SUM EFI Wiring Harness for GM LT-1/LT-4 Engine INSTALLATION INSTRUCTIONS

Transcription

1 SUM EFI Wiring Harness for GM LT-1/LT-4 Engine INSTALLATION INSTRUCTIONS

2 INTRODUCTION This harness is designed for GM LT1/LT4 fuel injected engines. Even with minimal electrical experience, this kit should provide an easy installation of this engine into a vehicle of your choice. This harness can also control a 4L60E transmission. When using this harness on a 1996 or 97 engine you must replace the coil, coil wire and knock sensor with the components from a engine, for proper compatibility. Please be aware that the factory EFI computer has a Vehicle Anti Theft System (VATS), and will not normally allow the engine to run if you do not have the proper ignition key. This harness kit includes a VATS Bypass Module, and it will be required for use with a production type computer NOTE FOR AUTOMATIC TRANSMISSION: The use of a 40 PPR (Pulse Per Revolution) Vehicle Speed Sensor, such as the one that comes standard in the 4L60E transmission, is required when using a 1994 or newer computer. Using this transmission will also require using an electronic speedometer, as there are no provisions available in the transmission for a cable driven speedometer. The computer, fuse box, and relays are intended to be mounted under the dash. The instructions that follow are for the installation of the SUM EFI Wiring Harness Kit. Please pay close attention to any BOLD statements as they are intended to provide special notations which are intended to offer a trouble free installation. OVERVIEW These instructions will guide you through the preparation and installation of all the required steps to equip your engine with fuel injection. Please read the instructions thoroughly before starting the installation. To insure a trouble-free installation, please read over each step that pertains to the installation procedure. If you have any questions relating to the installation of this harness, or need to know what parts may be compatible, please contact Summit Racing at (800) HARNESS KIT CONTENTS Check to be certain have received everything you are supposed to have in this harness kit. It should consist of the following items: Wiring Harness VATS Module Wiring Harness Manual REQUIRED TOOLS In addition to common hand tools, you should have the following: Wire Strippers Digital Volt/Ohm Meter Solder Gun/Solder Electric Tape / Shrink Tubing Electric Drill Motor 2 ½ Hole Saw (for firewall grommet) 2

3 Required components It is recommended that you use the parts listed in Figure 1, as they will meet all requirements and are compatible with the Summit Wiring Harness. The computer listed in Figure 1 ( ) is required for proper operation and must be used with this harness. For the additional sensors and relays, GM and AC Delco part numbers have been provided. Figure 1. Parts List LT1 Fuel Injection Harness Air Pump Delco # Air Pump Relay Delco # or GM # Brake Switch GM # Canister Purge Solenoid Delco # or GM # Coil Delco #D-573 Computer (Main) Service # Coolant Temperature Sensor GM # EGR Solenoid Delco # Fuel Pump Relay Delco # or GM # Gear Indicator Switch Delco #D2286A or GM # Idle Air Control GM # Ignition Module Delco #D-1986-A Intake Air Temperature GM # Knock Sensor Delco # MAF Sensor Delco # MAP Sensor GM # Oxygen Sensors Delco #AFS 75 or GM # Throttle Position Sensor GM # NOTE: Components with part numbers other than the ones listed may plug into this harness, but it is recommended that the part numbers should match the ones on this list to insure proper operation. LAYOUT Decide where the computer and fuse block will be mounted. This wire harness is designed to mount these items either under the dash or in the kick panel on the right side. They must be no further apart than the wiring will allow, which is approximately 16 inches. VEHICLE GROUNDS The absolute number one problem in a poor running fuel injected engine is commonly found to be a poor ground connection SOMEWHERE in the wiring. TAKE SPECIAL CARE TO INSURE THE FOLLOWING: 1. The power ground of the fuel injection wiring harness should go have a DIRECT PATH TO THE NEGATIVE POST OF THE BATTERY. While the grounds provided in this engine 3

4 harness are designed to mount to the back of the engine, it is a good practice to attach an additional 4 ga wire from this point directly to the battery negative. 2. If it you have trunk mounted battery, it may be tempting to use a chassis ground. Take the time to EXTEND THE NEGATIVE WIRE so that it reaches the battery! If you choose to ignore this HIGHLY EMPHASIZED RULE, you should be aware that even if it runs OK upon initial startup, problems can still occur once the vehicle is started as heat will change the resistance of the ground path. Cruising on a HOT day may enhance these problems as well. Take the extra time to do it right the first time, as it will certainly take more time if you have already secured the harness after installation, and will surely eliminate future frustration. 3. A properly grounded vehicle should consist of a triangle of grounds described as the following: a. Battery Negative to Engine: Connect a 4ga ground cable from the battery negative to the Engine b. Engine to Chassis: Connect a ground strap from the engine to the chassis. c. Chassis to Battery Negative: Connect 4 ga ground cable from the chassis to battery negative. WIRE HARNESS ROUTING Overlay the engine harness onto the engine and into the passenger compartment, noting locations to shy away from such as sharp edges, exhaust pipes, hood hinges, etc. If there is a concern of interference with these areas, be prepared to secure the harness zip-ties away from these areas using zip ties. Keep adequate slack in the harness to prevent possible harness damage by vehicle flexing. These areas of concern will primarily be from chassis to engine. FUEL SYSTEM The fuel pump must be an EFI type capable of providing the required volume at a minimum of 45 PSI. VERY IMPORTANT! The fuel pump used should be an in-tank design or GRAVITY FED meaning the tank is higher than the fuel pump. If the fuel pump is mounted higher than the level of the fuel itself, it will create a vacuum in the fuel line. Vacuum leads to cavitation (vapor bubbles) and this WILL create problems. Keep in mind that these vapor bubbles will be compressed and cannot escape the fuel system except through the injectors. When vapor bubbles pass across the injector, they are no longer under pressure, and the vapor bubble will expand which will displace fuel causing a lean condition and poor drivability. TO PREVENT DAMAGE TO THE COMPONENTS, THE FOLLOWING SHOULD BE STRICTLY ADHERED TO: DISCONNECT THE BATTERY PRIOR TO DOING ANY WIRING! DO NOT connect the computer connectors while the ignition is on, DAMAGE WILL OCCUR! Take care to insure that when routing the wires for the vehicle speed sensor (if used), that they are at least 12 inches away from any ignition wiring (spark plug wires, etc.) When testing circuits, only a digital volt/ohm meter should be used. The use of a test light can sometimes result in damage to the computer or components. 4

