Wire Harness Installation

Instructions
For Installing:

#10120 Classic Customizable Trunk Mount Harness – 21 Circuit

#10220 Classic Plus Customizable Trunk Mount Harness – 28 Circuit
 Painless Performance Products, LLC
2501 Ludelle Street
Fort Worth, TX 76105-1036
800-423-9696 phone
Web Site: www.painlessperformance.com
E-Mail: support@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.

Here we have provided you with accurate instructions for the installation of
this product. However, if you have comments/suggestions concerning these
instructions, 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 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, 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.

Should you damage or lose part of your manual, a full color copy of these
instructions can be found online at www.painlessperformance.com

Installation Manual: 90550

1ST Edition: January 14, 2014

Copyright © 1994 by Painless 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

Table of Contents…………………………………………………………………………………… I
List of Figures………………………………………………………………………………………… II
List of Tables…………………………………………………………………………………………. II

1.0 Introduction………………………………………………………………………………………….. 1
2.0 About These Instructions……………………………………………………………………….. 1
3.0 Contents Of The Painless Wire Harness Kit……………………………………………….. 2
4.0 Tools Needed…………………………………………………………………………………………. 5
5.0 Pre-Installation and General Harness Routing Guidelines……………………………. 5
6.0 Harness General Installation Instructions………………………………………………….. 7
6.1 Rough Installation…………………………………………………………………………. 7
6.2 Harness Attachment………………………………………………………………………. 7
6.3 Grounding The Automobile…………………………………………………………….. 7
6.4 Terminal Installation and Making Connections………………………………….. 8
6.5 Testing The System……………………………………………………………………….. 8
7.0 GM - Specific Circuit Connections……………………………………………………………… 9
7.1 Early GM Alternator - External Regulator…………………………………………. 9
7.2 Late GM Alternator - Internal Regulator………………………………………….. 9
7.2 GM One-Wire Alternator………………………………………………………………… 10
7.3 GM Ignition System………………………………………………………………………. 11
7.4 Steering Column Wiring - Turn Signal & Ignition Switch Connections…. 12
8.0 Ford - Specific Circuit Connections…………………………………………………………… 13
8.1 Ford Alternator…………………………………………………………………………….. 13
8.2 Ford Ignition System…………………………………………………………………….. 13
8.3 Steering Column Wiring - Turn Signal Connections…………………………... 16
8.4 Steering Column Wiring - Ignition Switch Connections……………………… 17
9.0 Mopar - Specific Circuit Connections…………………………………………………………. 19
9.1 Mopar Alternator…………………………………………………………………………… 19
9.2 Mopar Ignition System…………………………………………………………………… 21
9.3 Steering Column Wiring - Turn Signal Connections……………………………. 24
9.4 Steering Column Wiring - Ignition Switch Connections………………………. 24
10.0 All Makes - Specific Circuit Connections……………………………………………………… 25
10.1 Generator Charging System…………………………………………………………….. 25
10.2 Generator to Alternator Conversion………………………………………………….. 26
10.3 Connecting to Ammeter and the Maxi-Fuse……………………………………….. 26
10.4 Interior Lighting……………………………………………………..……………………… 27
10.5 Headlight Section "A"………………………………………………………………………. 28
10.6 Headlight Section "B"………………………………………………………………………. 29
10.7 Instrument Panel Wiring………………………………………………………………….. 29
10.8 Brake Light Switch…………………………………………………………………………… 30
10.9 Tail Section Wiring…………………………………………………………………………… 30
10.10 Helpful Hints for Tail Section Wiring………………………………………………….. 31
11.0 Wire Connection Index and Fuse Requirements…………………………………………… 31

i
 LIST OF FIGURES

Figure 3.1 The Painless Wire Harness Kit………………………………………………………….. 2

Figure 3.2 The 10120 12 Circuit Harness………………………………………………………….. 3
Figure 3.3 The 10220 18 Circuit Harness…………………………………………………………... 4
Figure 7.1 Early GM Alternator - External Regulator…………………………………………… 9
Figure 7.2A Late GM Alternator - Internal Regulator…………………………………………….. 9
Figure 7.2B High Output Wire……………………………………………………………………………. 10
Figure 7.2C GM CS-130 External Fan Alternator…………………………………………………… 11
Figure 7.2D GM CS-130 Connector and Pin Out…………………………………………………… 11
Figure 7.2E GM CS-130D Internal Fan Alternator………………………………………………… 11
Figure 7.2F GM CS-130D Connector and Pin Out………………………………………………… 11
Figure 7.3 Maxi-Fuse………………………………………………………………………………………. 11
Figure 7.4 GM Ignition System………………………………………………………………………… 12
Figure 7.5 GM Turn Signal Connectors……………………………………………………………... 12
Figure 8.1A Ford Alternator……………………………………………………………………………….. 14
Figure 8.1B High Output Wire……………………………………………………………………………. 14
Figure 8.1C Ford 2G Internal Regulator Alternator………………………………………………… 14
Figure 8.1D Ford 3G Internal Regulator Alternator……………………………………………………15
Figure 8.2 Ford Ignition System………………………………………………………………………… 16
Figure 8.3 Ford Ignition Start Diagram………………………………………………………………. 17
Figure 8.4 Ford Ignition Switch Connectors………………………………………………………. 18
Figure 8.5 Ford Ignition Diagram (Duraspark II Systems)…………………………………... 19
Figure 9.1A Mopar Alternator……………………………………………………………………………… 20
Figure 9.1B Mopar Mechanical Regulator…………………………………………………………….. 20
Figure 9.1C Mopar Electronic Regulator………………………………………………………………. 21
Figure 9.1D High Output Wire……………………………………………………………………………. 21
Figure 9.2A Mopar Ignition System (with Mopar Ign. Switch………………………………… 22
Figure 9.2B Mopar Ignition System ( with Universal switch)………………………………… 23
Figure 9.2C Mopar Electronic Ignition with Dual Ballast Resistor……………………………. 23
Figure 10.1 Generator Charging System………………………………………………………………. 25
Figure 10.2 Ammeter and Maxi-Fuse…………………………………………………………………… 26
Figure 10.3 Interior Lighting……………………………………………………………………………….. 27
Figure 10.4A Typical Fan Relay Installation……………………………………………………………. 27
Figure 10.4B Headlight Section "A" Wiring…………………………………………………………….. 28
Figure 10.5 Dimmer Switches…………………………………………………………………………….. 29
Figure 10.6 Headlight Section "B" Wiring…………………………………………………………….. 29
Figure 10.7A Integrated Brake Lights…………………………………………..……………………….. 30
Figure 10.7B Separate Brake Lights………………………………………………………………………. 31
Figure 11.0 Instrument Panel Wiring………………………………………………………………….. 38
Figure 11.1 Engine Wiring…………………………………………………………………………………. 39
LIST OF TABLES
Table 7.1 GM Ignition and Turn Signal Wiring…………………………………………………… 13
Table 8.1 Ford Ignition and Turn Signal Wiring…………………………………………………. 17
Table 9.1 Mopar Ignition and Turn Signal Wiring (1 of 2)…………………………………… 24
Table 9.1 Mopar Ignition and Turn Signal Wiring (2 of 2)…………………………………… 25
Table 11-1 Fuse Requirements………………………………………………………………………….. 32
Table 11-2 Wire Connection Index (1 of 3)…………………………………………………………. 33
Table 11-2 Wire Connection Index (2 of 3)…………………………………………………………. 34
Table 11-2 Wire Connection Index (3 of 3)…………………………………………………………. 35
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 11.0.

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.

Please Note, This trunk mount harness is quite different from our factory style chassis harness. This harness requires
extra time and forethought when routing and looming wires, as many of the circuits pre-installed in our factory style
chassis harness must be put in place by the installer , at the time of installation. Even if you have installed a
PainlessWiring harness before, PLEASE, read this manual & plan accordingly when installing this trunk mount unit. A
successful installation requires time, and attention to detail.

Installation requires five (5) easy steps: 1. Mount the fuse block
2. Route the wires
3. Lay in the individual circuits (as required)
4. Cut off the excess wire
5. 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 GM - Specific Circuit Connection Details
8.0 Ford - Specific Circuit Connection Details
9.0 Mopar - Specific Circuit Connection Details
10.0 All Makes - Specific Circuit Connection Details
11.0 Wire Connection Index and Fuse Requirements

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 Individual Sections of the Harness, to be laid in by the Installer.
C Headlamp Connector Kit. (Extra Headlamp Cables are available separately under P/N 80300.)
D Maxi Fuse
E Firewall Grommet (large) [NOT INCLUDED IN 20101, 20102, 20103 AND 20104 KITS]
F 2 Fender Well Grommets (for Headlamps)
G 2 packages of Nylon Tie Wraps
H 2 GM Turn Signal Connectors (if applicable)
I Parts Box, containing a GM Alternator Connector, Terminals, Splices, etc. This booklet, P/N 90550 Painless
Wiring Manual.

