Painless Performance Products PERFECT TORC, Installation Instructions Manual

Page 1: ...Installation Instructions PERFECT TORC GM 4L60 65E and 4L80 85E Part 66501 ...

Page 2: ...erned about corrections or improvements that can be made If you have found any errors or omissions or if you simply have comments or suggestions concerning these instructions please call or email using the number or email address above We sincerely appreciate your business Perfect Performance Products LLC shall in no event be liable in contract or tort including negligence for special indirect inc...

Page 3: ...stallation of this product It is likely if this manual is not read completely that either the product not work due to improper installation and or damage to this product or the transmission may result SO PLEASE READ THIS ENTIRE INSTALLATION MANUAL BEFORE PROCEEDING THANK YOU CONTENTS INTRODUCTION Page 4 KIT CONTENTS Page 5 INSTALLATION STEPS Transmission Harness Page 6 Module Mounting Page 8 Vehic...

Page 4: ...nector General Motors has several Technical Service Bulletins recommending the upgrade to the newer style connector and harness The TORC Controller s main harness connector is not compatible with the early harnesses If an early 4L80E transmission is being used the harness must be upgraded to the 1993 and newer style to use with this system The 1994 and earlier 4L80E transmissions use a Bosch style...

Page 5: ... Small 4 Zip Ties 1 Installation Instruction Manual X Necessary crimp on terminals to complete installation Software Note Due to the growing number of PCs lacking a CD drive the software is not included with this kit but rather downloadable to a Windows PC from the 66501 product page on the Painless website You will need the Second Generation Software with this module If a CD is preferred contact ...

Page 6: ...the input shaft speed sensors on the 4L65E or the 4L80E 85E transmissions See Figure 1 page 7 for the pin out of required connections 2 Next plug in the transmission connector and the vehicle speed sensor connector into their appropriate locations on the transmission The transmission connector is located on the passenger side of the 4L60E transmission housing and on the driver side of the 4L80E tr...

Page 7: ...7 Install Picture 2 VSS Vehicle Speed Sensor Connector Figure 1 Transmission Harness Connections on Transmission ...

Page 8: ...e unit in a way that gives easy access to the USB port knob and display If you will be using a desktop PC for programming install the unit so that it can be unplugged and moved easily 3 To mount the module 10 bolts nuts and 8 self tapping screws have been provided if permanent mounting is desired Hook Loop strips have also been provided to allow installation but also easy removability 4 The Transm...

Page 9: ...9 Diagram 1 4L60E 65E Connection Diagram ...

Page 10: ...10 Diagram 2 4L80E 85E Connection Diagram ...

Page 11: ...ap Instructions 1 Unscrew the larger cap from the end of the Posi Tap The slot in this cap will slide over the existing wire you are tapping into 2 Screw the body of the Posi Tap onto the cap watching the needle of the body to insure it pierces the wire insulation 3 Strip about 3 8 of an inch of insulation from the wire coming from the module 4 Remove the small cap from the end of the Posi Tap bod...

Page 12: ...e The reason for this connection method is because the TPS is shared between the two systems and improper grounding will corrupt the TPS signal Splices and a Posi Tap have been provided to allow this connection If this step is overlooked there is a good possibility the Throttle Position Sensor TPS will not read correctly Carbureted Mech Injected Diesel Connect the MODULE GROUND wire Pin 15 Black d...

Page 13: ...t GM Throttle By Cable applications this is the Dark Blue wire at the Throttle Position Sensor connector Splices and a Posi tap have been provided to make this connection Carbureted Mech Injected Diesel See below for connection of the TPS signal wire D Orange Wire printed 5 Volt TPS Feed This is the 5 volt power source for carbureted and mechanical injected diesel applications where an external Th...

Page 14: ...closed throttle position measure the resistance between the wiper output and each of the end terminals the two whose resistance did not change in step 2 of the sensor The end terminal with the lowest resistance to the wiper at idle is the ground terminal and should connect to the black TPS GROUND wire of the controller Vehicle pin 16 The terminal with the higher resistance to the wiper is the 5 vo...

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Page 16: ...al on the speedometer output Reset SPO will clear all saved data for the speedometer output and revert to using values from the tune The speedometer output is adjustable and is essentially the electronic equivalent of a ratio corrector gear box for a mechanical speedometer When adjusting the speedometer output the correction factor is entered as a decimal number The correction factor is the freque...

Page 17: ...ed to the coil negative terminal For this configuration add the supplied 47K Ohm resistor yellow violet orange and gold bands to the yellow lead pin 7 in line with the tachometer signal The correct setting will need to be set in the tuning software under Settings Speed Sensor Gearing For COP Coil on Plug ignition systems that do not have a conventional tachometer output such as later Mustang engin...

Page 18: ...b until Setup Menu is highlighted Click the knob to enter the menu The first item that will be highlighted is TPS Setup Click the knob to enter the TPS screen It will show the current idle and WOT voltage values as well as the current throttle position sensor voltage Press the knob again to enter the TPS setup menu To calibrate throttle position the ignition should be in the ON position but the en...

Page 19: ...es for specific tunes Possible TPS Calibration Errors Pedal Not Pressed Acc Pedal Not Held The throttle wasn t pushed or held at maximum long enough for the test to complete Accelerator pedal must be held for 3 seconds and voltage must not drop more than 0 168V below the maximum recorded value Pedal Not Released The throttle wasn t released within 5 seconds The voltage must drop at least 0 96V bel...

