber grommet in the firewall)

4.0 PRE-INSTALLATION AND HARNESS ROUTING GUIDELINES

The installation of your harness kit will consist of two parts:

~ The physical routing, positioning, and securing of the harness, wire groups, and individual wires and
connectors.

~ The proper electrical connection of the individual circuits.

We cannot tell you how to route the harness in your automobile. That depends a great deal upon the particular make of the automobile
and what extent you want to secure and conceal the harness. We do offer some general guidelines and routing practices starting in
Paragraph 5.3, general installation instructions in Section 5.0, and precise instruction concerning the electrical connections you will
have to make beginning in Section 6.0. To help you begin thinking through the installation of your wire harness, read the following
sections:

4.1 TRANSMISSION FUNCTION

If you are not using the 4L60E transmission, read Paragraph 4.1.1, then skip to Paragraph 4.1.3. If you ARE going to use 4L60E,
then skip Paragraph 4.1.1, and start at paragraph 4.1.2.

4.1.1 If you ARE NOT using a 4L60E transmission, tape off and store the light blue/black and pink (brake switch) wires
in the dash group and the 13-position (transmission) round connector in the tail section.

4.1.2 If you ARE going to use a 4L60E transmission then you MUST have a two-position vehicle speed sensor (VSS),
and the 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.

4.1.3 Regardless of whether you use the 4L60E or not, the vehicle speed sensor (VSS) and park/neutral indicator switch
must be used and is needed by the computer so it can command the emissions control devices on the engine. This
part is necessary if you want your car to be street-legal.

NOTE; Emission devices

This harness has provisions for 3 emission devices, which are EGR solenoid, Air Pump relay and a Canister Purge
solenoid. We have rolled up the canister purge solenoid wiring and air pump wiring in the dash section and
may be left there if these items are not to be used. If you plan on using the canister purge solenoid and air
pump you will need to route these wires out to the engine compartment and install an air pump relay.
Secure the wires to the main harness using the tie wraps supplied.

To keep the check engine light from coming on you will need to plug in a canister purge solenoid and air
pump relay to the wires in the dash section. (The computer looks for signals from these controls and does

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 not care if the actual devices are installed.)
4.2 YOU SHOULD GET TO KNOW THE PARTICULAR ENGINE YOU ARE USING:

4.2.1 Painless Performance recommends the use of the following parts. See Table 4.1. These will meet all requirements
and are compatible with this Painless harness. The numbers given are GM and AC Delco part numbers.

LT1 Fuel Injection Harness Part # 60502 or 60505

EGR. Solenoid................................ Delco# 214-396

Brake Switch.....................................GM# 25524845 Gear Indicator Switch..................GM# 15705308 or
Intake Air Temperature.....................GM# 12110319 Delco #D2286A
Ignition Module.............................Delco# D-1986-A MAP Sensor ....................................GM# 16137039
Idle Air Control ................................GM# 17113099 Coolant Temperature Sensor ..........GM# 25036979
Coil.......................................................Delco# D-573 Air Pump Relay....GM# 14100455 Delco# 15-8426
Oxygen Sensors...GM# 25312184 or Delco# AFS 75 Air Pump......................................Delco# 2604-4885
TPS Sensor.........................................GM# 17106680 MAF Sensor.....................................Delco# 213-252
Canister Purge Solenoid GM# 1997201 Delco# 214-565

NOTE: Components with part numbers other then the ones listed may plug into the 60502 or 60505
harness, but the part numbers MUST match the ones on this list for proper operation. An adapter is
included to adapt the 4-pin square IAC connector to the '94-'96 flat 4-pin connector.
ECM Part #’s
88961150 1994-1995 Camaro
16188051 1994-1995
16181333 1994-1995
88999183 1994 Corvette
88961148 1995 Corvette
88963801 1996 Camaro, Vette
16242921 1996 Camaro
16214399 1996/1997

Table 4-1 Compatible Parts

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. Painless wire harness kits are designed
to mount either under the dash or in the kick panel. They must be no further apart than the wiring will allow (approx.
16 inches).

4.2.4 A good exercise is to lay out the wire harness on the floor beside your vehicle and identify all the
connectors and wires.

4.2.5 You will want to route the harness through and around open areas. Inside edges provide extra
protection from hazards and also provide places for tie wraps, clips and other support.