Figure 3-1 The Painless Wire Harness Kit (typical)

2
 2

Figure 3.2 10120 (21 circuit trunk mount harness)

3
Figure 3.3 10220 (28 circuit trunk mount harness)

4
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, 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 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:
NOTE: This harness has sections of wires that must be integrated into the main harness as you proceed with the
installation. Careful thought and attention to detail will result in a clean, trouble free installation TAKE YOUR
TIME!!

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.) Note that, according to the particular harness you have purchased, some of these sections
may not be present, and some are not labeled:

ACCESSORY SECTION SWITCHES HEADLIGHT SECTION A

ACCESSORY SECTION B+ HEADLIGHT SECTION B
DIMMER SWITCH SECTION IGNITION SWITCH SECTION
DOOR SECTION A INSTRUMENT PANEL SECTION
DOOR SECTION B RADIO SECTION
ENGINE SECTION
ENGINE SECTION (Single, 10 ga. red wire) TAIL SECTION
ENGINE SECTION A TURN SIGNAL SECTION

Note: For complete information concerning the individual circuits and wires that make up the harness
SECTIONS, see Section 11.0.

5.2 Decide where the fuse block will be mounted. This Painless Harness is designed to be mounted in the Trunk
Or rear compartment of the vehicle
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:

5
 ROUTING LOCATION AND PLACEMENT

Emergency Flashers
Horn
Dome Lights
Lights
Power Windows*
Power Door Locks*
Cigarette Lighter*
Wipers
Electric Fuel Pump*
Air Conditioner
Electric Cooling Fan
Coil
Trunk Light*
Turn Signals
Radio Ignition Switched Power
Radio Constant Power
Power Antenna*
Gauges
Accessories
Backup Lights*
Cruise Control*

*These circuits are included in the 18-circuit kit only.

5.4 Where will the following harness groups be routed?

Headlights
Engine
Dash
Tail Lights
Doors

5.5 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.
5.6 Route the harness away from sharp edges, exhaust pipes, and hood, trunk and door hinges.
5.7 Plan where harness supports will be located. Allow enough slack at places where movement could occur
(body to frame, frame to engine, etc.). Use a support every 12 inches unless the harness routes under the
floor carpet.
5.8 At wire ends don't depend on the terminals to support the harness. The weight of the harness could cause
terminals to disconnect or copper wire strands to break.
5.9 The wires should be bundled into groups. Use nylon ties, powerbraid, or tape.

6
6.0 HARNESS GENERAL INSTALLATION INSTRUCTIONS

6.1 Rough Installation

CAUTION: DISCONNECT THE POWER FROM YOUR VEHICLE BY REMOVING THE NEGATIVE
(BLACK) BATTERY CABLE FROM THE BATTERY.

Note: Make no wire connections or permanent mounting of any kind at this time!

6.1.1 Position the fuse block in its mounting area.

6.1.2 Drill a 1-1/4" (1.25") hole near the fuse block for the forward group of wires to pass through
(ENGINE SECTION, ENGINE SECTION A, SINGLE 10 GA. (Red wire #916),HEADLIGHT SECTION A,
HEADLIGHT SECTION B, IGNITION SWITCH SECTION, INSTRUMENT PANEL SECTION, and TAIL
SECTION).
6.1.3 Install the body grommet. Route forward group of wires through the grommet and position the
harness groups in the areas decided upon in Sections 5.1 and 5.3.
6.1.4 Route dash group (ACCESSORY SECTION B+, ACCESSORY SECTION SWITCHES, HEADLIGHT
SECTION B, INSTRUMENT PANEL SECTION and RADIO SECTION) upward to rear of dash and
temporarily tie in place.
6.1.5 Position rear group, TAIL SECTION, on floor pan area decided upon in Sections 5.3 and 5.4.

6.2 Harness Attachment

Note: Harness routing and shaping is and should be a time-consuming task. Taking your time will
enhance the beauty of your installation. Please be patient and TAKE YOUR TIME!

6.2.1 Permanently mount the fuse block. (Note: The fuse block itself does not have to be grounded.)
6.2.2 Mold harness groups to the contour of floor pan, firewall, fender panels, and any other area where
wires or harness groups are routed. Remember to route the harness away from sharp edges,
exhaust pipes, hood, trunk and door hinges, etc.
6.2.3 Attach harness groups to your automobile with clips or ties starting at the fuse block and working
toward the rubber grommet for the front groups and along the floor pan for the rear group. The
dash wires should be routed out of the way of any under-dash obstacles, such as cowl vent, air
conditioning, radio, etc.

Note: Do not tighten tie wraps and mounting devices at this time. Make all harness attachments
LOOSELY.

6.2.4 When used every 1-1/2" or so on the visible areas of the harness, the plastic wire ties make a very
attractive assembly. A tie installed in other areas every 6" or so will hold the wires in place nicely.
Remember to take your time!

6.3 Grounding the Automobile

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. You must supply ground wire (14-16 gauge) for all circuits.

6.3.1 Connect a Ground Strap or Cable ( 2ga MINIMUM ) from the negative battery terminal to the
block.
6.3.2 Connect a Ground Strap from the Engine to the chassis. (even a 10 gauge wire is too small) DO
NOT RELY UPON THE MOTOR MOUNTS TO MAKE THIS CONNECTION.
6.3.3 Connect a Ground Strap from the Engine to the Body.
6.3.4 If you have a fiberglass body you should install a terminal block to ground all your Gauges and
Accessories. Ground the Terminal Block with at least a 12-gauge wire to the chassis.

7
6.4 Terminal Installation and Making Connections

Note: In the following steps you will be making the circuit connections. Before you start, you should
carefully read Sections 7.0 through 10.0, as appropriate, and continually refer to Section 11.0, DOUBLE-
CHECKING your routing and length calculations before cutting any wires and making connections. Give
special attention to Turn Signal and Ignition Switch connections. These can be somewhat confusing.

6.4.1 Have all needed tools and connectors handy.

6.4.2 Select the correct size terminal for the wire and stud application.
6.4.3 Determine the correct wire length and cut the wire. 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 insulation away from wire. Strip only enough necessary for the type of terminal lug you are
using.

Note: In the following step, make sure that the terminal is crimped with the proper die in the crimping
tool. An improper crimp will NOT make a good connection.

6.4.5 Crimp the terminal onto the wire.

CAUTION: DO NOT OVER-CRIMP!

6.4.6 Connecting the harness throughout the groups is a redundant process. Make sure that each wire is
FIRST properly routed and THEN attach. DO NOT ATTACH FIRST THEN ROUTE AFTERWARD.
6.4.7 When all wires are attached, tighten the mounts and ties to secure harness permanently.

6.5 Testing The System

6.5.1 Use a small (10 amp or less) battery charger to power up the vehicle for circuit testing. If there is a
problem anywhere, the battery charger's low amperage and internal circuit breaker will provide
circuit protection.

CAUTION: IF YOU HAVE NOT YET DISCONNECTED THE BATTERY FROM THE AUTOMOBILE,
DO SO NOW! DO NOT CONNECT THE BATTERY CHARGER WITH THE BATTERY CONNECTED.

Connect the battery charger's NEGATIVE output to the automobile chassis or engine block and its
POSITIVE output to the automobile's positive battery terminal.

6.5.2 INDIVIDUALLY turn on each light, ignition, wiper circuit, etc. and check for proper operation.

Note: The turn signals will not flash properly if you do not have both the front and rear bulbs installed
and connected.

6.5.3 When all circuits check out THEN attach the battery cable to the battery for vehicle operation.

8
7.0 GM - SPECIFIC CIRCUIT CONNECTIONS

Note: Your alternator may not appear exactly as represented in the Figures. The circuits are wired the
Way, however.

7.1 Early GM Alternator (before 1969) - External Regulator. See Figure 7-1.

7.1.2 With a short 16-gauge jumper wire, connect Voltage Regulator terminals 3 & 4 together. Connect
ENGINE SECTION wire #914 (wht) to Voltage Regulator terminal 3 or 4.
7.1.3 Connect ENGINE SECTION wire #915 (red) to the Alternator Output lug (Bat).
7.1.4 Connect a 14-gauge wire from Voltage Regulator terminal 2 to Alternator terminal R. Connect a 14-
gauge wire from Voltage Regulator terminal F to Alternator terminal F.
7.1.5 Connect a 16-gauge ground wire from the Alternator Ground lug (G) to chassis ground.

