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Wire Harness Installation InstructionsFor Installing Harness Numbers:60221: 03 – 06 GM Gen III 4.8/5.3/6.0L EFI Harness - Throttle by WireManual P/N 90570Painless Performance Products recommends you, the installer, read thisinstallation manual from front to back before installing this harness.1

Painless Performance Products, LLC2501 Ludelle St.Fort Worth, TX 76105-1036PHONE: 800-423-9696 FAX: 817-244-4024EMAIL: [email protected] you have any questions concerning the installation of this harness,feel free to call Painless Performance Products' Tech Line at 1-800-4239696. The Tech Line can be reached from 8 A.M. to 5 P.M. central time,Monday through Thursday, and 8 A.M. to 4:30 P.M. on Fridays.We have attempted to provide you with as accurate of instructions aspossible and are always concerned about corrections or improvements thatcan be made. If you have found any issues or omissions, or simply havecomments or suggestions concerning these instructions, please write us atthe above address, send us a fax at (817) 244-4024, or email us [email protected] We sincerely appreciate your business.Painless Performance Products, LLC shall in no event be liable incontract or tort (including negligence) for special, indirect, incidental, orconsequential damages, such as but not limited to, loss of property damage,or any other damages, costs or expenses which might be claimed as theresult of the use or failure of the goods sold hereby, except only the cost ofrepair or replacement.2nd Edition: November 2019Copyright 2019 by Painless Performance Products, LLCCAUTION: BEFORE THE REMOVAL OF YOUR ORIGINALHARNESS AND/OR THE INSTALL OF YOUR NEW PAINLESSHARNESS, DISCONNECT THE POWER FROM YOUR VEHICLE BYREMOVING THE NEGATIVE OR POSITIVE BATTERY CABLE FROMTHE BATTERY.2

TABLE OF CONTENTSPAGE M PROGRAMMINGTOOLS NEEDEDKIT CONTENTSPRE-INSTALLATION AND HARNESS ROUTING GUIDELINESHARNESS ATTACHMENTGROUNDING THE VEHICLEINSTALLATION INSTRUCTIONSFUSE BLOCK, ECM, TAC MODULE, PEDAL MOUNTING ANDCONNECTIONSDASH PORTION; INFORMATION & INSTALLATIONENGINE CONNECTIONTAIL/TRANSMISSION GROUP INSTALLATIONTRANSMISSION FUNCTIONCONVERTING THE 4L60E TRANSMISSION CONNECTOR TO A 4L80ECONNECTORCONCLUSIONTHINGS TO REMEMBERRETRIEVING TROUBLE CODES FROM THE COMPUTERTROUBLE SHOOTING GUIDE FOR YOUR PAINLESSPERFORMANCE HARNESSLIMITED WARRANTY AND RETURN POLICYLIST OF FIGURESPAGE #SECTIONFIG. #6CONTENT OF THE 602219ACCELERATOR PEDAL9TAC MODULE CONNECTIONS10DATA LINK CONNECTOR10CRUISE CONTROL11BRAKE SWITCH CONNECTIONS11BRAKE SWITCH RELAY12’03 & ’04 KNOCK SENSOR CONNECTION13CRANKSHAFT POSITION SENSOR14CAM PROSITION SENSOR14MAP SENSOR14DRIVER SIDE COIL CONNECTOR14PASSENGER SIDE COIL CONNECTOR15ECT SENSOR15ALTERNATOR15MAF/IAT SENSOR16INJECTORS 1, 3, 5, & 7Continued 31234567891011121314151617

LIST OF FIGURESPAGE #16181919192022SECTIONFIG. #INJECTORS 2, 4, 6, & 8PARK/NEUTRAL POSITION SWITCHVSS SENSOR (4L60E)VSS & INPUT SPEED SENSOR, TRANSMISSIONCONNECTION (4L80E)4L60E/65E TRANSMISSION CONNECTIONTRANSMISSION CONNECTOR PIN-OUTNOID LIGHT181920214222324