4.2.6 Route the harness away from sharp edges, exhaust pipes, and the hood, trunk and door hinges.

4.2.7 Plan where harness supports will be located. Use a support approximately every 6 inches unless
the harness routes under the floor carpet.

4.2.8 Allow enough slack in the harness at places where movement could possibly occur (body to frame, frame to engine,
etc.).

4.2.9 The wires should be bundled into harness groups. Use tape, nylon ties or poly split loom.

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4.3 KNOCK SENSORS

4.3.1 All LT1 engines utilize a sensor to detect combustion detonation and will adjust timing in the event pre-detonation
occurs. All engines have one sensor mounted on the passenger side of the engine, just forward of the starter.
Depending on the vehicle the engine came out of and/or the knock sensor module in the ECM you are using, some
installs will require an addition knock sensor to be installed on the driver side of the engine.

4.3.2 Using the chart below verify you have the right combination of knock sensor module, knock sensor part number, and
the number of knock sensors needed for your application. Using the wrong combination will result in error codes
being stored in the ECM and/or poor ignition timing.

KNOCK MODULE BODY # OF

YEARS ENGINE KNOCK SENSOR PART #
NUMBER STYLE SENSORS

16214681 1996 Y 5.7/LT4 2 213298 / 10456222

1996-
16214661 F 5.7 1
1997
16214671 1996 B 5.7 2 213325 / 10456287

16214691 1996 B 4.3 2

1994-
16177690 Y 5.7 2
1995
1994-
16177700 F 5.7 1
1995
21396 / 10456126
1994-
16188309 B 5.7 2
1995
1994-
16188709 B 4.3 2
1995
F= Camaro/Firebird Y= Corvette B=CAPRICE, IMPALA, ROADMASTER
Table 4-2 Knock Sensor

4.3.3 The knock sensor module can be found on the ECM, under the sealed cover. The part number of the module will be
printed on it.

FIGURE 4.1 Knock Module Location

4.3.4 If you require 2 knock sensors, a knock sensor pigtail has been provided. The knock sensor will connect to the
Painless chassis harness according to the ECM you are using, see the diagram on the next page. 1996-1997 ECMs
require the knock sensor pigtail to be added to the BLUE ECM connector, the correct terminal has been pre-
installed; instructions for this are on the next page. 1994 & 1995 ECMs will require you to splice the blue wire of the
pigtail to the blue wire going to the knock sensor connector of the Painless harness. Splices and heat shrink have
been provided. When splicing these wires, the pigtail will need to be cut to length. Both connector should break out
from the main harness about 34-36”.
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 1996-1997 ECMs Only

1. Locate the BLUE ECM connector. Undo the locking tangs of the connector, giving
you access to the wire insertion side of the connector. Using a small screw driver,
press the locking tang on one side of the blue terminal lock and pull the lock away
from the connector. Once one side is done, do the other side as well to completely
remove the lock from the connector.

2. Locate the knock sensor pigtail supplied with this kit. This pigtail will be a blue wire
with a round gray connector pre-installed. Plug the terminal pre-installed on the blue
wire into pin #21.

3. Route the pigtail down the harness to where the other knock sensor is. Use zip ties or
tape to secure the wire to the harness.
Figure 4.2 ECM Terminal Lock

FIGURE 4.3 Knock Sensor Add On

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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.

~ Each connector in this harness is different and will not fit in the wrong place. NEVER FORCE ANY
CONNECTOR.
~ When connecting the plugs to the computer USE EXTREME CARE to make sure none of the pins in
the computer are or become bent.
~ The fuel pump you are using MUST be rated at a minimum of 45 PSI (pounds per square inch).

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 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.

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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 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. 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. BEING 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.

10
6.0 INSTALLATION
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 wire harness with the connectors already on the ends of most of the wires.
~ Fuel Injection Installation Instructions P/N 90517 (This Booklet).
~ WH 427 ECM data wire (purple)

6.1 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.

6.1.1 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), and 13 other wires.

Note: You may need to connect the check engine light wires to their mates in the wire harness.

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. 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.