Figure 7-1 Early GM Alternator - External Regulator

7.2 GM Alternator (after 1972) - Internal Regulator. See Figure 7-2A.

7.2.1 Connect ENGINE SECTION wire #914 (wht) to Alternator terminal 1. Connect ENGINE SECTION
wire #915 (red) to the Alternator Output lug (Bat).

7.2.2 Connect a short 14-gauge jumper wire from Alternator terminal 2 to the Alternator Output lug
(Bat).
7.2.3 A connector and terminal spades for late GM Alternators are included in the parts box.

* Under some circumstances the

connection of the alternator will not
allow the engine to be shut off. If this
occurs a diode will need to be installed
inline on wire #914. This will prevent
the alternator from back feeding into
the ignition system and thus causing
the engine to run with the ignition
switch turned off. The Radio Shack
part number for the diode is 276-1661.
It is to be installed with the stripe
towards the alternator.

#914 Alternator

Figure 7-2A Late GM Alternator - Internal Regulator

 9

GM One-Wire Alternator.

7.2.4 Connect ENGINE SECTION wire #915 (red) to the Alternator Output lug (Bat).
Insulate and stow ENGINE SECTION wire #914 (wht). Do not install jumper wire. No wires are
connected to Alternator terminals 1 & 2. If alternator output is greater than 65 amps refer to
Figure 7-2B and the caution on page 6.
7.2.5 When using a 1-wire alternator you must use a voltmeter or ammeter. A WARNING LIGHT
CANNOT BE WIRED IN.

CAUTION: IF USING AN ALTERNATOR WITH AN OUTPUT LARGER THAN 65 AMPS, YOU WILL ALSO NEED

TO USE THE RED 10 GAUGE WIRE #960 AND THE RED 8 GAUGE WIRE INCLUDED IN THE BOX. THE WIRE END
WITH THE RING TERMINAL AND RUBBER BOOT WILL CONNECT TO THE ALTERNATOR OUTPUT LUG WITH
#915. ROUTE THE OTHER END TO THE MAXI FUSE TERMINAL WITH WIRE #916. CUT THE WIRE AND CRIMP
ON A RING TERMINAL. NOW INSTALL A RING TERMINAL ON THE REMAINING RED 8 GAUGE WIRE AND
ATTACH IT TO THE STARTER SIDE TERMINAL OF THE MAXI FUSE. CUT THE 8 GAUGE RED WIRE TO LENGTH,
CRIMP ON A RING TERMINAL AND ATTACH IT TO THE MAIN SOLENOID LUG WITH THE POSITIVE BATTERY
CABLE. SEE FIGURE 7-2B.

Figure 7-2B High Output Wire

* These terminals will not be used on One Wire

alternators. They will normally have a black plastic plug
which blocks off the terminals.
** If you do not have a One Wire alternator refer to
Figure7-2A.
 10

Figure 7-2C CS-130 External Fan Alternator Figure 7-2D CS-130 Connector and Pin Out

Figure 7-2E CS-130D Internal Fan Alternator Figure 7-2F CS-130D Connector and Pin Out

7.3 GM Ignition (Start/Run) System. See Figure 7-4.

Note: If you are going to install an ammeter, see Section 10.3 first.

7.3.1 With crimping tool, attach Maxi Fuse (Figure 7-3)

onto end of ENGINE SECTION (single) 10 ga.
wire #916 (red) AFTER having routed wire from
the Fuse Panel to the Starter Solenoid. This serves
as a fuse to protect the entire harness.
DO NOT OMIT IT!

7.3.2 Connect wire #916 - with Maxi Fuse installed – to

the Starter Solenoid Battery terminal. This is the
same lug that the large red cable from the battery
is normally connected to.
Figure 7-3 Maxi Fuse

7.3.3 Connect ENGINE SECTION A wire #919 (pur) to the Starter Solenoid Start (S) terminal. (See
illustration on page 31)

11
7.3.4 If you are using the Ballast Resistor, mount it away
from other wiring or hoses. The Ballast Resistor gets
very hot during operation. Connect ENGINE
SECTION A wire #920 (pnk) to one end of the Ballast
Resistor. Connect the other end of the Ballast Resistor
to the Ignition Coil B+ terminal with 14-gauge wire
(you may have enough pink wire left over to
accomplish this). If you are not using a Ballast
Resistor, connect wire #920 directly to the Ignition
Coil B+ terminal.
Note: The ballast resistor has been deleted from
this kit due to lack of consumer usage. If one is
needed in your application, please call Painless
Performance at 800-423-9696 for assistance.
Important Note! For HEI systems route wire
#920 (pnk) to the Distributor and attach it to
the terminal labeled BAT. No Ballast Resistor
is required. Figure 7-4 GM Ignition (Start-Run) System

7.3.5 The Ignition Coil NEGATIVE (-) terminal is connected to the Distributor. Also Connect ENGINE SECTION A
wire #923 (pur/wht) to the Ignition Coil NEGATIVE (-) terminal. This is the tachometer source. If you are
not using a tachometer, insulate and stow wire #923.
7.3.6 A 14-gauge wire connected from the Starter Solenoid Ignition (l) terminal to the ignition coil side of the
Ballast Resistor is optional. This wire (the dashed line in Figure 7-4) serves as a ballast resistor BYPASS
during engine starting. However, if the starter solenoid shorts out, which is not unusual, the engine will stop
running and will not restart as long as this wire is connected. You may therefore choose to omit it. If you
are not using a Ballast Resistor, leave the Starter Solenoid Ignition (l) terminal unconnected and do not
install the bypass wire.

7.4 Steering Column Wiring - Turn Signal & Ignition Switch Connectors

7.4.1 There are two different plugs on most tilt columns. The difference is in the length of the male plug that is
mounted ON THE COLUMN. One plug is 3-7/8” (3.875”) long and the other is 4-1/4" (4.250"). This is only a
difference of 3/8" (0.375"), so measure the plug carefully. The Wire Harness Kit has included two different
female connectors to mate with the column-mounted plug. See Figure 7-5 to determine which female
connector is correct for your automobile.

The TURN SIGNAL SECTION wires may have already been terminated for you. If not, cut wires to length
and install the terminals provided. Choose the proper plug and install the terminals according to Table 7-1,
as shown in Figure 7-5. The GM wire color codes have been included for reference. Note: The terminals
will only insert into the connector ONE WAY, as shown in Figure 7-5. Make certain you are inserting the
wire into the CORRECT LOCATION as the terminals are difficult if not impossible to remove once inserted.

Figure 7-5 GM Turn Signal Connectors

 12

7.4.2 The Steering Column Wiring comes with GM ignition switch connectors pre-wired. See Table 7-1 and Figure 7-5 for
color codes, wire numbers, and wire designations for the Ignition Switch Connectors.

7.4.3 IGNITION SWITCH SECTION wire #919 (pur) has been cut and spade lugs installed on the GM keyed steering
column harnesses. These spade lugs are to be connected to the Neutral Safety Switch at the base of the steering
column. If using a neutral safety switch on a floor shifter or in the transmission, the two purple wires with the yellow
spade lugs must be connected together and the (pur) #919 needs to be routed to the neutral safety switch, cut and
connected to it, then continued on to the starter solenoid.

7.4.4 The harness does not support seat belt buzzers or key alarms.

7.4.5 To supply power to a fuel injection system, use ENGINE SECTION A wire #920 (pnk) as the fused ignition power
source.

TURN SIGNAL SECTION

GM Designation Painless Painless Turn Signal

Color Wire No. Color Connector

Blk Horn 953 Blk G

Lt.Blu LF Turn Signal 926 Lt.Blu H
Dk.Blu RF Turn Signal 925 Dk.Blu J
Brn Hazard Flasher 951 Brn K
Pur Turn Flasher 952 Pur L
Ylw LR Turn Signal 949 Ylw M
Grn RR Turn Signal 948 Grn N
Wht Stop Lamp Switch 918 Wht P

IGNITION SWITCH SECTION Painless Painless

Wire No. Color
Pur/Wht Ignition Start 919 Pur
Pnk Ignition Coil 931 Pnk
Brn Accessory Fuse Panel 932 Brn
Orn Ignition Switched Fuse Panel 933 Orn
Red* Battery B+ 934 Red
Red* Battery B+ 934 Red

* See note 8 on page 28

Table 7-1 GM Ignition & Turn Signal Wiring

8 FORD - SPECIFIC CIRCUIT CONNECTIONS

8.1 Ford Alternator (3 configurations). See Figure 8-1.

Note: Your Alternator may not appear exactly as represented in Figure 8-1. The circuits are wired the
same way, though.

