Painless Performance Products 10106, Installation Instructions Manual

Page 1: ...WIRE HARNESS INSTALLATION INSTRUCTIONS For Installing 22 Circuit Chassis Harness Kits 10105 Classic Customizable Jeep CJ 74 back 10106 Classic Customizable Jeep CJ 75 later Manual 90504...

Page 2: ...e 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...

Page 3: ...gtails 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 conne...

Page 4: ...d Ignition Systems As Originally Manufactured by Jeep 16 8 1 1974 and Earlier 16 8 1 1 Generator Charging System 16 8 1 2 Generator to Alternator Conversion 17 8 1 3 Motorola Alternator Charging Syste...

Page 5: ...m 20 8 6 Prestolite BID Ignition Start Run System 21 8 7 Motorcraft Electronic Ignition Start Run System 23 8 8 Ford Ignition Diagram Duraspark II Systems 24 8 9 Ford Ignition Switch Connectors 24 9 1...

Page 6: ...starter solenoid and battery feed alternator and alternator exciter wire distributor water temperature oil pressure and air conditioning Dash Group Includes wires to connect gauges indicator lights a...

Page 7: ...ention to the Notes especially those in Tables and ANY text marked CAUTION Note Painless Performance has elected to use GM wire color codes throughout this manual Jeep has changed color codes too many...

Page 8: ...d 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 wi...

Page 9: ...circuits you will be using in your system and where the harness groups or wires will be routed Routing Location and Placement Emergency Flashers ______________________________________________ Horn __...

Page 10: ...REVIEW THE DIFFERENT SECTIONS OF THE PPPI WIRE HARNESS AND THE INDIVIDUAL CIRCUIT CONNECTIONS SEE TABLE 12 1 IT IS OF THE UTMOST IMPORTANCE THAT YOU DO NOT REMOVE ANY EXISTING WIRING IN THE FOLLOWING...

Page 11: ...the 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 or so on the visible areas of the...

Page 12: ...heck 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 wi...

Page 13: ...te 7 3 4 If you are using a Delco Starter route the remainder of wire 716 from the Ammeter POSITIVE terminal to the Starter Solenoid Battery B terminal This is the terminal to which the battery cable...

Page 14: ...his 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 2 to determine w...

Page 15: ...t belt buzzers or key alarms NOTE To supply power to a throttle body or tuned port fuel injection use ENGINE SECTION A wire 720 pnk as the fused ignition power source Table 7 1 Keyed Column Ignition a...

Page 16: ...Vio Ground Ylw Buzzer Switch Ylw Buzzer Switch Orn Gear Shift Lamp NOTES 1 12 gauge wire 2 20 gauge wire 1 The Painless harness does not support these TURN SIGNAL CONNECTOR Designation 79 w tilt 79 w...

Page 17: ...nect HEADLIGHT SECTION A wires 708 lt grn and 709 tan to the green and tan wires of BOTH Headlamp Connectors Connect the black wires of the Headlamp Connectors to Chassis Ground You should have enough...

Page 18: ...n wire for the fan relay DO NOT TRY TO POWER THE FAN WITH THIS WIRE 7 6 5 Connect the DIMMER SWITCH SECTION cable to its mating connector in the harness if applicable and your floor mounted Dimmer Swi...

Page 19: ...Panel 7 8 1 Connect the wires of the INSTRUMENT PANEL SECTION as indicated in Table 12 1 Insulate and stow any wires you do not use 7 8 2 Connect a jumper from wire 735 red wht to all Gauges power or...

Page 20: ...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...

Page 21: ...arging System See Figure 8 1 A 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...

Page 22: ...to either Section 8 0 9 0 10 0 or 11 0 as appropriate 8 1 3 Motorola Alternator Charging System See Figure 8 2 A Locate the Alternator Voltage Regulator It may not appear exactly as represented B Find...

Page 23: ...oltage Regulator S terminal to the S terminal of Alternator Connect a 14 gauge wire from the Voltage Regulator F terminal to the Alternator Field F terminal D Connect the Alternator Ground lug and the...