INTRODUCTIONYou have purchased what we at Painless Performance Products believe to be the mostup-to-date and easiest-to-install automotive fuel injection harness on the market. It is designedfor easy installation, even if you have no electrical experience.This harness is designed to be a complete wiring system for the fuel injection system usedon General Motors 2003 - 2006 4.8L, 5.3L, & 6.0L Electronic Throttle, also known as Throttle byWire or Fly by Wire, engines and to control the 4L60E, 4L65E, 4L80E, 4L85E automatictransmissions. This includes all wiring that is needed by the computer to run and control theinjection system and transmission.Most of the wiring in the harness has been pre-terminated and had the properconnector pre-installed, also all wire has been GM color-coded. Note: Wire color (Example:Black/White) is one wire with a stripe. In the case of the example shown, Black/Whiterepresents a black wire with a white stripe. The second color (the stripe) may not be bold.Observe all two-color wires closely. All wiring is TXL, 600 volt, and 125 degree centigrade withcross-link insulation.DO NOT RECONNECT THE BATTERY CABLES UNTILL THE ENTIRE HARNESS HASBEEN INSTALLED. At no point during the install should you power the system or reconnect thebattery, fault codes will be set in the ECM if done so. Power is not to be applied to the Painlessharness until the entire installation is done.ECM PROGRAMMINGYou must use one of the following computer part numbers 89017733, 12576106,12583560, or 12602802 with this harness.No matter what changes are made to the engine and even if it is remaining factory originalor “stock” the vehicle’s ECM, or computer, must be re-programmed before engine start up. Thevehicle absolutely will not start and run until this is done due to the anti-theft Passlockprogramming. This harness along with the removal of the Passlock software will get the Vortecengine and transmission up and operating.The computer’s program must have the emissions portion turned off or removed*. It isrecommended that you also have the computer reprogrammed to remove anything in the originalfactory programming that relates to a device or devices that are not being used in your particularvehicle. Most likely the check engine light will come on and stay on when using a computer withoutremoving the programming for any unused devises.NOTE: *This harness is not emissions legal. The 2003–2006 4.8L, 5.3L & 6.0L TBW Vortecengines had four oxygen sensors from the factory, but we have provisions for only two,one on the driver side and one on the passenger side of the engine. We removed the tworear oxygen sensors since they originally where behind the catalytic converters and mostpeople don’t want to run more than two oxygen sensors.NOTE: Most remanufactured computers come without any programming in them and must beprogrammed before they can be used.NOTE: The program in your computer must match the transmission that you plan on using, the4L60E, 4L65E, 4L80E, 4L85E, or a manual transmission (if you are using a manualtransmission or a non-electronic automatic transmission)5

TOOLS NEEDEDIn addition to your regular tools, you will need, at least, the following:Crimping toolWire stripperContinuity testerElectric drill1 5/8" Hole sawNOTE: USE A QUALITY TOOL TO AVOID OVER-CRIMPING.CAUTION: DO NOT USE A TEST LIGHT TO TEST THE COMPUTER ORSENSOR WIRING OR YOU WILL DAMAGE THE COMPUTER.NOTE: for the rubber grommet in the firewall.KIT CONTENTSTake inventory to see that you have everything you are supposed to have in this kit, ifanything is missing, contact the dealer where you obtained the kit or contact PainlessPerformance at (800) 423-9696 or (817) 244-6898.The kit should contain the following items: The main wire harness Fuel Injection Installation Instructions P/N 90570 (This Booklet) 4” & 7” tie wraps, fuse block mounting bracket & screws, brake switch, splices andterminals TAC Module to Accelerator Pedal Pigtail, Gas Injector Harness, Flex Fuel InjectorHarness, ’05-’06 Knock Sensor PigtailFigure 1 Content of the 602216

PRE-INSTALLATION AND HARNESS ROUTINGGUIDELINESFamiliarize yourself with the harness by locating each of the harness groups and bylooking at the connectors on the wire ends. A good exercise is to lay out the wire harness on thefloor and identify all the connectors, sections, and wires.Disconnect the battery if it has not already been disconnected. The sensors andcontrol systems used by electronic fuel injected vehicles are very sensitive. Any shorts can andwill cause severe damage to these components.The installation of your harness kit will consist of two parts: The physical routing, positioning, securing, group/ individual wires and connectors.The proper electrical connection of the individual circuits.We cannot tell you how to route the harness in your vehicle. That depends a great dealupon the particular make of the automobile and what extent you want to secure and conceal theharness. To help you begin thinking through the installation of your wire harness we can onlyreally offer some general guidelines and routing practices, general installation instructions in, allof which can be found below. You will want to route the harness through and around open areas. Inside edges provideextra protection from hazards and also provide places for tie wraps, clips, and othersupport. Route the harness away from sharp edges, exhaust pipes, and the hood, trunk, and doorhinges. Plan where harness supports will be located. Use a support or zip tie approximately every6 inches. Allow enough slack in the harness at places where movement could possibly occur (bodyto frame, frame to engine, etc.)HARNESS ATTACHMENTNOTE: Harness routing and shaping will be a time-consuming task. Taking your time willenhance the beauty of your vehicle. Please take your time and be patient.Mold harness groups to the contour of the dash, engine, frame, etc. Remember to routethe harness away from sharp edges, exhaust pipes, hinges, and moving parts.Attach harness groups to your vehicle with clips or ties starting at the computer andworking your way outward.Note: Do not tighten tie wraps or mounting devices until the entire harness is installed.Make all harness attachments LOOSELY.Connecting the wires and connectors throughout the harness is a simple process. Makesure that each wire is properly routed and then attached.When all the wires are attached, tighten the mounts and ties to secure the harnesspermanently.When used every 1-1/2" or so on the visible areas of the harness, plastic wire ties makea very attractive assembly. Otherwise, a tie installed in other areas every 6" or so will hold thewires in place securely.REMEMBER TO TAKE YOUR TIME.7

