ion

Perfect Performance Products, LLC
2501 Ludelle St., Fort Worth, Texas 76105-1036
Phone (800) 423-9696


We have attempted to provide you with as accurate
instructions as 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 concerning these instructions, please write us
at the address on the cover and let us know about them. Or,
better yet, send us a fax at (817) 244-4024 or e-mail us at
painless@painlessperformance.com. We sincerely appreciate
your business.

















Perfect Performance Products, LLC shall in no event be liable in contract or tort (including
negligence) for special, indirect, incidental, or consequential damages, such as but not limited
to, loss of property damage, or any other damages, costs or expenses which might be claimed
as the result of the use or failure of the goods sold hereby, except only the cost of repair or
replacement.


P/N 90501 Painless Wiring Manual February 1993

13
th
Edition August 2008
Copyright
© 1994 by Perfect Performance Products, LLC










NOTE :


If your vehicle has an existing harness, you will want to retain it for the possible re-
use of various Pigtails & Connector housings, particular to your application.

If you do not have an existing harness, there is a package of terminals included with
the harness that will enable you to make most of the connections needed.
Replacement lighting pigtails & sockets can be readily obtained from your local
parts distributor






























TABLE OF CONTENTS

List
of
Figures ii

List of Tables ii

List of Diagrams ii

1.0 Introduction 1
2.0
About These Instructions 1
3.0
Contents of the Painless Wire Harness Kit2
4.0 Tools
Needed 2
5.0
Pre-Installation and General Harness Routing Guidelines 2
6.0
Harness General Installation Instructions 4
6.1
Rough
Installation 4
6.2
Harness
Attachment 4
6.3
Grounding
The
Automobile 5

6.4
Terminal Installation and Making Connections 5

6.5
Testing The System 5
7.0 Specific Circuit Connections.... 6
8.0 Charging Systems..6

8.1
Generator Charging Systems6

8.2 Generator Charging Systems.6

8.3
GM External Regulator...7

8.4
GM Internally Regulated Alternator..8

8.5
High Output Wire...8

8.6A CS 130 Alternator.9
8.6B CS 130 Connector Pinout..9

8.6C CS 130D Alternator..9
8.6 D CS 130D Connector Pinout
9.0 Ignition Start /Run System...9
10.0 Turn Signal Switch...10
11.0 Ignition Switch11
12.0 Connecting Ammeter & Maxi Fuse..11
13.0 Headlight Section A.12
14.0 Instrument Panel Wiring..13
15.0 Headlight Section B (Headlight Switch)14
16.0 Brake Light Switch14
17.0 Interior Lighting.15
18.0 Tail Section..15
19.0 Hints For Tail Section.17
20.0 Wire Connection Index.17
21.0 Fuse Requirements.17







i



LIST OF FIGURES

Figure 3.1
The Painless Wire Harness Kit 2
Figure 8.1 Generator Charging System. 6
Figure 8.3
GM Externally Regulated Alternator..7
Figure 8.4
GM Internally Regulated Alternator (10SI)...7
Figure 8.5 High Output Wire8
Figure 8.6A CS 130 External Fan Alternator..9
Figure 8.6B CS 130 Connector & Pinout..9
Figure 8.6C CS 130D Internal Fan Alternator9


Figure 8.6D CS 130D Connector & Pinout..9
Figure 9.1
Maxi Fuse .9
Figure 9.2 GM Ignition (start-run)...10
Figure 10.1 Early (67-68) Turn Signal Connection.10
Figure 10.2 Column Mounted Ignition Switch..11
Figure 11.1 Camaro Dash Mounted Ignition Switch..11
Figure 12.1 Maxi Fuse & Ammeter..11
Figure 13.1 Headlight Section A wiring.12
Figure 13.2 Fan Relay Installation12
Figure 13.3 Dimmer Switches.13
Figure 14.1 Headlight SectionB (headlight switch) wiring..14
Figure 16.1 Interior Lighting15
Figure 17.1 Integrated Brake Lights..16
Figure 17.2 Separate Turn/Brake Lights..16