Page 24: ...uded in the alternator bag C If engine run on occurs after the ignition is turned off the provided diode in the alternator bag will need to be installed Instructions can be found in the illustration b...

Page 25: ...ed the coil will overheat within a few minutes to the point that it will no longer work A ballast resistor has been provided with part 10105 those with part 10106 a resistor can be obtained at your lo...

Page 26: ...T REMAIN CONNECTED IN THEIR ORIGINAL CONFIGURATION You may replace them one at a time and incorporate them into the new harness if you wish B Route and connect the provided 6 gauge red wire from the a...

Page 27: ...RATION You may replace them one at a time and incorporate them into the new harness if you wish 1 The red wire in the 2 way connector of the module will need to be spliced or connected with wire 720 p...

Page 28: ...accomplish this If you are using a Ballast Resistor mount it away from other wiring or hoses It gets very hot during operation F A 14 gauge wire connected from the Starter Relay l terminal to the ign...

Page 29: ...Figure 8 8 Ford Ignition Diagram Duraspark II Systems Figure 8 11 Ford Switch Connectors 24...

Page 30: ...idi fuse 9 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 9 1 5 Connect a 16...

Page 31: ...other end of the Ballast Resistor to the Ignition Coil POSITIVE terminal with 14 gauge wire you may have enough pink left over to accomplish this If you are not using a Ballast Resistor connect wire 7...

Page 32: ...ong as they are BOTH connected The mechanical regulator has terminals marked F Field and I Ignition In contrast to the electronic regulator it DOES make a difference how these are connected 11 1 2 Con...

Page 33: ...e cut off end of the provided 6 gauge red wire from the other side of the MIDI fuse to the Starter Relay Battery terminal This is the same lug to which the large red cable from the battery is normally...

Page 34: ...ft over to accomplish this If you are not using a Ballast Resistor connect wire 720 directly to the Ignition Coil POSITIVE terminal 11 2 5 Connect a 14 gauge wire from the Starter Relay Ignition l ter...

Page 35: ...ch as the one at the end of this sentence The term B means Battery Positive or Battery Power Table 12 1 is divided into sections that correspond to the sections of your wire harness ACCESSORY SECTION...

Page 36: ...Fuse Panel Fuse Panel Tan 18 760 Brake Pressure Switch master cylinder Emergency Brake Indicator Instrument Panel Section Orn 18 763 Hood Light Fuse Panel Fuse Panel ENGINE SECTION SINGLE WIRE Red 3...

Page 37: ...Panel Fuse Panel IGNITION SWITCH SECTION Pnk 14 731 Ign Switch Coil Ign Fuse Panel Fuse Panel Orn 12 733 Ignition Switch Ignition Fuse Panel Fuse Panel Red 12 734 Ignition Switch B Fuse Panel Fuse Pa...

Page 38: ...rn Signal Switch Turn Signal Section Lt Grn 1 18 756 Backup Lights Backup Switch Cruise Control Section Table 12 1 Wire Connection Index 3 of 3 Notes 1 Depending upon the particular wire harness you p...

Page 39: ...Requirements Table 12 2 Fuse Requirements 34 Headlight Switch 30 Emergency Flashers 15 Turn Signals 15 Gauges 10 A C Heat 30 Horn 20 Wipers 15 Brake Switch 20 Dome 10 Electric Fan 5 Coil 30 Radio Ign...

Page 40: ...Diagram 1 Engine Wiring Diagram 35...

Page 41: ...Diagram 2 Instrument Panel Section Wiring Diagram 35...

Page 42: ...Diagram 3 Integrated Brake Lights Separate Turn Brake Lights 36...

Page 43: ...ge shows how you can cut the bulkhead hole clean and precise using a 1 hole saw to cut 4 holes using a jigsaw or cut off wheel to connect the outsides of the 1 holes and using a drill bit for the fuse...

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Page 45: ...riginal 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...