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90558Installation ManualFor #602502003-2005Cummins 5.9L Common Rail Diesel1st Edition March 2008Copyright 2008 by Perfect Performance Products, LLC1

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] sincerely appreciate yourbusiness.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 propertydamage, or any other damages, costs or expenses which might be claimedas the result of the use or failure of the goods sold hereby, except only thecost of repair or replacement.2

TABLE OF CONTENTS1.0 INTRODUCTION. 32.0 TOOLS NEEDED . 33.0 PRE-INSTALLATION AND HARNESS ROUTING GUIDELINES. 44.0 ADDITIONAL COMPONENTS NEEDED 44.1 ENGINE SENSOR PARTS LIST . 54.2 GROUNDING THE VEHICLE . 54.3 YEAR SPECIFIC CONNECTORS 55.0 ROUGH INSTALLATION .6-96.0 ENGINE SPECIFIC CONNECTIONS.10-197.0 FUSE BLOCK . 207.1 RELAYS . . 207.2 FUSES . . 208.0 FIRE WALL . .219.0 OPEN ENDED WIRES . . 21-2510.0 FINAL NOTES. 26WARRANTY. 27NOTES. 28LIST OF PICTURESENGINE COMPONENTS DRIVER SIDE . 6ENGINE COMPONENTS PASSENGER SIDE . 7HARNESS ROUTING ON ENGINE. 8-9ECM . .10FUEL HEATER . 10WATER IN FUEL SENSOR . 10OIL PRESSURE SENSOR . . 11FUEL CONTROL ACTUATOR . . 12CAM POSITION SENSOR . 13CRANK POSITION SENSOR . 13RADIATOR FAN DRIVE.13INJECTOR 1&2 .14INJECTOR 3&4 . .15INECTOR 5&6 .15MAP/IAT SENSOR .15FUEL PRESSURE SENSOR.16EARLY APPS .17COOLANT TEMPERATURE SENSOR.18ALTERNATOR .18WASTEGATE.19PRE-TURBO IAT/PRESSURE.19BATTERY TEMPERATURE SENSOR.19FUSEBLOCK/ RELAYS/ FUSES. .20FIREWALL.21LATE APPS.21PARK/NEUTRAL SAFETY.22CRUISE CONTROL .23BATTEY. .24INTAKE AIR HEATER RELAYS.24-253

1.0 INTRODUCTIONWe at Painless Performance Products believe you have purchased the most up-to-date and easiest toinstall Cummins common rail engine swap harness on the market. All components of this harness arenew. All harnesses are tested for faults before they leave the factory floor. This harness is designed foreasy installation, even if you have no electrical experience. Please read entire manual before installation.Download a color version of this manual from www.painlessperformance.com.The 60250 harness is a complete wiring system for the turbo diesel injection systems on 2003-2005Cummins 5.9L engines. Only the factory ECM is to be used with this harness. This harness includes allwiring that is needed by the computer to run and control the turbo diesel injection system. It isrecommended that you have the computer reprogrammed to remove anything in the original factoryprogramming that relates to a device or devices that are not being used in your particular vehicle.NOTE 1: Most remanufactured computers come without any programming and must be programmedbefore they can be used. Call our tech line and we can refer you to someone with this capability.NOTE 2: Factory 2006-2007 Cummins’ ECMs have an anti-theft feature programmed into them. Theyare also pinned out incorrectly for this harness. Do not use a 2006 or 2007 ECM with thisharness.NOTE 3: The program in your computer must match the transmission that you plan on using. Forinstance, you cannot run a 48RE transmission with a computer programmed for a G56 standardtransmission. If you are not using a transmission that originally came behind the Cumminsengine, it is suggested that you flash the ECM for a standard shift transmission and purchase anaftermarket controller for the transmission.NOTE 4: 2003-2004 Cummins engines with 47RE automatic transmissions have the throttle positionsensor mounted on a bell crank located towards the front of the intake manifold. 2004 Cumminsengines with standard transmissions and 2005 both automatic and standard have an APPSmounted to the accelerator pedal. This harness supports the 2003-2004 bell crank or 2004-2005accelerator pedal mounted APPS. Your ECM will need to be flashed accordingly. Do not try touse a 2005 or later accelerator pedal mounted APPS with an ECM flashed for 2003 to 2004. Youmust purchase the correct pedal to match the ECM programming. The ECM pin outs changefrom 2003-2005 which makes the APPS sensors non-interchangeable. See page 17 and 21 formore information.NOTE 5: Up until 2004.5 the factory lift pump was mounted to the back of the water/fuel separator andheater. This harness does not include this connector. If you wish to use this lift pump keep theconnector from your old factory harness and splice it to this one. Otherwise, use the suppliedfuel pump relay output wire to power a factory fuel tank mounted lift pump or any aftermarketfuel pump. The fuel pump relay is rated for continuous 30 amps.2.0 TOOLS NEEDEDYou will need the following tools in order to install this wire harness:Crimping toolNOTE: USE A QUALITY TOOL TO AVOID OVER-CRIMPING.Wire stripperVolt/Ohm MeterElectric drill with 1 1/4” hole sawScrew driversSAE and Metric sockets w/ratchet/extensions and wrenchesOBD II code readerAllen wrenches4

