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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). 

 

 

 

 

 

 

Summary of Contents for 60217

Page 1: ...VORTEC FUEL INJECTION 4 8L 5 3L 6 0L WIRE HARNESS INSTALLATION INSTRUCTIONS Manual P N 90530 Third Edition July 2014 Copyright November 2004 PAINLESS PERFORMANCE PRODUCTS 2501 Ludelle Street Fort Wor...

Page 2: ...ke 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...

Page 3: ...f 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 3012...

Page 4: ...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 INSTALLA...

Page 5: ...G 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 remove...

Page 6: ...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 po...

Page 7: ...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 shapi...

Page 8: ...nnection 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 t...

Page 9: ...mp 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 circ...

Page 10: ...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 recomm...

Page 11: ...FIGURE 6 1 DLC Connector Check Engine Light FIGURE 6 2 Brake Switch Connections FIGURE 6 3 Brake Switch Relay 9...

Page 12: ...Pump Air Pump Gray Green White Black Orange 4 Fuel Relay Fuel Pump Relay Green White VSS Output Speedometer White Tach Tachometer Pink Purple Brake Switch Brake Switch Pink Fuse Block Ignition Igniti...

Page 13: ...is used to excite turn on the voltage regulator When using the stock alternator equipped on the 4 8 5 3 or 6 0L Vortec engines this wire will connect to the L terminal in the voltage regulator plug Y...

Page 14: ...ions are secure H IAC mandatory The purpose of the Idle Air Control Motor IAC is to control engine idle speed The IAC valve mounted in the throttle body controls the amount of bypass air See Figure 6...

Page 15: ...14 Black Red Green Brown Lt Blue Purple Pink Black Red White Green White Brown White Lt Blue White Purple White Pink White Purple Brown Gray Red Black Tan Black White Pink Yellow Lt Green Black Lt Gre...

Page 16: ...FIGURE 6 10 EGR Valve FIGURE 6 11 Knock Sensor Connector FIGURE 6 12 Oxygen Sensor FIGURE 6 13 MAP Sensor FIGURE 6 14 CMP Sensor FIGURE 6 15 CKP Sensor 13...

Page 17: ...FIGURE 6 16 Injectors 1 3 5 7 FIGURE 6 17 Injectors 2 4 6 8 FIGURE 6 18 TPS Sensor FIGURE 6 19 IAC Sensor FIGURE 6 20 MAF IAT Sensor FIGURE 6 21 Driver Side Coil Connector 15...

Page 18: ...n Connect this wire to a circuit from the ignition switch start position This wire should only have power in the start position C FUEL PUMP mandatory This circuit provides power to the electric fuel p...

Page 19: ...UIT DIRECTLY TO THE STARTER SOLENOID You can substitute Painless part 30202 Hot Shot Relay if the stock starter relay is not available H TRANS optional These circuits are used by the PCM to determine...

Page 20: ...ission connector 1 With the terminal end of the connector and the arrow on top pointing towards you carefully remove the white retaining lock located in the center of the connector 2 Locate the white...

Page 21: ...e greatest number of problems with new cars is the same kinds of problems that older cars without computer controls have Begin all troubleshooting by checking the basics Certain basic faults may be un...

Page 22: ...nded and will not turn off the check engine light Once a DTC has been identified contact the Painless tech dept or a GM Service Manual for a procedure to identify why a particular code is being set Do...

Page 23: ...urate instructions possible and are always concerned about corrections or improvements that can be made If you have found any errors or omissions or if you simply have comments or suggestions concerni...

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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