8.1.1 Connect ENGINE SECTION wire #915 (red) to the Alternator Output lug (Bat). Connect ENGINE
SECTION wire #914 (wht) to the Voltage Regulator (l) terminal.

CAUTION: IF USING AN ALTERNATOR WITH AN OUTPUT LARGER THAN 65 AMPS, YOU

WILL ALSO NEED TO USE JUMPER WIRE #960 (RED), INCLUDED IN BOX. THE WIRE END WITH
THE RING TERMINAL AND RUBBER BOOT WILL CONNECT TO THE ALTERNATOR OUTPUT LUG.
ROUTE THE OTHER END TO THE STARTER RELAY. CUT THE WIRE AND CRIMP ON A RING
TERMINAL. INSTALL ON RELAY TERMINAL WITH CABLE COMING FROM BATTERY. SEE FIGURE
8-1B.

8.1.2 Connect a 14-gauge jumper from the Voltage Regulator A terminal to the Alternator Output lug
(Bat).

13
 8.1.3 Connect a 14-gauge wire from the Voltage Regulator S terminal to the Alternator Stator (S)
terminal. Connect a 14-gauge wire from the Voltage Regulator F terminal to the Alternator Field (F)
terminal.
8.1.4 Connect the Alternator Ground lug and the Voltage Regulator to chassis ground.
8.1.5 An alternate (and less-used) method is to omit the Alternator Stator wire, install a 14-gauge
jumper across Voltage Regulator terminals A & S, and connect wire #914 to either the A or S
terminal of the Voltage Regulator. The FIELD wire and wire #915 are connected as above. Do NOT
install a jumper as in Paragraph 8.1.2. The Voltage Regulator Ignition (l) terminal is not
connected. Install ground wires as in Paragraph 8.1.4. This alternate configuration is illustrated
in dashed lines in Figure 8-1A.

Figure 8-1A Ford Alternator (2 configurations) Figure 8-1B High Output Wire

Figure 8-1C Ford 2G Internal Regulator Alternator

8.1.6 Connect ENGINE SECTION wire #915 RED to three wires as noted in Figure 8-1C.
8.1.7 Connect ENGINE SECTION wire #914 WHT to the Light Green/Red stripe wire as noted in Figure
8-1C.

14
Figure 8-1D Ford 3G Internally Regulated Alternator

NOTE: This alternator requires AT LEAST a 4ga wire, from the charge post of the alternator
to the B+ side of the Solenoid. This MUST be a fused connection, rated at least at 125
amps. Failure to do so will result in an unsafe condition.

8.1.8 Connect the # 914 wire to the “I” terminal on the regulator connector (Fig 8-1d)
8.1.9 Connect the “S” terminal to the single wire stator connector (Fig 8-1d)
8.1.10 Connect the “A” terminal to the B+ side of the solenoid (Fig 8-1d)
8.1.11 Connect the #915 wire to the output post of the alternator. This is in conjunction with
the large gauge wire as mentioned above. Both wires MUST be connected to the output
post.

15
8.2 Ford Ignition (Start/Run) System. See Figure 8-2.

Note: If you are going to install an ammeter, see Section 10.3 first.

Note: Original ignition module wire should be retained if possible. If your ignition harness connections
are not salvageable, Painless offers a Duraspark harness, part # 30812

8.2.1 With crimping tool, attach the Maxi Fuse (Figure 7-3) onto end of ENGINE SECTION (single) 10
ga. wire #916 (red) AFTER having routed wire (with or without ammeter) from the Fuse Panel to
the Starter Relay. This serves as a fuse to protect the entire harness. DO NOT OMIT IT!
8.2.2 Connect wire #916 - with Maxi Fuse installed - to the Starter Relay Battery terminal. This is the
same lug that the large red cable from the battery is normally connected to.
8.2.3 Connect ENGINE SECTION A wire #919 (pur) to the Starter Relay Start (S) terminal.
8.2.4 If you are using the Ballast Resistor, mount it away from other wiring or hoses. The Ballast Resistor
gets very hot during operation. Connect ENGINE SECTION A wire #920 (pnk) to one end of the
Ballast Resistor. Connect the other end of the Ballast Resistor to the Ignition Coil B+ terminal with
14-gauge wire (you may have enough pink wire left over to accomplish this). If you are using a
Ballast Resistor, connect wire #920 directly to the Ignition Coil B+ terminal.

Note: The Ballast Resistor has been deleted from this kit due to lack of consumer usage. If one is needed
in your application, please call Painless Performance at 800-423-9696 for assistance.

8.2.5 The Ignition Coil NEGATIVE (-) terminal is connected to the Distributor. Also connect ENGINE
SECTION A wire #923 (pur/wht) to the Ignition Coil NEGATIVE (-) terminal. This is the tachometer
source. If you are not using a tachometer, insulate and stow wire #923.
8.2.6 Connect a 14-gauge wire from the Starter Relay Ignition (l) terminal to the ignition coil side of the
Ballast Resistor. This wire serves as a ballast resistor BYPASS during engine starting. If you are not
using a ballast resistor, leave the Starter Relay Ignition (l) terminal unconnected and do not
connect the bypass wire.
8.2.7 Be sure the large, red battery cable is connected from the other side of the Starter Relay to the
Starter Motor.

Figure 8-2 Ford Ignition (Start/Run) System

8.3 Steering Column Wiring - Turn Signal Connections

8.3.1 Connect the nine (9) TURN SIGNAL SECTION wires to your automobile's existing Turn Signal
Connector according to Table 8-1. Ford wire color codes are provided for reference. Ford has not
been uniform in assigning wire colors over the years; so you may find that the wire colors in your
existing Ford harness differ from those shown.
 16

8.3.2 If there is any doubt, be on the safe side. Trace the wire(s) with an ohmmeter, circuit tester, or
test light. DON'T GUESS! Note: Disconnect one end of the wire you are tracing. If you leave it
connected, there is the possibility of tracing it back through some other circuit and getting false
results.

8.3.3 Connect the Horn Ground wire to chassis ground. The Painless harness has no corresponding
ground wire, nor does it support seat belt buzzers or key alarms.

8.4 Steering Column Wiring - Ignition Switch Connections

8.4.1 Connect the wires of the IGNITION SWITCH SECTION according to Table 8-1. Figure 8-3
represents three (certainly not all) possible Ford ignition switch connector configurations and how
they should be wired to the Painless steering column pigtail connector.

Note: The connectors are shown from the wire side, NOT the connection side. It is important to
understand the difference. Again, trace the wires if in doubt.

8.4.2 On some Fords, the Ignition Switch is designed to bypass the ballast resistor during start. In Table
8-1, the red/blu wire supplies power to the coil, bypassing the ballast resistor when the switch is in
the "Start" position. Once the engine has started and the switch is released (Run), power is
supplied to the coil (through the ballast resistor) by the (variously-colored) wire shown. Jumper
these two terminals to the Ignition Switch Connector and connect IGNITION SECTION wire #931
(pnk) to one or the other. DO NOT ROUTE AN ADDITIONAL WIRE. The ballast resistor bypass
circuit was wired at Paragraph 8.2.4.
8.4.3 IGNITION SWITCH SECTION wire #919 (pur) needs to be routed to the neutral safety switch, cut
and connected to it. If the switch is mounted on the floor shifter, add some length of wire to reach
it. FOR SAFETY, PLEASE USE A NEUTRAL SAFETY SWITCH!

TURN SIGNAL SECTION

Ford Designation Painless Painless

Color Wire No. Color

Grn Stop Light 918 Wht

Wht/Blu RF Turn Signal 925 Blu
Grn/Wht LF Turn Signal 926 Lt.Blu
Orn/Blu RR Turn Signal 948 Grn
Grn/Orn LR Turn Signal 949 Ylw
Wht/Red Hazard Flasher 951 Brn
Blu Turn Flasher 952 Pur
Ylw Horn 953 Blk
Dk.Blu Horn Ground Gnd ----

IGNITION SWITCH SECTION

Brn/Pur or Wht/Blu¹ Start 919 Pur

Wht/Grn, Red/Grn, Ignition Coil (run) 931 Pnk

Wht/Blu or Brn/Pur

Red/Blu Ignition Coil (start) ² ----

Blk/Grn or Blk/Ylw Accessory Fuse Panel 932 Brn

Gry, Gry/Ylw, or Blk Ignition Switched Fuse Panel 933 Orn

Ylw Battery B+ 934 Red

NOTES:
1. Wire may be one of the colors shown, or some other color. See Paragraph 8.3.1.
2. Jumper to wire #931. See Paragraph 8.4.2.
Table 8-1 Ford Ignition and Turn Signal Wiring
17

13

Figure 8.3 Motorcraft Electronic Ignition System

Figure 8-4 Ford Ignition Switch Connectors (See note on Page 10, Section 8.2)
 18

Figure 8-5 Ford Ignition Diagram (Duraspark II Systems)

9 MOPAR - SPECIFIC CIRCUIT CONNECTIONS

9.1 Mopar Alternator. See Figure 9-1

Note: Your Alternator may not appear exactly as represented in Figure 9-1. The circuits are wired the
same way, though.