3.0 PRE-INSTALLATION AND HARNESS ROUTING GUIDELINESIf you plan to loom this harness, do so before you install it onto the engine/vehicle. Looming yourharness is definitely recommended. Painless Performance Powerbraid is a great way to protect yourharness from the elements and it makes the harness look great and the installation look professional.Look online at www.painlessperformance.com for more information.The ECM is pre-mounted to the driver side of the engine block. If you move the ECM anywhere from thefactory position, the 60250 harnesses will not properly fit. The fuse block is weather proof by design andshould be mounted in the engine compartment. Most of the wiring in the harness has been preterminated to the proper connector and all wire has been factory color-coded.The installation with of your harness kit will consist of two parts: The physical routing, positioning, and securing of the harness, wire groups, and individual wiresand connectors. Many of the factory harness clips can be reused to install this aftermarketharness. When you remove the factory harness make sure to keep the factory clips and retainerbolts.The proper electrical connection of the individual circuits. Most circuits are pre-terminated with afactory style connector. Please look carefully at the connector and its intended component youare connecting to. Each connector is specifically keyed and can only be pushed onto its mateone way. Forcing the connector on the wrong way will damage it and its terminals. Troubleshooting damaged connectors is not as fun as driving your re-powered Cummins vehicle. Soplease take care when making connections, double check you are following these instructions.4.0 ADDITIONAL COMPONENTS NEEDEDThe 60250 harness fits 2003-2005 Cummins common rail engines. You will need the followingcomponents in addition to this harness for a successful installation.1.2.3.4.5.6.ECM- This must be a factory ECM flashed for a manual transmission. This harness only fitsECMs from 2003-2005 Dodge trucks with the 5.9L Cummins engine.IAT heater relays- This harness provides ECM output wires in order to turn on factory styleIAT heater relays. You must purchase these relays or get them from a salvaged vehicle. Seepage 25 for a schematic on how to wire these relays.APPS- This harness supports the 2003 early Accelerator Pedal Position Sensor that wasmounted on the front of the engine to the intake, the 2004 APPS mounted under the battery boxand the 2005 late model Accelerator Pedal Position Sensor that was mounted on the acceleratorpedal. You must use which ever APPS your ECM is programmed for. All APPS units are availablefrom your local Chrysler dealer.CTS- This harness only supports the late model style coolant temperature sensor. See page 18for more details.LIFT PUMP- There are several options when choosing a lift pump. This harness provides a 30amp power wire. It is relayed and ECM controlled.A. Use a factory style lift pump; this may be a good budget minded option if this Cumminsmotor is transplanted into a vehicle that already had a diesel engine. Be sure to checkvolume and pressure from your factory lift pump if going with this option.B. 2003-2004.5 Cummins engines had lift pumps mounted to the back of the fuel filter/waterseparator.C. Use an aftermarket lift pump.RADIATOR FAN DRIVE- This is factory mounted to the fan shroud and controls the speedof the mechanical radiator cooling fan. This part can be taken from the donor vehicle orpurchased new. If