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