LIST OF TABLES

Table 11-1 Ignition & Turn Signal Wiring11
Table 21 Fuse Requirements.17


Wire Connection Index (1 of 3).............18
Wire Connection Index (2 of 3)..19
Wire Connection Index (3 of 3)..20

LIST OF DIAGRAMS

Diagram 1 Instrument Panel Section Wiring 22
Diagram 2 Engine Wiring 23
Diagram 3 Wiper Switch Connection.24
Diagram 4 Firewall Opening Template.25




ii 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 wire harness on the market. It is designed for easy installation, even if you have no electrical
experience.

All kits have a built-in-anti-theft feature. Removing the fuse labeled "coil" from the fuse block will prevent the vehicle
from starting.

The proper fuses have been pre-installed in the fuse block. In addition, all wires are color-coded. This will help you
identify the different circuits during installation and later on if additions to the overall system are necessary. For fuse
specifications and wire color designations, see Section 20.0 and 21.0

In addition all of our kits have "accessory" terminals at the front of the fuse block for your convenience. These
terminals may be constantly hot or "switched" hot but all are un-fused. If you plug into one of these terminals you
must provide your own in-line fuse or circuit breaker.

The Painless wire harness is designed to be used in vehicles with a General Motors - keyed steering column, or other
steering columns, depending on the kit purchased. All wire is 600 volt, 125°c, TXL. Standard automotive wire is GPT,
300 volt, 80°c, with PVC insulation.

This complete automobile wiring system has been designed with three major groups incorporated into it:

ENGINE/HEADLIGHT GROUP



Includes high beam, low beam, park, right turn, left turn, electric fan, horn, starter solenoid and battery feed,
alternator and alternator exciter wire, distributor, water temperature, oil pressure, and air conditioning.

DASH GROUP

Includes wires to connect gauges, indicator lights, and switches to their proper sources. Trunk accessory, door locks,
power windows, and electric fuel pump are included in the 18-circuit kit.

REAR LIGHT GROUP

Includes tail lights, dome lights (see Paragraph 10.4.2), left and right turn signals, brake lights, and fuel sender.

Installation requires four (4) easy steps:
1. Mount the fuse block





2. Route the wires





3. Cut off the excess wire





4. Terminate the wires

2.0

ABOUT THESE INSTRUCTIONS

The contents of these instructions are divided into major Sections, as follows:

1.0

Introduction
2.0

About These Instructions
3.0

Tools Needed
4.0

Contents of Painless Wire Harness Kit
5.0

Pre-Installation and General Harness Routing Guidelines
6.0

General Harness Installation Instructions
7.0

Specific Circuit Connection Details
8.0

Charging Circuit Connection Details
9.0



Sections are divided into subsections and Paragraphs. Throughout these instructions, the Figure numbers refer to
illustrations and the Table numbers refer to information in table form. These are located in Sections or Paragraphs
corresponding to the number. Always pay special and careful attention to any
Notes
, especially those in the Tables,
and any text marked
Caution
.





1

3.0

CONTENTS OF THE PAINLESS WIRE HARNESS KIT

Refer to Figure 3-1 to take inventory. See that you have everything you're supposed to have in this kit. If anything
is missing, contact the dealer where you obtained the kit or Painless Performance at (800) 423-9696. The Painless
Wire Harness Kit should contain the following items:


A
The Main Wire Harness, with the Fuse Block wired in and fuses installed.
B The Console gauge pigtail
C
Headlamp Connector Cables. (Extra Headlamp Cables are available separately under P/N 80300.)
D
Maxi Fuse
E
2 Fender Well Grommets (for Headlamps)
F
2 packages of Nylon Tie Wraps
G
2 GM Turn Signal Connectors
I
Parts Box, containing a GM Alternator Connector, Terminals, Splices, etc. This booklet, P/N 90551 Painless
Wiring Manual.





























Figure 3-1 The Painless Wire Harness Kit

4.0

TOOLS NEEDED

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, r