P/N 60520 & 60521 2005-06 GM LS2 FUEL INJECTION WIRE HARNESS INSTALLATION INSTRUCTIONS Manual P/N 90543 First Edition June 12, 2006 PAINLESS PERFORMANCE PRODUCTS 2501 Ludelle Street - Fort Worth, Texas 76105-1036 - (800) 423-9696 1
TABLE OF CONTENTS 1.0 2.0 3.0 4.0 5.0 6.0 7.0 INTRODUCTION.......................................................................................................................... ABOUT THESE INSTRUCTIONS............................................................................................... TOOLS NEEDED.......................................................................................................................... PRE-INSTALLATION AND HARNESS ROUTING GUIDELINES.........................
1.0 INTRODUCTION We at Painless Performance Products believe you have purchased the most up-to-date and easiest to install automotive fuel injection harness on the market. All components to this harness are new. All harnesses are tested for faults before they leave the factory floor. This harness is designed for easy installation, even if you have no electrical experience. Please read entire manual before installation.
5.0 6.0 7.0 GENERAL INSTALLATION INSTRUCTIONS GM LS2 FUEL INJECTION HARNESS KIT TROUBLE-SHOOTING INSTRUCTIONS AND TROUBLE CODES Sections are further divided into Paragraphs and Steps. Throughout, the Figure numbers refer to illustrations and the Table numbers refer to information in tables. These are located in or near the sections or paragraphs to which they correspond. Always pay careful attention to any notes or any text labeled CAUTION. 3.
4.2 YOU SHOULD GET TO KNOW THE PARTICULAR ENGINE YOU ARE USING: NOTE: The 2005-2006 LS2 engines had four oxygen sensors from the factory. We have included provisions for only two oxygen sensors, which include one on the driver side and one on the passenger side of the engine. We have removed the two rear oxygen sensors since they originally where behind the catalytic converters and most people don’t want to run more than two oxygen sensors. 4.2.1 PPPI recommends the use of the following parts.
5.0 GENERAL INSTALLATION INSTRUCTIONS CAUTION: ~ ~ ~ ~ ~ DO NOT DISCONNECT THE BATTERY OR THE COMPUTER CONNECTORS WHILE THE IGNITION IS ON. DO NOT SHORT ANY WIRES IN THIS HARNESS TO GROUND (WITH THE EXCEPTION OF LABELED GROUND WIRES) OR DAMAGE TO THE COMPUTER WILL RESULT. GIVING OR RECEIVING A JUMP START MAY DAMAGE THE COMPUTER. DO NOT USE A TEST LIGHT WHEN TESTING COMPUTER SENSORS OR COMPUTER CIRCUITS.
5.3 HARNESS ATTACHMENT Note: Harness routing and shaping will be a time-consuming task. Taking your time will enhance the beauty of your vehicle. Please take your time and be patient. 5.3.1 Permanently mount your computer. You should mount the fuse block, TAC Module and fuel pump relay at this time. Mount the accelerator pedal. Note the pigtail that plugs into the accelerator pedal and then to the TAC module is either 8ft or 12ft long depending on the harness purchased.
6.0 GM 2005-06 LS2 SYSTEM WIRE HARNESS INSTALLATION INSTRUCTIONS 6.1 CONTENTS OF THE 60520-21 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 (817) 244-6898. The kit should contain the following items: ~ ~ ~ ~ 6.2 The main fuel injection wire harness. Fuel Injection Installation Instructions P/N 90543 (This Booklet). 4” & 7” tie wraps.
A. B. Find a suitable location to mount the DLC connector (using the bracket that the light is mounted in) that will allow access to the front of the connector and still allow you to see the light while driving. Mount the DLC connector using the bracket containing the check engine light in the place selected. C. Locate the 18 gauge, pink, ignition hot activation wire labeled FUSE BLOCK IGNITION and attach it to a fused, 12 volt source where there is power WHEN THE KEY IS IN THE START AND RUN POSITION.