9.1.1 Mopar uses one of two kinds of voltage regulators: An electronic regulator and a mechanical one.
The electronic voltage regulator is represented in Figure 9-1. It does not matter how the two
terminals are connected, so long as they are BOTH connected. The mechanical regulator has
terminals marked "F" (Field) and "l" (Ignition). In contrast to the electronic regulator, it DOES
make a difference how the mechanical regulator is connected.
9.1.2 Connect ENGINE SECTION wire #914 (wht) to the Alternator Field (F) terminal as shown in Figure
9-1A. Connect ENGINE SECTION wire #915 (red) to the Alternator Output lug (Bat).

CAUTION: IF USING AN ALTERNATOR WITH AN OUTPUT LARGER THAN 65 AMPS, YOU

WILL ALSO NEED TO USE JUMPER WIRE #960 (RED), INCLUDED IN BOX. THE WIRE END WITH
THE RING TERMINAL AND 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 STARTER TERMINAL WITH CABLE COMING FROM BATTERY. SEE FIGURE 9-1B.

9.1.3 Connect a 14-gauge wire from the Alternator terminal where wire #914 is connected to either of
the ELECTRONIC Voltage Regulator terminals OR terminal (l) of the MECHANICAL Voltage
Regulator. On existing Mopar harnesses, this would be a blue wire.
9.1.4 Connect a 14-gauge wire from the other Alternator Field terminal (as shown in Figure 9-1) to the
second terminal of the ELECTRONIC Voltage Regulator OR terminal (F) of the MECHANICAL
Voltage Regulator. On existing Mopar harnesses, this would be a green wire.
9.1.5 Finally, be sure BOTH the alternator and the voltage regulator itself are grounded.

19
 Figure 9-1A Mopar Alternator

Figure 9-1B Mopar mechanical regulator

 20

Figure 9-1C Mopar Electronic regulator

9.2 Mopar Ignition (Start/Run) System. See Figure 9-2

Note: If you are going to install an ammeter, see Section 10.3 first.

9.2.1 Connect ENGINE SECTION (single) 10-gauge red wire #916 (with or without ammeter) to the
Starter Relay Battery Terminal. Retain excess wire.

Figure 9-1D High Output Wire

 21

9.2.2 With crimping tool, attach the Maxi Fuse (Figure 7-3) 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 9-2. USE ONLY 10-GAUGE WIRE.
9.2.3 Connect ENGINE SECTION A wire #919 (pur) to the Starter Relay Ignition (l) terminal.

9.2.4 Connect a 14-gauge wire from the Starter Relay Ground (G) terminal to the center terminal of the
transmission mounted Neutral Safety Switch. Older Mopar neutral safety switches have only one
terminal. On newer switches, the two outside terminals are for backup lights. Use existing wiring to
connect these two terminals as shown in Figure 9-2.
9.2.5 If using a harness with the GM column connectors, but using the Mopar Neutral Safety Switch, or
neutral safety switch on a floor shifter, you will need to splice together the purple (pur) wires at
the steering column wiring.
9.2.6 If the Neutral Safety Switch is mounted in the floor shifter, connect the Starter Relay Ground (G)
terminal to chassis ground. Refer to Paragraph 9.4.2 to wire the Neutral Safety Switch.
9.2.7 If you are using the Ballast Resistor (Figure 3-1), mount it away from other wiring or hoses. The
ballast resistor gets very hot during operation. Connect ENGINE SECTION A wire #920 (pnk) to
one end of the Ballast Resistor. Connect the other end of the ballast resistor to the Ignition Coil
POSITIVE (+) terminal with 14-gauge wire (you may have enough pink wire left over to accomplish
this). If you are not using a Ballast Resistor, connect wire #920 directly to the Ignition Coil B+
terminal.

Note: The Ballast Resistor has been deleted from this kit due to lack of consumer usage. If one is needed
in your application, please call Painless Performance at 800-423-9696 for assistance.

9.2.8 Connect a 14-gauge wire from the Starter Relay Ignition (l) terminal to the ignition coil side of the
Ballast Resistor. This wire serves as a ballast resistor BYPASS during engine starting. You must add
a diode (8 amp min., 100 PIV) to this wire as shown in Figure 9-2A. If you are not using a ballast
resistor, do not connect this wire.
9.2.9 The Ignition Coil NEGATIVE (-) terminal is connected to the Distributor. Also connect ENGINE
SECTION A wire #923 (pur/wht) to the Ignition Coil NEGATIVE (-) terminal. This is the tachometer
source. If you are not using a tachometer, insulate and stow wire #923.

9.2.10 Be sure the large, red battery cable is connected from the Battery to the Starter Motor Battery
terminal (the same place the Maxi Fuse is connected).

Figure 9-2A Mopar Ignition (Start/Run) System with Mopar switch

 22

Figure 9-2B Mopar Ignition (Start/Run) with Universal Switch

Figure 9-2B Mopar Electronic Ignition with Dual Ballast Resistor

Figure 9-2C Mopar Electronic Ignition with Dual Ballast Resistor

 23

9.2.11 Connect 920 (pink) to both dark blue wires as labeled in Figure 9-2B. Connect a ballast bypass
wire as labeled in Figure 9-2B. NOTE: This ballast bypass wire will only provide 12 volts when
cranking the engine. This is done for ease of starting the engine.

9.3 Steering Column Wiring - Turn Signal Connections

Refer to Table 9-1. Check your existing wiring (by tracing the wire, if necessary) against the data given.

9.3.1 Connect the nine (9) wires of the TURN SIGNAL SECTION to your automobile's existing Turn Signal
Connector according to Table 9-1. Mopar wire color codes for a number of years are provided for
reference. Mopar has not been uniform in assigning wire colors over the years; so you may find
that the wire colors in your existing Mopar harness differ from those shown.
9.3.2 If there is any doubt, Trace the wires with an ohmmeter, circuit tester, or test light.
Don’t Guess!
Note: Disconnect one end of the wire you are tracing. If you leave it connected, there is a
possibility of tracing it back through some other circuit and getting false results.

9.3.3 If your existing Turn Signal Connector requires a Horn Ground wire, install one. The TURN SIGNAL
SECTION has no ground wire, nor does it support seat belt buzzers, key alarms, or shifter lights.

9.4 Steering Column Wiring - Ignition Switch Connections

9.4.1 Connect the wires of the IGNITION SWITCH SECTION according to Table 9-1.
9.4.2 IGNITION SWITCH SECTION wire #919 (pur) is to be connected to a Neutral Safety Switch.
However, Mopar switches are mounted in the transmission. The transmission-mounted neutral
safety switch was wired at Paragraph 9.2.4. FOR SAFETY, PLEASE USE A NEUTRAL SAFETY
SWITCH!
9.4.3 If the neutral safety switch is mounted on a floor shifter, see note 11 in wire connection index.

1970-74 WITHOUT TILT COLUMN

TURN SIGNAL CONNECTOR

Mopar Designation Painless Painless

Color Wire No. Color

Wht Stop Light Switch 918 Wht

Tan RF Turn Signal 925 Blu
Grn LF Turn Signal 926 Lt.Blu
Brn RR Turn Signal 948 Grn
Grn LR Turn Signal 949 Ylw
Pnk Hazard Flasher 951 Brn
Red Turn Flasher 952 Pur
Blk Horn 953 Blk

IGNITION SWITCH CONNECTOR

Ylw¹ Ignition Start 919 Pur

Brn Ignition Coil 931 Pnk
Blk Accessory Fuse Panel 932 Brn
Blu Ignition Switched Fuse Panel 933 Orn
Red Battery B+ 934 Red
Vio Ground ---- ----
Ylw² Buzzer Switch ³ ----
Ylw² Buzzer Switch ³ ----
Orn Gear Shift Lamp ³ ----

NOTES:
1. 12 gauge wire
2. 20 gauge wire
3. The Painless harness does not support these.