NOTE: If using a 1997 computer you will have to install the serial data wire provided in this
kit. This wire connects into port number 7 in the Blue connector in your ECM, and to the
number 2 port in the DLC connector

B. Mount the DLC connector using the bracket containing the check engine light in the place
selected.

FIGURE 6.1 DLC Connector & Check Engine Light

C. Locate the pink ignition hot activation wire, labeled "fuse block ignition B+ (18 Ga.) for the fuse block and attach it
a 12V fused power source where there is power when the ignition switch is in in the Start and On/Run position

WHEN THE KEY IS IN THE START AND RUN POSITION. This is the power wire for the fuel injection harness. If the
pink wire is connected correctly, the check engine light will come on when the ignition is "ON or START".

D. Locate the Orn/Blk and Blk/Wht wires in the dash group. These two wires are for the Park/Neutral
INDICATOR Switch, NOT the Neutral Safety Switch. If you have a GM column then you can
use the combination switch P/N 15679680 and wire it as described in paragraph 2 or 3 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.

CAUTION: DO NOT CONNECT THESE WIRES USING DIRECTIONS FROM DIFFERENT

PARAGRAPHS. YOU MAY DAMAGE THE COMPUTER.
D.1. If you are NOT using a vehicle speed sensor (VSS) or Park/Neutral Indicator Switch then you will
need to connect these two wires together.

Note: If you do this, the computer will stop controlling the exhaust gas recirculation (EGR)
solenoid. THIS WILL PREVENT THE SYSTEM FROM BEING STREET-LEGAL.

D.2. If you are going to use the recommended switch for the computers benefit ONLY, then you will
wire it as shown in Illustration A.

D.3. The recommended switch is a combination reverse light AND neutral safety switch. You may use
it for these purposes AND the computer signal IF you wire it EXACTLY as shown in
Illustration B.
D.4. 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. You may or may not want to use the Blk/Wht wire. The other end of the Blk/Wht wire is
already grounded throughout the harness.

E. The single light blue wire is the wire that lets the computer know when the brake is applied. If you ARE NOT using a
4L60E then you will tape off and store this wire. If you ARE using the 4L60E transmission then you will have to install
an electrical switch described in Paragraph 4.1.2. The pink wire provides power for this switch.

FIGURE 6.2 Brake Switch Connection

FIGURE 6.3 Brake Switch Relay

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 FIGURE 6.4 Gear Indicator Switch

F. 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.

CAUTION: FAILURE TO WIRE THIS SWITCH CORRECTLY WILL RESULT IN A

DANGEROUS SITUATION ON THE VEHICLE.

G. 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.

The fuel pump connector has a small gray wire at the bottom of it that terminates in a female connector. This wire is
a test point for the fuel pump. After the vehicle has been wired and tested OK, tape off this wire and store it in the
harness.

H. The wires labeled VATS (lt. green, red and black) are to be connected to the matching wires on the VATS module
supplied in the kit.

I. Fan #1 relay wire (green) and fan #2 relay wire (blue) are relay ground wires activated by the computer.

Note: The green wire labeled A/C CLUTCH B+ splices (using the blue T-Tap in the parts bag) into the ignition hot
wire going to the A/C compressor clutch. This is the A/C REQUEST wire.

13
J. The wire labeled TACH (white) is the signal wire for a tachometer is used.

K. The VSS output wire sends out a signal to operate the electronic cruise control or speedometer if so equipped.

6.1.2 Dash Section Connections

WIRE COLOR # OF POSITIONS LABELED CONNECT TO:

IN CONNECTOR
Brown (4) Red (2) 4 Air Pump Relay Relay
Brown, Green/White 2 Canister Purge Canister Purge Solenoid
Black, Red (2) 3 Air Pump Air Pump
Gray, Green/White, Black/White, Pink 4 Fuel Relay Fuel Pump Relay
Green/White VSS Output Speedometer/ Cruise
White Tach Tachometer
Orange/Black, Black/White P/N switch Park/Neutral Switch
Pink, Light Blue/Black Brake Switch Brake Switch
Pink Fuse Block B+ Ignition Power

TABLE 6.1 Dash Section Connections

FIGURE 6.5 Air Pump Relay Connector FIGURE 6.6 Canister Purge Solenoid

FIGURE 6.7 Air Pump Connection

14
6.2 ENGINE GROUP INSTALLATION
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 right side of the engine has the connectors for the idle air control, throttle
position sensor, distributor, and map sensor, all of which ARE labeled. When you begin routing, FIRST separate the engine
group into left and right sections and place them accordingly.