FIGURE 6.2 Brake Switch Connections FIGURE 6.3 Brake Switch Relay G. If your vehicle has a pressure type brake switch, you may use a relay as shown in Figure 6.3. The relay must be a SPDT Relay and wired correctly or it could result in a dangerous situation with the vehicle. The torque converter may not unlock.
FIGURE 6.4 Gear Indicator Switch CAUTION: H. FAILURE TO WIRE THIS SWITCH CORRECTLY WILL RESULT IN A DANGEROUS SITUATION ON THE VEHICLE. Illustration A is for Park/Neutral only. Illustration B is for Park/Neutral, Reverse and Gear Indicator. Plug in the fuel pump relay to the fuel pump relay connector. The wire labeled FUEL TEST is a test point for the fuel pump. After the vehicle has been wired and tested, tape off this wire and store it in the harness. FIGURE 6.
I. Fan #1 relay wire (green) and fan #2 relay wire (blue) are relay ground wires activated by the computer. The factory cooling fan settings are listed below. Note: Fan #1 will come ON at 226°f and go OFF at 217°f. Fan #2 will come ON at 235°f and go OFF at 226°f. J. K. L. M. The wire labeled TACH (white) is the signal wire for a tachometer if used. A tachometer filter might need to be purchased depending on the brand of tachometer used.
6.3 ENGINE GROUP INSTALLATIONS The engine group is designed to be separated into left side (driver) and right side (passenger) sections. Each side is tie-wrapped separately, BUT NOT LABELED. The left side of the engine has the connectors for the cam position sensor, alternator, and engine coolant sensor, all of which ARE labeled. When you begin routing, FIRST separate the engine group into left and right sections and place them accordingly. 6.3.
FIGURE 6.7 Alternator FIGURE 6.8 Knock Sensor Connector FIGURE 6.9 Oxygen Sensors FIGURE 6.10 Map Sensor FIGURE 6.12 Crank Position Sensor FIGURE 6.
FIGURE 6.13 Injectors 1, 3, 5, 7 FIGURE 6.14 Injectors 2, 4, 6, 8 FIGURE 6.15 Throttle body FIGURE 6.16 Accelerator Pedal FIGURE 6.17 MAF/IAT Sensor FIGURE 6.
FIGURE 6.19 Passenger Side Coil Connector FIGURE 6.20 ECT Sensor FIGURE 6.21 Oil Pressure Sensor FIGURE 6.22 TAC Module Connections FIGURE 6.23 Passenger Side Knock Sensor This knock sensor threads into the engine block behind the starter.
6.4 TAIL SECTION INSTALLATION 6.4.1 Locate the tail section that you earlier separated from the engine group. Begin routing it towards the rear of the vehicle. Be sure to avoid all sharp edges, moving or hot parts, or anything else that may damage the harness. 6.4.2 If you ARE using the 4L60E transmission, route the 13-position connector to the transmission and plug it in. Tape up the reverse lockout and skip shift solenoid connectors and store them in the harness. 6.4.
Skip Shift Solenoid Reverse Lockout Solenoid VSS FIGURE 6.26 Transmission Connections (T56) 7.0 TROUBLE SHOOTING INSTRUCTIONS If you are having trouble with your engine running badly or not running at all, first perform basic troubleshooting (ensure that you are using the correct parts (Table 4.1), check for faulty connections, blown fuses, spark, fuel pressure, etc.), then see if the computer has stored a trouble code in its memory. FIGURE 7.
7.1 THE "CHECK ENGINE" LIGHT Normally, the "check engine" light should come on when the ignition is turned on and then go out a few moments after the engine starts running. If it reappears, or stays on while the engine is running, the computer has detected a problem and a trouble code has been set. NOTE: The engine will not run unless the computer has been reprogrammed to remove the antitheft functions.
The Engine Code Sticker is located at the back of the driver side head. Figure 7.2 Engine Code Sticker We have attempted to provide you with the most accurate 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 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.
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