Related Manuals for Painless Performance Products 90542
Summary of Contents for Painless Performance Products 90542
- Page 1 Wire Harness Installation Instructions For Installing: #10127 Customizable Mopar Chassis Harness 21 Circuit Manual #90542...
- Page 2 E-Mail: painless@painlessperformance.com If you have any questions concerning the installation of this product, feel free to call Painless Performance Products' tech line at 1-800-423-9696. Calls are answered from 8am to 5pm central time, Monday thru Thursday, 8am- 4:30pm Friday, except holidays.
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Page 3: Table Of Contents
List of Figures………………………………………………………………………………………… List of Tables…………………………………………………………………………………………. List of Diagrams…………………………………………………………………………………….. Introduction………………………………………………………………………………………….. About These Instructions……………………………………………………………………….. Contents Of The Painless Wire Harness Kit……………………………………………….. Tools Needed…………………………………………………………………………………………. Pre-Installation and General Harness Routing Guidelines……………………………. Harness General Installation Instructions………………………………………………….. Rough Installation…………………………………………………………………………. Harness Attachment………………………………………………………………………. Grounding the Automobile…………………………………………………………….. Terminal Installation and Making Connections………………………………….. Testing the System……………………………………………………………………….. - Page 4 Engine Wiring………………………………………………………………………………….. 23 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.
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Page 5: Contents Of The Painless Wire Harness Kit
Headlamp Connector Cables. (Extra Headlamp Cables are available separately under P/N 80300.) Maxi Fuse Firewall Grommet (large) 2 Fender Well Grommets (for Headlamps) 2 packages of Nylon Tie Wraps Parts Box, containing Terminals, Splices, etc. This booklet, P/N 90542 Painless Wiring Manual. Figure 3-1 Painless Wire Harness Kit TOOLS NEEDED... -
Page 6: Pre-Installation And General Harness Routing Guidelines
In addition to your regular tools, you will need, at least, the following tools: Note: Use a quality tool to avoid over-crimping. Crimping Tool Wire Stripper Test Light or Volt Meter Electric Drill 1-1/4" Hole Saw Small (10 amp or less) Battery Charger PRE-INSTALLATION AND GENERAL HARNESS ROUTING GUIDELINES The installation of your wire harness mainly consists in two parts: ... -
Page 7: Harness General Installation Instructions
Headlights Engine Dash Tail Lights A good exercise is to lay out the wire harness on the floor beside your automobile and identify all the SECTIONS. You will want to route the harness through and around open areas. Inside edges provide protection from hazards and also provide places for tie wraps, clips and other support. -
Page 8: Terminal Installation And Making Connections
A perfectly and beautifully wired automobile will nevertheless have bugs and problems if everything is not properly grounded. Do not go to the careful effort of installing a quality wire harness only to neglect proper grounding. Note: The Painless Wire Harness Kit includes no ground wire except the black wire from the two headlamp connectors. -
Page 9: Mopar Alternator
Mopar Alternator. See Figure 9-1 Note: Your Alternator may not appear exactly as represented in Figure 7-1. The circuits are wired the same way, though. 7.1.1 Mopar uses one of two kinds of voltage regulators: An electronic regulator and a mechanical one. The electronic voltage regulator is represented in Figure 7-1A. -
Page 10: Figure 7.1B High Output Wire
Figure 7-1B High Output Wire 7.2.2 With crimping tool, attach the Maxi Fuse onto remaining length of red 10-gauge wire. It serves as a fuse to protect the entire harness. DO NOT OMIT IT! Connect this wire from the Starter Motor Battery terminal, as shown in Figure 7-2A. -
Page 11: Figure 7.2A Mopar Ignition System
Figure 7-2A Mopar Ignition (Start/Run) System Figure 7-2B Mopar Electronic Ignition with Dual Ballast Resistor... -