6.2.1 Before you connect any wires, separate the tail section from the engine group and place it out of
the way.

6.2.2 Locate the two Blk/Wht wires in the harness that end in a single, large ring terminal and ground
them to the engine.

6.2.3 Using Figure 6.4-6.8, and the specific connections indicated in Table 6.1, connect the wiring as
directed.
NOTE: The air pump connector is rolled up in the dash section and must be routed out to the engine
compartment if the air pump is to be operational. See section 4.1 Paragraph 4.1.3

6.2.4 Check to make sure that the 60502-wire harness has the correct distributor connector on it for your particular engine.
There are two different connectors used on LT1 engines. The 92 &93 engines used a short connector, 1" long and the
94 and up engines use a 2" connector. This 60502 harness has the 2" connector made on it. You may reuse the
original connector or contact Painless Performance for a 1" pigtail connector.

6.2.5 The pink wire labeled coil power needs to be connected to the wire that powered the coil on the original engine.

6.2.6 Engine Section Connections

WIRE COLOR # OF POSITIONS LABELED CONNECT TO:

IN CONNECTOR
Brown, Gray 2 EGR EGR Solenoid
Blue 1 Knock Knock Sensor
Ylw, Pink/Black, Pink 3 CKP Crank Position Sensor
Purple/White, Tan/White, Brown, Black 4 Driver Side Oxy Left Oxygen Sensor
Purple, Tan, Brown, Black 4 Pass. Side Oxy Right Oxygen Sensor
Red Ring Terminal (2) Starter B+ Starter Solenoid
Gray, Light Green, Black 3 MAP Map Sensor
Pink, Black 2 Inj # 1 Drivers Side Front Inj
Pink, Light Green/Black 2 Inj # 2 Pass Side Front Inj
Pink, Pink/Black 2 Inj # 3 Drivers Side 2nd Inj
Pink, Light Blue/Black 2 Inj # 4 Pass Side 2nd Inj
Pink, Black/White 2 Inj # 5 Drivers Side 3rd Inj
Pink, Yellow/Black 2 Inj # 6 Pass Side 3rd Inj
Pink, Red/Black 2 Inj # 7 Drivers Side 4th Inj
Pink, Blue/White 2 Inj # 8 Pass Side 4th Inj
Gray, Black, Blue 3 TPS Throttle Position Sensor
Light Green/Black, Light Green/White
Light Blue/Black, Light Blue/White 4 IAC Idle Air Control Motor
Yellow, Black/White, Pink 3 MAF Mass Airflow Sensor
Red/Black, Pink/Black,
Red, Light Blue/Black 4 DIST Distributor
White, Black, Pink/Black, White/Black 4 IGN MOD Ignition Module
Pink, White 2 Coil Ignition Coil
Pink/Black, White/Black 2 Coil Ignition Coil
Black, Yellow 2 ECT Engine Coolant Temp.Sensor
Black, Tan 2 IAT Intake Air Temp Sensor
Black, Black/White (3) Ring Terminal (2) Ground Engine Ground
Pink Coil Power Po wer For Coil

TABLE 6.2 Engine Section Connections 15

 FIGURE 6.9 EGR Solenoid FIGURE 6.10 Knock Sensor

FIGURE 6.11 Oxygen Sensor FIGURE 6.12 MAP Sensor

CKP- The crank position sensor will only be found on

1996-1997 engines. Those using a 1996-1997
ECM must connect to a crank position sensor or
have codes 335 & 336 turned off in the ECM.
The crank position sensor simply detects engine
misfires and has zero control over engine fueling
or timing.

FIGURE 6.13 CKP Sensor

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FIGURE 6.14 Injectors 1, 3, 5, 7 FIGURE 6.15 Injectors 2, 4, 6, 8

FIGURE 6.16 TPS Sensor FIGURE 6.17 IAC

FIGURE 6.18 MAF Sensor FIGURE 6.19 Distributor

17 connection
 FIGURE 6.20 Ignition Module FIGURE 6.21 Coil

FIGURE 6.22 ECT Sensor FIGURE 6.23 IAT Sensor

6.3 TAIL SECTION INSTALLATION

6.3.1 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.