Table 9-1 Mopar Ignition and Turn Signal Wiring 1 of 2

 24

TURN SIGNAL CONNECTOR

Designation 79 w/tilt 79 w/o tilt 82 RWD w/o tilt 82 RWD w/tilt

Stop Light Wht Wht Wht Wht

RR Turn Signal Dk.Grn Brn Brn/Red Brn/Red
LR Turn Signal Ylw Dk.Grn Dk.Grn/Red Dk.Grn/Red
Turn Signal Flasher Pur Red Red Red
Hazard Signal Flasher Brn Pnk Pnk Pnk
RF Turn Signal Dk.Blu Tan Tan Tan
LF Turn Signal Lt.Blu Lt.Grn Lt.Grn Lt.Grn
Horn Blk Blk Blk/Red Blk/Red

Not supported by the Painless wire harness:

Horn ---- Blk/Red ---- ----
Horn Ground ---- Blk Blk ----
Key Alarm Pnk ---- Blk/Lt.Blu ----
Key Alarm Blk ---- Lt.Blu ----
R Corner Lamp Blk/Wht Tan/Wht Tan/Wht Tan/Wht
L Corner Lamp Gry Lt.Grn/Blk Lt.Grn/Blk Lt.Grn/Blk
Corner Feed Lamp Brn Vio Vio Vio

Table 9-1 Mopar Ignition and Turn Signal Wiring 2 of 2

10 ALL MAKES - SPECIFIC CIRCUIT CONNECTIONS

10.1 Generator Charging System. See Figure 10-1.

10.1.1 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.
10.1.2 Be sure both the generator and the voltage regulator are securely grounded. The voltage regulator
may have a terminal for this purpose (labeled "G") or you may have to ground the regulator case.
10.1.3 Connect ENGINE SECTION wire #915 (red) to Voltage Regulator terminal B.
10.1.4 Insulate and stow ENGINE SECTION wire #914 (wht).

Figure 10-1 Generator Charging System

 25

10.2 Generator to Alternator Conversion

10.2.1 You may be able to convert your generator charging system to use an alternator and external
regulator without altering or re-routing existing wires.
10.2.2 Install the new alternator and replace the existing generator voltage regulator with the new,
alternator compatible one.
10.2.3 Connect the existing wiring according to either Section 7.0, 8.0 or 9.2, as appropriate.

Figure 10-2 Ammeter & Maxi Fuse

10.3 Connecting an Ammeter and the Maxi Fuse. See Figure 10-2.
10.3.1 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 the Starter Solenoid on GM (Section
7.4) and from the Fuse Panel to the Starter Relay on Ford (Section 8.2) and Mopar (Section
9.2).
10.3.2 The overall physical length of this circuit should be as short as possible (allow some slack,
however). You may have to cut wire #916 and you may have to add some additional length of 10-
gauge wire. USE ONLY 10-GAUGE WIRE OR LARGER.
10.3.3 Route wire #916 (from the Fuse Panel) and connect to the Ammeter NEGATIVE terminal. To
complete the installation, follow ONE of the next three (3) paragraphs, as appropriate.
10.3.4 If you are using a GM starter, route the remainder of wire #916 from the Ammeter POSITIVE
terminal to the Maxi Fuse terminal. Connect the other side of the Maxi Fuse (Figure 7-3) to the
Starter Solenoid Battery (B+) terminal.
10.3.5 If you are using a Ford starter with a starter relay, route the remainder of wire #916 from the
Ammeter POSITIVE terminal to the Maxi Fuse terminal. Connect the other side of the Maxi Fuse
(Figure 7-3) to the Starter Solenoid Battery (B+) terminal.
10.3.6 If you are using a Mopar starter with a starter relay, route the remainder of wire #916 from the
Ammeter POSITIVE terminal to the Maxi Fuse terminal. Connect the other side of the Maxi Fuse
(Figure 7-3) to the Starter Solenoid Battery (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 DILIGENCE IN CONNECTING
AMMETERS.

CAUTION: BE SURE YOUR AMMETER'S CURRENT (AMPS) RATING EXCEEDS THE

CURRENT OUTPUT OF YOUR ALTERNATOR. PERFECT PERFORMANCE PRODUCTS, LLC
DOES NOT RECOMMEND USING ANY AMMETER RATED AT LESS THAN 65 AMPS. DO
NOT USE AN AMMETER WITH ANY HIGH OUTPUT ALTERNATOR (MORE THAN 65
AMPS).

26
 Figure 10-3 Interior Lighting (GM Style Jamb Switch – Painless Part #80170)

10.4 Interior Lighting. See Figure 10-3

10.4.1 Interior Lights are switched through the door switches and the dash-mounted headlight switch,
which is usually rotated counter-clockwise to turn on. These switches apply ground to the circuit.
YOU WILL NEED TO SUPPLY THESE GROUND WIRES. 12V is continually present at the light bulbs.
See Figure 10-6.
10.4.2 If possible leave your existing interior light wiring intact. The Painless harness supplies the 12V
feed (B+) to the circuit via TAIL SECTION wire #945 (wht) and a ground via TAIL SECTION wire
#961 (blk).

Figure 10-4A Typical Fan Relay Installation (Painless Part #30101)

 27

Figure 10-4B HEADLIGHT SECTION A Wiring

10.5 HEADLIGHT SECTION A. See Figure 10-4B.

10.5.1 Connect HEADLIGHT SECTION A wire #924 (grn) to the Horn's hot terminal. TURN SIGNAL
SECTION wire #953 (blk) was connected in the Turn Signal Connector section of these
instructions. The Horn Relay is pre-wired into the Fuse Panel.
10.5.2 Route the HEADLIGHT SECTION A wires #908 (lt.
grn) and #909 (tan) to BOTH Headlamps.
Headlamp connectors, ground wires and terminals
for the headlamps are provided in the parts kit.
Ring terminals and self-tapping screws have also
been provided for the ground connection.
10.5.3 Use the connector photo to the right for proper
wire pinout. The connector is shown from the wire
insertion side.
10.5.3 Connect HEADLIGHT SECTION A wire #927 (brn)
to ALL front Park Lights. Connect HEADLIGHT
SECTION A wire #925 (blu) to the RIGHT FRONT
Turn Signal. Connect wire #926 (lt.blu) to the LEFT
FRONT Turn Signal. Note: Don't confuse Park Lights with Turn Signals.
10.5.4 Connect HEADLIGHT SECTION A wire #901 (gry/wht) to the Electric Fan Relay. This wire is an
activation wire for the relay, NOT A POWER FEED. The other end of wire #901 is in the
ACCESSORY SECTION SWITCHES and should be connected to the electric fan switch in the dash.
Connect 906 (gry/wht) from ACCESSORY SECTION B+ to the other side of the fan switch. Figure
10-4A shows a typical fan relay installation. Note: The wire going to the fan in Figure 10-4B 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 are using a thermostatic switch in the engine to control the ground for the fan relay,
you will then connect the 901 (gry/wht) from ACCESSORY SECTION SWITCHES directly to the 906
(gry/wht) from ACCESSORY SECTION B+.
10.5.5 Connect the DIMMER SWITCH SECTION Extension Cable (Figure 3-1) to its mating connector in
the harness (if applicable) and your floor-mounted Dimmer Switch or column-mounted Dimmer
Switch.

28
 Figure 10-5 Dimmer Switches (Push Button Style – Painless Part #80150)

10.6 HEADLIGHT SECTION B Wiring. See Figure 10-6.

10.6.1 Connect the 907,928, & 959 wires, the Dome and Interior Light return circuit, and the Headlamp
Switch Ground as shown. If you do not have a GM headlight switch, you should trace out the wires
of your existing harness and connect the new harness according to Table 11-2.
10.6.2 The 927 wire (HEADLIGHT SECTION A) and 929 and 930 wires (HEADLIGHT SECTION B
,Headlight switch).The shortest section ,of the taillight wire before the splice attaches to the
appropriate terminal of the light switch. The small length of wire for the instrument lights is used
as a jumper from light to light.
Note: On late-style GM headlight switches, the park lights terminal to which wire #927 (brn) is
connected (shown in Figure 10-6) has been omitted. In this case, wire #927 must be connected
as indicated by the dashed line in Figure 10-6.
10.7 Instrument Panel Wiring
10.7.1 Connect the wires of the INSTRUMENT PANEL SECTION as indicated in Table 11-2. Insulate and
stow any wires you do not use.
10.7.2 Connect a jumper from wire #935 (red/wht) to all Gauges' power or “I” terminals. Connect a
jumper from wire #930 (brn) to all Gauges' Instrument Lighting terminals. Connect a jumper to all
Gauges' Ground terminals and connect to Chassis Ground.