Page 20: ...faults When low range is engaged LO will be shown beside speed KEY OFF will show in the PRNDL location if ignition is off and the controller is being powered by USB Error will show in the PRNDL location if there is a PRNDL sensor error When in park or neutral P N will be displayed because 4L60E 4L80E transmissions don t provide a way for the controller to see which is engaged Fault messages will b...

Page 21: ...21 Home Screen Normal Mode Home Screen Enlarged Mode ...

Page 22: ...w the main menu The tutorial will continue to play until you select home screen info screen or turn off the vehicle Display Off Keeps the screen off until you turn the knob The display will continue to switch off until you select home screen info screen or turn off the vehicle SETUP MENU TPS Setup Clicking this will take you to the TPS Setup menu which shows the idle and WOT settings as well as th...

Page 23: ...st option is to reset the speed sensor settings This will revert all of the settings for the speed sensor axle ratio and tire diameter back to the defaults from the currently loaded tune Axle Ratio Allows you to input your axle ratio which improves speed display accuracy in the home screen and will also will affect speed sensor calibration for certain types of speed sensors Tire Diam Allows you to...

Page 24: ...access options such as enabling torque converter clutch TCC activation above 1800 RPM disabling the TCC and exiting dyno mode Please note that it is not safe to use this mode while driving Data Display Allows you to see readings on the inputs and outputs such as Solenoid Ohms and current PRNDL values and the voltage or status of various inputs such as table select and manutronic Manutronic push bu...

Page 25: ...ally Use this only if you were instructed to do so by a Painless technician TCC Sol can be used to manually lock the TCC by holding the knob down When released the TCC will unlock Doing this while idling in gear will usually cause the engine to stall if your transmission allows TCC engagement in first gear Mode Lamp not used on this module ...

Page 26: ...k the Open button on the toolbar left hand side of the screen then browse to the folder where the transmission calibration files are located Default location is C Shiftware The files are named according to the transmission and RPM range and have the btc file extension Choose the calibration file and click Open Once the calibration file is loaded click the System Settings button on the toolbar to c...

Page 27: ...tion button and then clicking on an item This can be used in any area of the software Pressing F1 will show help on whatever item is currently active The help messages in the settings pages are transmission specific and are more like getting professional advice than normal help tips The graph has ten points from left to right 0 being idle and 9 being Wide Open Throttle WOT On the left side of the ...

Page 28: ...e unusual TCC operation This is normal and will end once learning is complete Once learned the data will not change unless it is erased using the clear command on the controller s user interface found in Diagnostics Clear Shift Timing Clearing the data will cause another learning cycle to begin This could be useful if the transmission is altered or upgraded in some way For optimum accuracy learnin...

Page 29: ... is disconnected from the computer the Write Calibration button will be grayed out IMPORTANT INFORMATION How to Avoid Errors The Shiftware software gives you complete freedom and flexibility to customize your shifting calibration however you want This freedom requires diligence to avoid errors It is very important that the up shift and down shift curves for a given gear do not cross The up shift p...

Page 30: ...ds renders engine RPM values meaningless It is usually desirable to have light throttle shift points within a low RPM range In this case it is best to base light throttle shift points on vehicle speed rather than engine RPM as most auto manufacturers do ...

Page 31: ...ounting location Battery voltage is too low The voltage to the controller has dropped below 8 volts Battery voltage is too high The voltage to the controller is above 17 2 volts Shift Solenoid A SSA overcurrent error An over current condition was detected on the indicated shift solenoid A short circuit may be present in the solenoid circuit The controller will attempt to disable the solenoid with ...

Page 32: ... turned off EPC PCS Solenoid overcurrent error An over current condition was detected on the line pressure control solenoid A short circuit may be present in the solenoid circuit The controller will attempt to disable the solenoid with the over current condition until the ignition is turned off Shift Solenoid A SSA undercurrent error Current measured on the indicated shift solenoid was too low ind...

Page 33: ...enoid resistance Shift Solenoid B SSB circuit shorted The indicated Shift Solenoid s resistance measured too low during the power on solenoid check Refer to the data display screen in the diagnostic menu to see the measured solenoid resistance 3 2 D S Solenoid circuit shorted 3 2 downshift solenoid resistance measured too low during the power on solenoid check Refer to the data display screen in t...

Page 34: ...d Shift Solenoid s resistance measured too high during the power on solenoid check Refer to the data display screen in the diagnostic menu to see the measured solenoid resistance 3 2 D S Solenoid circuit open 3 2 downshift solenoid resistance measured too high during the power on solenoid check Refer to the data display screen in the diagnostic menu to see the measured solenoid resistance TCC On O...

Page 35: ...n the setup menu TFT Circuit Voltage Low or Shorted The Transmission Fluid Temperature sensor voltage is too low A possible cause of this could be that it is shorted to ground TFT Circuit Voltage High or Open The Transmission Fluid Temperature sensor voltage is too high The TFT sensor circuit could be open Transmission is Overheating The temperature in the transmission is above the allowed thresho...

Page 36: ...twice in this drive cycle max line pressure latched Ratio too High in Gear s 2 3 4 etc Transmission gear ratio appears to be too high in the indicated gear or gears Error PRNDL Out of Range Sensor voltage is out of tolerance limits but within approximate range Error PRNDL Signal Low Sensor voltage is low Error PRNDL Signal High Sensor voltage is high Error No PRNDL PWM Signal Connect the controlle...

Page 37: ...l 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 purchase...