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6.2  DASH SECTION INSTALLATION 

 

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. 

 

 

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), fuel pump relay, emissions devises 

(optional) and 6 other wires. 

 

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.   AC REQUEST – 

This circuit is used to inform the PCM that the AC compressor has been turned on. This 

wire is to be spliced into the circuit from the AC switch to the AC compressor. 

This is not a power supply for the compressor 

 

B.  The secondary Air Injection (AIR) system helps reduce hydrocarbon (HC), carbon 

monoxide (CO), and oxides of nitrogen (NOx) exhaust emissions. 

 

1.  AIR PUMP (not equipped on all models) - The AIR pump assembly is mounted 

in the right rear corner of the engine compartment and supplies the air to the AIR 

system. The electric air pump sends air to the check valves near the exhaust 

manifolds. The AIR pump is controlled by the Powertrain Control Module (PCM) 

through the AIR pump 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 circuit for the secondary AIR 

pump solenoid relay, battery voltage applies power to the AIR pump and the 

solenoid. Intake manifold vacuum is then applied through the solenoid to the 

vacuum operated shut off valve. The vacuum operated shut off valve then opens up 

and allows air to be delivered to the check valves. See Figure 6.7 

2.  AIR RELAY (not equipped on all models) - The PCM controls the operation of 

the AIR system through the AIR pump solenoid relay. When the PCM provides a 

ground circuit for the secondary AIR pump solenoid relay, battery voltage is allowed 

to power up the AIR pump and the solenoid. See Figure 6.4 

3.  AIR SOL (not equipped on all models) - The AIR solenoid is activated by the 

AIR pump solenoid relay. The AIR solenoid allows intake manifold vacuum to the 

shut off valve. The shut off valve then opens allowing air flow. See Figure 6.8 

4.  CAN VENT (not equipped on all models) - The Evaporative Emissions (EVAP) 

control system used on all vehicles is the charcoal canister storage method. This 

method transfers fuel vapor from the fuel tank to an activated carbon, charcoal, 

storage device, 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 6.6 

 

 

 

 

 

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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