6.3.2 If you ARE using the 4L60E transmission, route the 13-position connector to the transmission and
attach it.

6.3.3 If you ARE NOT using the 4L60E transmission, tape up the connector and store it in the harness.

6.3.4 Take the gray wire and route it to the fuel pump. This is the power wire for the fuel
pump.

6.3.5 Take the connector for the Vehicle Speed Sensor (VSS) and connect to the Vehicle Speed Sensor.

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 6.3.6 Tail Section Connections

WIRE COLOR # OF POSITIONS LABELED CONNECT TO:

IN CONNECTOR
Purple, Yellow 2 VSS Speed Sensor
Gray Fuel Pump Fuel Pump
Light Green, White, Light Blue/White,
Tan/Black, Brown, Pink, Yellow/Black,
Red/Black, Pink/Black, Blue, Red,
Yellow/White, Black 13 Trans Transmission

TABLE 6.3 Tail Section Connections

FIGURE 6.23 VSS FIGURE 6.24 Transmission Connection

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, connection of VATS module, spark,
timing, fuel pressure, etc.), then see if the computer has stored a trouble code in its memory.

FIGURE 7.1 Fuse Identification

7.1 THE "CHECK ENGINE" LIGHT

Normally, the "check engine" light should come on when the ignition is turned on, then go out a few moments 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.

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7.2 RETRIEVING TROUBLE CODES FROM THE COMPUTER

The chart below shows the type of ALDL test connector each vehicle came with from the factory. If you
are using a computer with ’94 Camaro/Firebird, ’94-’95 Caprice or ’95 Impala programming you must
install the OBD 1 connector. We have included this connector as a pig tail assembly.

If you need to install the OBD 1 connector start by cutting the zip ties holding the OBD 11 connector to the check
engine light bracket. After you disconnect the negative battery cable you can cut the 5 wires coming from the OBD 11
connector. The cut ends of Orange and Black wires should be insulated and zip tied so that they will not short. You can now
use the supplied butt connectors to connect the Black/White, White/Black and Tan wires coming from the harness to the
matching wires coming from the OBD 1 pig tail. Install the OBD 1 connector on the check engine light bracket where you
removed the OBD 11 connector from, using the supplied zip ties. If you have any issues with this process please contact the
Painless Performance Tech line at 1-800-423-9696.

1994 1995 1996

Camaro OBD 1 OBD 11 OBD 11
Firebird OBD 1 OBD 11 OBD 11
Caprice OBD 1 OBD 1 OBD 11
Impala --------- OBD 1 OBD 11

7.2.1 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.

7.2.2 After you have read any codes, write them down for reference. Remove the connector from the DLC connector.

7.2.3 Take the codes one at a time and match them to the codes in Table7.1. This will tell you in which
circuit the computer has detected a problem.

Note: A code indicates a problem in a specific circuit, NOT THAT A PARTICULAR PART IS
BAD.

7.2.4 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 and secure.

7.2.5 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.

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7.2.6 Trouble Code Chart, Diagnostic Trouble Code (DTC)