Page 12: Steering Column Wiring - Turn Signal Connections
7.3 Steering Column Wiring - Turn Signal Connections Refer to Table 7-1. Check your existing wiring (by tracing the wire, if necessary) against the data given. 7.3.1 According to Table 7-1, connect the wires of the TURN SIGNAL SECTION using the supplied terminals (see Figure 7.3) to your automobile's existing Turn Signal Connector. -
Page 13: All Makes - Specific Circuit Connections
ALL MAKES - SPECIFIC CIRCUIT CONNECTIONS Generator Charging System. See Figure 8-1. 8.1.1 Connect Generator ARMATURE terminal (A) to Voltage Regulator terminal A. Connect Generator FIELD terminal (F) to Voltage Regulator terminal F. Use 14-gauge wire (color optional) for FIELD and 12-gauge wire for Armature. -
Page 14: Interior Lighting
Connecting an Ammeter and the Maxi Fuse. See Figure 8-2. 8.3.1 Most, but not all Ammeters must be inserted IN SERIES onto the ENGINE SECTION (single) 10- gauge wire #916 (red) that routes from the Fuse Panel to Maxi Fuse (Section 7.2). 8.3.2 The overall physical length of this circuit should be as short as possible (allow some slack, however). -
Page 15: Headlight Section "A
Figure 8-4A Typical Fan Relay Installation (Painless Part #30101) Figure 8-4B HEADLIGHT SECTION A Wiring 8.5 HEADLIGHT SECTION A. See Figure 8-4B. 8.5.1 Connect HEADLIGHT SECTION A wire #924 (GRN/RED) to the Horn's hot terminal. TURN SIGNAL SECTION wire #953 (BLK) was connected in the Turn Signal Connector section of these instructions. -
Page 16: Headlight Section "B
Figure 8.5A Dual Headlamp Connections 8.5.3 Connect HEADLIGHT SECTION A wires #927 (BLK/YLW) to ALL front Park Lights and wires# 927 (GRN/BLK) to both Marker Lights. Connect HEADLIGHT SECTION A wires #925 (TAN) to the RIGHT FRONT Turn Signal(s). Connect wires #926 (GRN/RED) to the LEFT FRONT Turn Signal(s). Note: Don't confuse Park Lights or Marker Lights with Turn Signals. -
Page 17: Instrument Panel Wiring
Instrument Panel Wiring 8.7.1 Connect the wires of the INSTRUMENT PANEL SECTION as indicated in Table 9-2. Insulate and stow any wires you do not use. 8.7.2 Connect a jumper from wire #935 (BLK) to all Gauges' power or “I” terminals. Connect a jumper from wire #930 (ORN) to all Gauges' Instrument Lighting terminals. -
Page 18: Helpful Hints For Tail Section Wiring
Figure 8-7B Separate Turn/Brake Lights 8.10 Helpful Hints for Tail Section Wiring 8.10.1 When you have Integrated Brake Lights on your vehicle the Turn Signal switch acts as a brain to control when the Lights in the rear are on constantly (braking) or flashing (turning) or a combination of both. -
Page 19: Wire Connection Index
9.0 WIRE CONNECTION INDEX Wire Connection Index In each section, connect the wire, as identified by its wire color, to the appropriate item in the CONNECT TO column. Pay close attention to the Notes in this section, as identified by a small, raised number such as the one at the end of this sentence.... - Page 20 Color Connect to Wire Starting Point Section of Starting Point ACCESSORY SECTION SWITCHES Gry/Wht Cooling Fan Switch Fan Relay Headlight Section A Blk/Wht AC/Heat Switch A/C Compressor Engine Section A ACCESSORY SECTION B+ Blk/Wht AC/Heat Switch B+ Fuse Panel* Fuse Panel Wiper Switch B+ Fuse Panel* Fuse Panel...
- Page 21 Color Connect to Wire Starting Point Section of Starting Point INSTRUMENT PANEL SECTION Voltmeter Source & Gauges B+ Fuse Panel* Fuse Panel High Beam Indicator Dimmer Switch* Dimmer Switch Section Lt.Grn Left Turn Indicator Left Front Turn Signal Turn Signal Section Right Turn Indicator Right Front Turn Sig.
- Page 24 Painless Performance Limited Warranty and Return Policy Chassis harnesses, fuel injection harnesses, and Striker ColdShot units are covered under a lifetime warranty. All other products manufactured and/or sold by Painless Performance are warranted to the 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 the purchase date.