GROUNDING THE VEHICLEA perfectly and beautifully wired automobile will nevertheless have problems if everythingis not properly grounded. Don't go to the effort to installing a quality wire harness only to neglectproper grounding.NOTE: The installer of this harness is responsible for all ground wires not provided withthis part. These grounds are as followed: Connect a ground strap or cable (minimum of a 4 Ga. wire) from the negative batteryterminal to the chassis (frame). Connect a ground strap (minimum of a 4 Ga. wire) from the engine to the chassis (frame).Do not rely upon the motor mounts to make this connection. Connect a ground strap from the engine to the body.INSTALLATION INSTRUCTIONSFuse Block, ECM, TAC Module, Pedal Mounting and ConnectionsBelow you will find part numbers for parts compatible with this wire harness.Main ComputerTAC ModuleAccelerator PedalGM #89017733, 12576106, 12583560, or 12602802GM#12588923Delco#15264643 Decide where and how the ECM, TAC Module, and fuse block will be mounted. In mostcases these components can be mounted either under the dash or in the kick panel area.All parts are weatherproof and can be mounted in the engine compartment if necessary. Take notice of how much distance the harness will allow for ECM and Fuse Blockmounting. A bracket and mounting screws have been included for fuse block mounting.ECM mounting must be handled by the installer. The TAC Module and Pedal can both be mounted using the mounting holes found onthese components. The TAC Module must be mounted within 96” of the accelerator pedal,due to the length of the pigtail contained in the kit, and within 15” of The ECM due to thelength given in the harness. Once these locations have been determined, and double checked for accuracy, mount theECM, Fuse Block, TAC Module, and Accelerator Pedal. Drill a 15 8" hole for the firewall grommet near the ECM for the engine group and tail sectionto pass through. If the ECM and fuse block are mounted in the engine compartment, asmaller hole and grommet for the “Dash” portion will be required instead of the 15 8” hole.The “Dash” portion of the harness will not be labeled as such, information on identifyingthis portion can be found on the next page. Route the engine group, cooling fan wires, fuel compensation connector (if used, see p.15), and tail section through the hole. Push the grommet (already installed on the harness)into the hole until it is seated. Again, if the ECM and fuse block are mounted in the enginecompartment, the “dash” section of the harness will pass through this hole. Route the dash group over to the driver's side of the vehicle if it is not already there. Attach both ECM connectors to the computer. When connecting the plugs to thecomputer USE EXTREME CARE to make sure none of the pins in the computer areor become bent.8

Locate the “Accelerator pedal to TAC Module” pigtail. Connect the pedal connector to theaccelerator pedal. See Figure 2 Attach the TAC module connection from the “Accelerator pedal to TAC Module” pigtail tothe TAC module. Attach the TAC Module connection from the main harness to the TACmodule. See Figure 3FIGURE 2 Accelerator PedalFIGURE 3 TAC Module ConnectionsDASH PORTION; INFORMATION & INSTALLATIONThe wires in this group consist of the Diagnostic Link Connector or DLC and check enginelight (pre-mounted into a mounting bracket), Cruise Control (4 wires), Ignition Voltage source (1wire), Fuel Test (1 wire), VSS Output (1 wire), A/C Request (1 wire), Brake Switch (3 wires), andTach (1 wire).All of these connections, with the exception of the DLC, are open ended wires. Thesewires will require you, the installer, to crimp on a terminal from the parts kit in order to make thecorrect connections needed. Follow the instructions given for proper terminal installation.Terminal Installation Information Have all tools and connectors handy. Select the correct terminal for the wire and application. Determine the correct wire length and cut the wire. Remember to allow enough slack inthe harness and wires at places where movement could occur. DOUBLE CHECK YOURCALCULAT

Take notice of how much distance the harness will allow for ECM and Fuse Block mounting. A bracket and mounting screws have been included for fuse block mounting. ECM mounting must be handled by the installer. The TAC Module and Pedal can both be mounted using the mounting holes found on these components. The TAC Module must be mounted within 96” of the accelerator pedal,File Size: 1MBPage Count: 20