DTC 11 = Malfunction Indicator Lamp

DTC 13 = Bank 1 (left) Heated Oxygen Sensor (HO2S) Open Circuit
DTC 14 = Engine Coolant Temperature (ETC) Sensor Circuit (Signal Voltage Low) Overheated
DTC 15 = Engine Coolant Temperature (ETC) Sensor Circuit (Signal Voltage High) Engine cold
DTC 16 = Distributor Ignition System (Low Resolution Pulse)
DTC 18 = Injector Circuits
DTC 21 = Throttle Position (TP) Sensor Circuit (Signal Voltage High)
DTC 22 = Throttle Position (TP) Sensor Circuit (Signal Voltage Low)
DTC 23 = Intake Air Temperature (IAT) Sensor Circuit (Signal Voltage High) Cold Intake Air
DTC 24 = Vehicle Speed Sensor (VSS) Circuit
DTC 25 = Intake Air Temperature (IAT) Sensor Circuit (Signal Voltage Low) Hot Intake Air
DTC 26 = Evaporative Emission (EVAP) Canister Purge Solenoid Valve Circuit
DTC 27 = Exhaust Gas Recirculation (EGR) Vacuum Control Solenoid Valve Circuit
DTC 28 = Transmission Range (TR) Pressure Switch Assembly Fault
DTC 29 = Secondary Air Injection (AIR) Pump Circuit
DTC 32 = Exhaust Gas Recirculation (EGR)
DTC 33 = Manifold Absolute Pressure (MAP) Sensor Circuit (Signal Volts High, Low Vacuum)
DTC 34 = Manifold Absolute Pressure (MAP) Sensor Circuit (Signal Volts Low, High Vacuum)
DTC 36 = Distributor Ignition System (Faulty High or Extra Low Resolution Pulse Detected)
DTC 37 = Brake Switch Stuck "ON"
DTC 38 = Brake Switch Stuck "OFF"
DTC 41 = Ignition Control (IC) Circuit (Open Circuit)
DTC 42 = Ignition Control (IC) Circuit (Shorted or Grounded Circuit)
DTC 43 = Knock Sensor (KS) Circuit
DTC 44 = Bank 1 (Left) Heated Oxygen Sensor (HO2S) Circuit (Lean Exhaust Indicated)
DTC 45 = Bank 1 (Left) Heated Oxygen Sensor (HO2S) Circuit (Rich Exhaust Indicated)
DTC 46 = Pass-Key Circuit
DTC 47 = Knock Sensor (KS) Module Circuit or Module Missing
DTC 48 = Mass Air Flow (MAF) Sensor Circuit
DTC 50 = System Voltage Low
DTC 51 = EEPROM Programming Error
DTC 53 = System Voltage High
DTC 55 = Fuel Lean Monitor
DTC 58 = Transmission Fluid Temperature (TFT) Sensor Circuit Low (High Temp Indicated)
DTC 59 = Transmission Fluid Temperature (TFT) Sensor Circuit High (Low Temp Indicated)
DTC 61 = A/C System Performance
DTC 63 = Bank 2 (Right) Heated Oxygen Sensor (H02S) Circuit (Open Circuit)
DTC 64 = Bank 2 (Right) Heated Oxygen Sensor (H02S) Circuit (Lean Exhaust Indicated)
DTC 65 = Bank 2 (Right) Heated Oxygen Sensor (H02S) Circuit (Rich Exhaust Indicated)
DTC 66 = A/C Refrigerant Pressure Sensor Circuit (Open or Shorted)
DTC 67 = A/C Refrigerant Pressure Sensor Circuit (Pressure Sensor or A/C Clutch Problem)
DTC 68 = A/C Relay Circuit (Shorted Circuit)
DTC 69 = A/C Clutch Circuit
DTC 70 = A/C Clutch Relay Driver Circuit
DTC 71 = A/C Evaporator Temperature Sensor Circuit (Open or Shorted)
DTC 72 = Vehicle Speed Sensor Loss (Automatic Transmissions Only)
DTC 73 = Pressure Control Solenoid (PCS) Circuit (Current Error)
DTC 74 = Traction Control Circuit (TCS) Circuit Low
DTC 75 = Transmission System Voltage Low
DTC 77 = Cooling Fan Relay Control Circuit
DTC 79 = Transmission Fluid Overtemp

21
 DTC 81 = Transmission 2-3 Shift Solenoid Circuit
DTC 82 = Transmission 1-2 Shift Solenoid Circuit
DTC 83 = Reverse Inhibit System (Manual Transmission)
DTC 83 = TCC PWM Solenoid Circuit Fault (Automatic Transmission)
DTC 84 = Automatic Transmission 3-2 Control Solenoid Circuit
DTC 84 = Skip Shift Solenoid Circuit (Manual Transmission)
DTC 85 = Transmission TCC Stuck "ON"
DTC 90 = Transmission TCC Solenoid Circuit (Manual Transmission)
DTC 91 = Skip Shift Lamp Circuit
DTC 97 = VSS Output Circuit
DTC 99 = Tach Output Circuit

TABLE 7.1 Diagnostic Trouble Codes

7.3 WHEN TO CALL PAINLESS PERFORMANCE PRODUCTS' TECH LINE

7.3.1 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.).

7.3.2 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) 560-8324. Calls are answered from 8am to 5pm central time,
Monday thru Friday, except holidays. Email questions to Tech@painlessperformance.com

Painless Performance Products, LLC

Limited Warranty and Return Policy
Chassis harnesses, fuel injection harnesses, and Trail Rocker units 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.

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