Painless Performance 60217 Installation Instructions Manual Download Page 3

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. 

 

 

 

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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