Figure 10-6 HEADLIGHT SECTION B Wiring (Painless Part #80152)

 29

10.8 Brake Light Switch

10.8.1 Connect wires #917 (orn) and #918 (wht) to the Brake Light Switch wherever it may be mounted.
These wires may be in ENGINE SECTION A or with the TURN SIGNAL SECTION wires, depending
on the harness purchased.
10.8.2 The Third Brake Light wire is pre-connected on the Switch end. Connect TAIL SECTION wire #950
(orn) to the Third Brake Light if applicable.

10.9 Tail Section Wiring

10.9.1 Connect the wires of the TAIL and TURN SIGNAL SECTIONS as indicated in Table 11-2 with the
exception of #918 (wht), #948 (grn), #949 (ylw) and #950 (orn).
10.9.2 These 4 wires will be connected according to one of the diagrams shown in BELOW. 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 you
have more than one bulb on each side and the Brake and Turn Signal Lights are hooked to
different bulbs (referred to as separate Brake/Turn Lights).

Note A: If you have Integrated Brake Lights you must use bulbs that have two (2) filaments in
them such as in an 1157 bulb.
Note B: The three wires shown in these diagrams are connected to the "brighter" of the two
filaments when using a two-filament bulb (the Tail Lights are usually connected to the
"Dimmer" filament). The Tail Lights, License Plate Lights, Reverse Lights, etc. are not
shown on the diagrams for clarity.
Note C: In the separate Brake Light diagram the arrangement shown is only one of several ways
to wire a vehicle. The important thing is that the Brake and Turn Signal Lights use
completely separate bulbs.

Figure 10-7A Integrated Brake Lights

 30

Figure 10-7B Separate Turn/Brake Lights

10.10 Helpful Hints for Tail Section Wiring

10.10.1 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. The Turn Signal switch you use must be built to do this! If you are
using a steering column out of a salvage yard that was originally in a vehicle that had
separate Brake Lights then the switch will not work for Integrated Brake Lights.
10.10.2 Almost all light bulbs get the ground they need through the socket housing. If you mount your
socket housing into anything other than a grounded metal part then you will need to provide a
separate ground wire.

11.0 WIRE CONNECTION INDEX AND FUSE REQUIREMENTS

11.1 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.

Table 11-2 is divided into sections that correspond to the sections of your wire harness. (ACCESSORY
SECTION B+, DIMMER SWITCH SECTION, etc.). The index is divided vertically into six columns. COLOR,
GAUGE, NUMBER, CONNECT TO, ORIGIN, and SECTION OF ORIGIN.

The columns labeled ORIGIN and SECTION OF ORIGIN are for your reference ONLY. The items in these
columns tell you where each wire originates (ORIGIN) and from which section (SECTION OF ORIGIN) of the
harness.

The column labeled NO. contains a 900-series number that is used to identify various wires in the wiring
diagrams that are a part of these instructions.
 31

Many, (but not all) of the wire numbers appear twice in this harness. This is because you will be
connecting BOTH ENDS of many of the particular wire segments. In this trunk mount harness, careful
attention must be paid, not only to the routing, but to the connection points on BOTH ENDS of the wires.

11.2 Fuse Requirements

Cigarette Lighter………………………………………………… 20
Headlight Switch………………………………………………… 30
Emergency Flashers……………………………………………. 15
Turn Signals………………………………………………………. 15
Gauges……………………………………………………………… 10
AC/Heat Relay…………………………………………………… 5
Radio (Constant)………………………………………………… 10
Horn………………………………………………………………….. 20
Door Lock………………………………………………………….. 20
Wipers………………………………………………………………. 15
Brake Switch……………………………………………………… 20
Dome/Trunk………………………………………………………. 10
Electric Fan Relay………………………………………………… 5
Power Antenna…………………………………………………… 10
Power Windows………………………………………………….. 20
Electric Fuel Pump………………………………………………. 15
Coil……………………………………………………………………. 30
Radio Ignition (Switched)…………………………………….. 10
Backup/Cruise Control…………………………………………. 10

Table 11-1 Fuse Requirements

32
 Color Ga. No. Connect to Wire Starting Point Section of Starting
Point
ACCESSORY SECTION
SWITCHES
Gry/Wht * 18 901 Cooling Fan Switch Fan Relay Accessory Switches
Blk/Wht * 14 902 AC/Heat Switch A/C Compressor Accessory Switches

ACCESSORY SECTION B+
Tan1 14 903 Cigarette Lighter B+ Fuse Panel* Fuse Panel
Blk/Wht 14 904 AC/Heat Switch B+ Fuse Panel* Fuse Panel
Blu 16 905 Wiper Switch B+ Fuse Panel* Fuse Panel
Gry/Wht 18 906 Cooling Fan Switch B+ Fuse Panel* Fuse Panel

DIMMER SWITCH SECTION

Blu/Ylw2 14 * 907 Dimmer Switch Headlight Switch Dimmer Switch Section
Lt.Grn 14 * 908 Dimmer Switch High Beam Dimmer Switch Section
Tan 14 * 909 Dimmer Switch Low Beam Headlight Section A

DOOR SECTION A
Ylw/Blk1 14 910 Right Door Lock B+ Fuse Panel* Fuse Panel
Ylw1 14 911 Right Power Window B+ Fuse Panel* Fuse Panel

DOOR SECTION B
Ylw/Blk1 14 912 Left Door Lock B+ Fuse Panel* Fuse Panel
Ylw1 14 913 Left Power Window B+ Fuse Panel* Fuse Panel

ENGINE SECTION
Wht 14 914 Alternator Exciter Fuse Panel* Fuse Panel
Red 10 915 Alternator B+ Fuse Panel* Engine Section
Blk/Wht 14 * 902 A/C Compressor A/C Central Switch Accy. Section Switches

ENGINE SECTION
(SINGLE WIRE)
Red3 10 916 Battery Positive or Starter Solenoid Fuse Panel* Fuse Panel
(Large Terminal)

ENGINE SECTION A
Orn4, 11 14 917 Brake Switch B+ Fuse Panel* Fuse Panel
Wht11 16 * 918 Brake Switch Turn Signal Switch Engine Section A
Pur10 12 * 919 Start Solenoid ("S" Terminal) Ignition Switch Start Ignition Switch Section
Pnk 14 920 Coil B+ Fuse Panel* Fuse Panel
Lt.Grn 18 * 921 Temperature Sending Unit Temperature Gauge Instrument Panel Section
Lt.Blu/Blk 18 * 922 Oil Pressure Sending Unit Oil Pressure Gauge Instrument Panel Section
Pur/Wht 18 * 923 Tachometer Source Tachometer Instrument Panel Section
Red 18 954 Electric Choke Fuse Panel* Fuse Panel

HEADLIGHT SECTION A
Grn 14 924 Horn B+ Horn Relay* Fuse Panel
Blu 18 * 925 Right Front Turn Signal Turn Signal Switch Turn Signal Section
Lt.Blu 18 * 926 Left Front Turn Signal Turn Signal Switch Turn Signal Section
Brn 18 * 927 Park Lights Headlight Switch Headlight Switch Section
Lt.Grn 16 * 908 High Beam Dimmer Switch Dimmer Switch Section
Tan 16 * 909 Low Beam Dimmer Switch Dimmer Switch Section
Gry/Wht 18 * 901 Fan Relay Fan Switch Accessory Section
Switches

Table 11-2 Wire Connection Index, 1 of 3

33
 Color Ga. No. Connect to Wire Starting Point Section of Starting
Point
HEADLIGHT SECTION B
Red/Blk8 12 928 Headlight Switch B+ Fuse Panel* Fuse Panel
Blu/Ylw * 14 907 Headlight Switch Dimmer Switch Dimmer Switch Section
Brn * 14 929 Headlight Switch Tail Lights Tail Section
Brn * 18 927 Headlight Switch Park Lights Headlight Section A
Brn7 * 18 930 Headlight Switch Instr. Panel Lighting Instrument Panel Section
Orn 10 14 959 Headlight Switch B+ Fuse Panel* Fuse Panel

IGNITION SWITCH SECTION

Pnk 14 931 Ignition Switch (Coil Ignition) Fuse Panel* Fuse Panel
Brn 12 932 Ignition Switch Accessory Fuse Panel* Fuse Panel
Orn 12 933 Ignition Switch Ignition Fuse Panel* Fuse Panel
Red8 12 934 Ignition Switch B+ Fuse Panel* Fuse Panel
Pur5 12 919 Ignition Switch Start Starter Solenoid Engine Section A

