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7.1 

Mopar Alternator. See Figure 9-1 

 

Note:  Your Alternator may not appear exactly as represented in Figure 7-1. The circuits are wired the 

same way, though. 

 

7.1.1  Mopar uses one of two kinds of voltage regulators: An electronic regulator and a mechanical one. 

The electronic voltage regulator is represented in Figure 7-1A. It does not matter how the two 
terminals are connected, so long as they are BOTH connected. The mechanical regulator has 

terminals marked "F" (Field) and "l" (Ignition). In contrast to the electronic regulator, it DOES 
make a difference how the mechanical regulator is connected. 

7.1.2  Connect ENGINE SECTION wire #914 (BLU) to the Alternator Field (F) terminal as shown in Figure 

7-1A. Connect ENGINE SECTION wire #915 (BLK) to the Alternator Output lug (Bat). 

 

CAUTION: 

IF USING AN ALTERNATOR WITH AN OUTPUT LARGER THAN 65 AMPS, 

YOU WILL ALSO NEED TO USE JUMPER WIRE #960 (RED), INCLUDED IN BOX. THE 
WIRE END WITH THE RING TERMINAL AND RUBBER BOOT WILL CONNECT TO THE 

ALTERNATOR OUTPUT LUG. ROUTE THE OTHER END TO THE STARTER. CUT THE WIRE 
AND CRIMP ON A RING TERMINAL. INSTALL ON SAME TERMINAL OF MAXI FUSE AS 

#916 RED. SEE FIGURE 7-1B. 

 
7.1.3  Connect a 14-gauge wire from the Alternator terminal where wire #914 is connected to either of 

the ELECTRONIC Voltage Regulator terminals OR terminal (l) of the MECHANICAL Voltage 
Regulator. On existing Mopar harnesses, this would be a blue wire. 

7.1.4  Connect a 14-gauge wire from the other Alternator Field terminal (as shown in Figure 7-1) to the 

second terminal of the ELECTRONIC Voltage Regulator OR terminal (F) of the MECHANICAL 

Voltage Regulator. On existing Mopar harnesses, this would be a green wire. 

7.1.5  Finally, be sure BOTH the alternator and the voltage regulator itself are grounded. 

 

 

 

 

Figure 7-1A  Mopar Alternator 

 

 

7.2 

Mopar Ignition (Start/Run) System. See Figure 7-2A 

 

Note:  If you are going to install an ammeter, see Section 8.3 first.

 

 
7.2.1  Connect ENGINE SECTION (single) 10-gauge red wire #916 (with or without ammeter) to the 

MAXI fuse. Use remaining 10 ga. to connect to Starter Relay Battery Terminal. Retain excess wire. 

 

 

 

Summary of Contents for 90542

Page 1: ...Wire Harness Installation Instructions For Installing 10127 Customizable Mopar Chassis Harness 21 Circuit Manual 90542...

Page 2: ...s 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...

Page 3: ...tor Conversion 13 8 3 Connecting to Ammeter and the Maxi Fuse 14 8 4 Interior Lighting 14 8 5 Headlight Section A 15 8 6 Headlight Section B 16 8 7 Instrument Panel Wiring 16 8 8 Brake Light Switch 16...

Page 4: ...he different circuits during installation and later on if additions to the overall system are necessary For fuse specifications and wire color designations see Section 9 0 All wire is 600 volt 125 c T...

Page 5: ...g to the number Always pay special and careful attention to any Notes especially those in the Tables and any text marked Caution 3 0 CONTENTS OF THE PAINLESS WIRE HARNESS KIT Refer to Figure 3 1 to ta...

Page 6: ...Section 7 0 To help you begin thinking through the installation of your wire harness read the following sections 5 1 Familiarize yourself with the harness by locating each of the harness sections in...

Page 7: ...the Firewall grommet in the plate or the new hole you drilled Route engine and headlight group wires through the grommet and position the harness groups in the areas decided upon in Sections 5 3 and 5...

Page 8: ...Remember to allow enough slack in the harness and wires at places where movement could possibly occur such as automobile body to frame frame to engine etc Double check your calculations 6 4 4 Strip i...

Page 9: ...RUBBER BOOT WILL CONNECT TO THE ALTERNATOR OUTPUT LUG ROUTE THE OTHER END TO THE STARTER CUT THE WIRE AND CRIMP ON A RING TERMINAL INSTALL ON SAME TERMINAL OF MAXI FUSE AS 916 RED SEE FIGURE 7 1B 7 1...

Page 10: ...mount it away from other wiring or hoses The ballast resistor gets very hot during operation Connect ENGINE SECTION A wire 931 BRN to one end of the Ballast Resistor Connect the other end of the balla...

Page 11: ...Figure 7 2A Mopar Ignition Start Run System Figure 7 2B Mopar Electronic Ignition with Dual Ballast Resistor 11...

Page 12: ...r does it support seat belt buzzers or key alarms If your using an aftermarket column which requires GM turn signal connectors you ll need Painless part 30806 7 4 Steering Column Wiring Ignition Switc...

Page 13: ...his purpose labeled G or you may have to ground the regulator case 8 1 3 Connect ENGINE SECTION wire 915 BLK to Voltage Regulator terminal B 8 1 4 Insulate and stow ENGINE SECTION wire 914 BLU Figure...

Page 14: ...attery B terminal CAUTION BOTH AMMETER TERMINALS MUST ABSOLUTELY BE ISOLATED FROM GROUND IF EITHER AMMETER TERMINAL COMES IN CONTACT WITH GROUND A HARNESS FIRE IS INEVITABLE USE EXTREME CARE AND DILIG...

Page 15: ...nectors For models with separate high beam head lamps extra head lamp connectors have been supplied To make connections for separate high beam lamps run a jumper wire from the connection of wire 908 R...

Page 16: ...Note The wire going to the fan in Figure 8 4B will be coming from the fan relay output terminal Wire 901 GRY WHT from the ACCESSORY SECTION SWITCHES is an activation wire for the fan relay NOTE If you...

Page 17: ...ELOW Which diagram you will use depends on whether or not you have one bulb on each side of the vehicle that is for the brake tail and Turn Signal Lights this is referred to as integrated lights or yo...

Page 18: ...nto anything other than a grounded metal part then you will need to provide a separate ground wire 8 10 3 This kit has a bag containing 30 Mopar lamp socket terminals These terminals fit all lamp sock...

Page 19: ...from the fuse panel and certain other wires such as those originating from the horn relay the dimmer switch and the instrument panel section These pre connected wires are identified by an asterisk in...

Page 20: ...el Section Gry Blk1 18 923 Tachometer Source Tachometer Instrument Panel Section Red 18 954 Electric Choke Fuse Panel Fuse Panel HEADLIGHT SECTION A Grn Red1 14 924 Horn B Horn Relay Fuse Panel Tan 18...

Page 21: ...rn Signal Section Blu 18 939 Fuel Sending Unit Fuel Gauge Instrument Panel Section Blk 14 929 Tail Lights Headlight Switch Headlight Section B Orn 18 950 Third Brake Light Turn Signal Switch Turn Sign...

Page 22: ...22...

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Page 24: ...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 t...

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