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In addition to your regular tools, you will need, at least, the following tools: 
 

 

Crimping Tool  

Note:  Use a quality tool to avoid over-crimping.

 

 

Wire Stripper 

 

Test Light or Volt Meter 

 

Electric Drill 

 

1-1/4" Hole Saw 

 

Small (10 amp or less) Battery Charger 

 
5.0

 

PRE-INSTALLATION AND GENERAL HARNESS ROUTING GUIDELINES 

 

The installation of your wire harness mainly consists in two parts: 

 
 

 

The physical routing and securing of the wire harness, wires, and groups. 

 

 

The proper connection of the individual circuits. 

 

These two major tasks are not separate steps, but are integrated together. That is, you will route some wires and 
make some connections, route some more wire and make some more connections. 

 
We cannot tell you how to physically route the harness in your automobile. That depends a great deal upon the 

particular make/model of automobile and to what extent you want to secure and conceal the harness. We do offer 
some general guidelines and routing practices starting in Section 5.2, GENERAL installation instructions in Section 

6.0, and precise instructions concerning the electrical connections you will have to make in beginning in 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 the following list. 

(Whenever a particular harness section is referred to in these instructions it is shown "all caps": ENGINE 
SECTION A) 

 
 

ACCESSORY SECTION SWITCHES 

TURN SIGNAL SECTION 

ACCESSORY SECTION B+ 

HEADLIGHT SECTION A 

DIMMER SWITCH SECTION 

HEADLIGHT SECTION B 

ENGINE SECTION 

IGNITION SWITCH SECTION  

ENGINE SECTION A (Single, 10 ga. red wire) 

INSTRUMENT PANEL SECTION 

ENGINE SECTION A 

RADIO SECTION 

TAIL SECTION 

HAZARD SWITCH SECTION 

PANEL LIGHT SECTION 

 

 

Note:  For complete information concerning the individual circuits and wires that make up the harness 

SECTIONS, see Section 9.0.

 

 

5.2

 

Decide where the fuse block will be mounted. The Painless Wire Harness is designed for the fuse block to be 
mounted on the driver's side, under the dash.  

5.3

 

Decide which of the following circuits you will be using in your system and where the harness groups or 
wires will be routed: 

ROUTING LOCATION AND PLACEMENT 

 

 

Emergency Flashers 

 

Horn 

 

Dome Lights 

 

Lights 

 

Air Conditioner 

 

Electric Cooling Fan 

 

Coil 

 

Turn Signals 

 

Radio Ignition Switched Power 

 

Radio Constant Power 

 

Gauges 

 

Accessories 

 

5.4

 

Where will the following harness groups be routed? 

 

Содержание 90542

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 22: ...22...

Страница 23: ...23...

Страница 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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