INSTRUMENT PANEL SECTION

Red/Wht 18 935 Voltmeter Source & Gauges B+ Fuse Panel* Fuse Panel
Grn * 18 936 High Beam Indicator Dimmer Switch* Dimmer Switch Section
Lt.Blu * 18 937 Left Turn Indicator Left Front Turn Signal* Turn Signal Section
Blu * 18 938 Right Turn Indicator Right Front Turn Sig.* Turn Signal Section
Brn * 18 930 Instrument Panel Lighting Headlight Switch Headlight Section B
Pnk * 18 939 Fuel Gauge Fuel Sending Unit Tail Section
Lt. Grn * 18 921 Temperature Gauge Temp. Sending Unit Engine Section A
Lt.Blu/Blk * 18 922 Oil Pressure Gauge Oil Pres. Sending Unit Engine Section A
Pur/Wht 18 923 Tachometer Tachometer Source Engine Section A
Orn/Blk 18 955 Accessory Power (Switched) Fuse Panel* Fuse Panel

RADIO SECTION
Red 18 940 Radio B+ Unswitched (Constant) Fuse Panel* Fuse Panel
Red/Blk 18 941 Radio B+ Switched Fuse Panel* Fuse Panel
Pur/Blk 18 942 Radio: Power Antenna Power Antenna Tail Section

TAIL SECTION
Wht 18 945 Dome Lights B+ Fuse Panel* Fuse Panel
Grn/Blk1 * 16 946 Trunk Accessory Light B+ Fuse Panel* Fuse Panel
Ylw/Wht1 * 14 947 Electric Fuel Pump B+ Fuse Panel* Fuse Panel
Grn * 14 948 Right Rear Turn Signal Turn Signal Switch Turn Signal Section
Ylw * 14 949 Left Rear Turn Signal Turn Signal Switch Turn Signal Section
Pnk * 18 939 Fuel Sending Unit Fuel Gauge Instrument Panel Section
Brn * 14 929 Tail Lights Headlight Switch Headlight Section B
Pur/Blk1 * 18 942 Power Antenna Radio: Power Antenna Radio Section
Orn * 18 950 Third Brake Light Turn Signal Switch* Turn Signal Section
Lt.Grn1 * 18 956 Backup Lights Backup Switch Cruise Control Section
Blk 18 961 Dome Light Ground Interior Light Harness Near Fuse Panel

Table 11-2 Wire Connection Index, 2 of 3

34
 TURN SIGNAL SECTION
Brn 14 951 Emergency Flasher Switch B+ Emer. Flasher Relay* Fuse Panel
Pur 14 952 Turn Signal Switch Flasher B+ Turn Flasher Relay* Fuse Panel
Blk 18 953 Horn Switch Horn Relay* Fuse Panel
Grn * 14 948 Turn Signal Switch Right Rear Turn Signal Tail Section
Ylw * 14 949 Turn Signal Switch Left Rear Turn Signal Tail Section
Blu * 18 925 Turn Signal Switch Right Front Turn Signal Headlight Section A
Wht * 16 918 Turn Signal Switch Brake Switch Engine Section A
Lt.Blu 18 926 Turn Signal Switch Left Front Turn Signal Headlight Section A

CRUISE CONTROL SECTION

Pnk1 18 957 Cruise Control Switch Fuse Panel* Fuse Panel
Lt.Grn1 * 18 958 Backup Switch Fuse Panel* Fuse Panel
Lt.Grn1 * 18 956 Backup Switch Backup Lights Tail Section

Table 11-2 Wire Connection Index, 3 of 3

NOTE: Wires with an asterisk ( * ) are in the separately rolled wires of this harness. They must be laid into the harness as it
installed

NOTES:

1. Depending upon the particular wire harness you purchased, you may not have some of these wires.

2. 2-color wires: 2nd color (stripe) may not be intense color. Observe two-color wires closely.

3. This section consists of only one large (10 gauge) wire.

4. From fuse panel to brake switch.

5. This wire is cut and spade lugs have been installed (GM-keyed kits only) so that your existing neutral safety switch
circuit can be wired into your harness. The neutral safety switch is located at the base of General Motors and Ford
steering columns and in Mopar transmissions. Do not attempt to defeat your automobile's neutral safety switch. If
your automobile does not have a neutral safety switch, please install one.

6. (obsolete)

7. This wire needs to go from the headlight switch to the instrument panel lights.

8. There are two (2) Red 934 wires that MUST both be connected to the "Batt" terminal of the ignition switch. These
wires supply all of the ignition switched power that goes to the fuse panel and both are needed because of the
amount of power required to power all of the accessories.

9. This wire is power for the portion of the headlight switch that goes out to the headlights and front parking lights.

10. This wire is power for the portion of the headlight switch that goes out to the instrument panel lights and the tail
lights. NOTE: This wire is only used if your headlight switch has two power input terminals.

11. Non-GM keyed column harnesses have 48” of extra length to accommodate a floor shifter. If a floor shifter is being
used, utilize this extra length to route the 919 Purple to the neutral safety switch on the shifter or transmission and
then to the starter solenoid. If not using a floor shifter, cut 919 Purple to length needed for starter solenoid and
discard extra length.
 35

The following information is the changes made for the 10120 / 10220 harness.

Accessory Section Switches;

These two wires are rolled up separate of the main harness. The gray/white (#901) wire is used to connect the fan switch in
the dash to the engine cooling fan relay. The black/white (#902) wire is used to connect the a/c thermostat switch to the
compressor.

Dimmer Switch Section;

The green wire (#936) attached to the light green wire (# 908) is to operate the high beam indicator light. The blue/yellow
wire (#907) attaches to the appropriate headlight switch terminal.

Door Section A & B;

These two sections are rolled together.

Engine Section;
The alternator B+ wire (#915) is a 10 gauge and the a/c compressor wire,(#902) is in the
accessory switches section.

Engine Section A;
The white wire (#918) for the brake switch now has the third brake light wire (#950) spliced to it which is to be routed to the
tail section after attaching. Attach the white wire ( the end that is about 3 inches long before the splice ) to the brake switch.

The purple wire (#919) for the start solenoid, the purple/white wire (#923) for the
tachometer, the light green wire (#921) for the temperature gauge and the light blue/black
wire (#922) for the oil pressure gauge have all been rolled together. The starter wire goes
from the ignition switch through the neutral safety switch to the activation terminal of the
starter solenoid. The other wires attach the sending units to their respective gauges

Headlight Section A;
The right front (#925) and the left front (#926) turn signal and the park light (#927) wires
have been rolled separately. Attach the shortest section, of these wires to their respective
switch connections. The extra shorter length of blue and light blue wires that are spliced onto
the longer wires are to operate the turn signal indicators
The headlight and cooling fan wires (#908, #909 & #901) were routed earlier in these
instructions.

Headlight Section B;
The taillight (#929) and instrument lighting (#930) wires have been rolled separately. The
shortest section, of the tail light wire before the splice attaches to the appropriate terminal of
the light switch. The small length of wire for the instrument lights is used as a jumper from
light to light.

Ignition Switch Section;

There are two red power wires (#934) from the fuse block to the ignition switch. Attach both
wires to the same terminal on a universal style switch or one in each of the respective
housings, as shown in illustration A, of this supplement.
The purple wire (#919) was covered in Engine section A
 36

Instrument Panel Section;

The green (#936) indicator wire, light blue (#937) indicator wire, blue (#938) indicator wire, brown (#930) panel lighting
wire, pink (#939) fuel gauge wire, light green (#921) temperature gauge wire, light blue / black (#922) oil gauge wire and
purple / white (#923) were covered in engine section A

The orange / black wire (#955) may be used as an accessory power wire.

Tail Section;

The green right turn signal wire (#948) and left turn signal wire (#949) have been rolled together. One end of each attaches
to the appropriate terminal at the switch and the other end to the appropriate rear light.

The pink (#939) fuel sending unit wire, brown (#929) tail light wire were covered in headlight section B, Orange (#950) third
brake light wire is described in engine section A

The purple / black (#942) wire is provided to operate a power antenna signal if needed.
The light green (#956) back up lights wire has been included with the other back up light wire in the cruise control section.
 37

30

Figure 11.0 Instrument Panel Wiring

 38

Figure 11.1 Engine Wiring

 39
Painless Performance Products, LLC
Limited Warranty and Return Policy
Chassis harnesses, fuel injection harnesses, and Trail Rocker 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. No
products will be considered for warranty without a copy of the purchase receipt
showing the sellers name, address, and date of purchase. You must return the product
to the dealer you purchased it from to initiate warranty procedures.
40