Painless Performance 60505 - Manual (Page 8)

5.2 ROUGH
INSTALLATION
CAUTION: DISCONNECT THE POWER FROM YOUR VEHICLE BY REMOVING THE
NEGATIVE BATTERY CABLE FROM THE BATTERY.
Note: Make no wire connections or permanent mounting of any kind at this time.
5.2.1 Position the computer and sensors in their intend locations.
5.2.2 Drill a 1-5/8" hole for the firewall grommet near the computer for the engine group and tail section
to pass through.
5.2.3 Route the engine group and tail section through the hole. Push the grommet (already installed on
the harness) into the hole until it is seated.
5.2.4 Route the dash group over to the driver's side of the car.
5.2.5 Route the fuse block and relays to the place they will be mounted.
5.3 HARNESS ATTACHMENT
Note: Harness routing and shaping will be a time-consuming task. Taking your time will enhance
the beauty of your vehicle. Please take your time and be patient.
5.3.1 Permanently mount your computer. You should mount the fuse block and relays at this time.
5.3.2 Mold harness groups to the contour of the dash, engine, frame, etc. Remember to route harness
away from sharp edges, exhaust pipes, hinges, and moving parts.
5.3.3 Attach harness groups to your automobile with clips or ties starting at the computer and working
your way outward.
Note: Do not tighten tie wraps or mounting devices at this time. Make all harness attachments
LOOSELY.
5.3.4 When used every 1-1/2" or so on the visible areas of the harness, colored plastic wire ties make a
very attractive assembly. Otherwise, a tie installed in other areas every 6" or so will hold the wires
in place securely. REMEMBER TO TAKE YOUR TIME.
5.4 TERMINAL INSTALLATION INSTRUCTION
Note: In the following steps you will be making the circuit connections. Before you start, you
should carefully read Sections 6.0, and continually refer to the wire charts, DOUBLE
CHECKING your length calculations before cutting any wire or making any connections.
These directions are for the wires, which do not have a connector already, installed on them.
5.4.1 Have all tools and connectors handy.
5.4.2 Select the correct terminal for the wire and application.
5.4.3 Determine the correct wire length and cut the wire. Remember to allow enough slack in the
harness and wires at places where movement could occur. DOUBLE CHECK YOUR
CALCULATIONS.
5.4.4 Strip insulation away from wire. Only strip as much insulation off as necessary for the type of
terminal lug you are using.
Note: In the following step, make sure that the terminal is crimped with proper die in the crimping
tool. An improper crimp will not make a good connection. DO NOT OVER-CRIMP.
5.4.5 Crimp the terminal onto the wire.
5.4.6 Connecting the wires and connectors throughout the harness is a simple process. Make sure that
each wire is properly routed and then attached. DO NOT ATTACH THEN ROUTE
AFTERWARD.
5.4.7 When all the wires are attached, tighten the mounts and ties to secure the harness permanently.
5.4.8 Attach the connectors to the computer. BEING VERY CAREFUL NOT TO BEND ANY PINS.
5.4.9 After all connections have been made throughout the harness, connect the battery to the vehicle.
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