5 Never force any connection. Each connector in this harness is unique, and is specifically keyed to a particular component. Use extreme care when connecting the computer connectors. If this is not performed properly, the pins in the computer can be damaged. PRE INSTALLATION OF HARNESS AND PARTS 1. Determine a suitable position to mount the computer and fuse block. 2. Identify where the wiring harness can pass through on the passenger side of the firewall. You will need to determine the proper location to cut a 2½ hole into the firewall for the harness to pass through. Check for any wires, hoses, etc. that may become damaged by the hole saw. 3. Use a center punch to mark the location of the center of the hole. By using the center punch, this will keep the drill bit from walking while you are cutting through the firewall. 4. Drill the 2½ hole into the firewall. Clean any sharp edges with a file or die grinder. 5. The grommet will need to be cut in order to be installed onto the harness. Using a utility knife, carefully make one cut starting from the inside of the grommet and cutting outwards. It is always safest to pull the knife away from you while cutting. 6. One by one, starting with the longest leads, route the connectors and fuse block through the hole. You will likely need to fold the computer connectors sideways over the harness to get them to pass through the hole. 7. Wrap the the grommet around the harness and fit it into the hole in the firewall until it is seated. 8. Route the fuse block and relays to their mounted locations. 9. Insure that all required engine sensors are installed at this time. HARNESS INSTALLATION These are intended to mount in the passenger compartment. 10. Lay the harness loosely on the engine and route each connector lead to the corresponding sensor. Remember to route harness away from hazards such as sharp edges, exhaust pipes, hinges and moving parts. Do not firmly secure the harness at this time. 11. If the harness correctly reaches all sensors on the engine, you can now permanently mount the computer, fuse block and relays at this time. 12. Insure that the harness has a fairly loose fit. It should not be at all tight from the engine to the firewall. Keep in mind that the motor mounts and chassis will need room to flex. Also, be certain that he harness is not routed near any hazards such as exhaust pipes, hood hinges, or sharp edges. 13. You may now secure the harness. 5

6 Terminal Installation Instructions The following directions are for wires that do not have a connector already installed on them. NOTE: In the following steps you will be making the circuit connections. Always double check your lengths before cutting any wire. 14. 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. 15. 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 OVERCRIMP. 16. Crimp the terminal onto the wire. 17. 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. 18. When all the wires are attached, tighten the mounts and ties to secure the harness permanently. 19. Attach the connectors to the computer. Being very careful NOT to bend any pins. 20. After all the connections have been made throughout the harness, the battery can be connected to the vehicle. CAUTION BE SURE THE IGNITION IS OFF WHEN YOU RECONNECT THE BATTERY OR YOU MAY DAMAGE THE COMPUTER!! 6

7 UNDER-DASH INSTALLATION The wires in this group consist of the diagnostic link connector (DLC) and the Check Engine light (pre-mounted into a mounting bracket), and 13 other wires. CAUTION DO NOT MAKE ANY CONNECTIONS WHILE THE COMPUTER IS PLUGGED INTO THE HARNESS. DLC Connector & Check Engine Light 21. Using the bracket that the light is mounted in, locate a suitable spot and mount the DLC connector that will allow access to the front of the connector, and still allow you to see the light while driving. 22. Locate the PINK iwire, labeled Fuse Block Ignition B+. Connect this wire to a SINGLE SOURCE which will have 12 Volts when the key is in both the Start (cranking) AND in the Run positions. This is the primary circuit which will provide power to all of the relays and to the ignition system. If this wire is connected correctly, the check engine light will come on when the ignition is in the RUN or START position. 23. Locate the OG/BK and BK/WH wires. These two wires are for the Park/Neutral INDICATOR switch, NOT for the Neutral Safety switch. If you have a GM column, you can use the combination switch P/N and wire it as described in paragraph 2 or 3 below. The OG/BK wire needs to be grounded in Park and Neutral and ungrounded in Drive. This can also be done with a toggle switch or a switch on the parking brake. 24. If you are NOT using a vehicle speed sensor (VSS) or Park/Neutral Indicator Switch then you will need to connect these two wires together. NOTE: If you do this, the computer will stop controlling the exhaust gas recirculation (EGR) solenoid. This WILL PREVENT the system from being street legal. 25. If you are going to use the recommended switch for the computers benefit ONLY, then you will wire it as shown in Illustration A. 7

8 26. The recommended switch is a combination reverse light AND neutral safety switch. You may use it for these purposes, AND the for the computer input signal IF you wire it EXACTLY as shown in Illustration B 27. You may choose to install your own switch. This switch must connect the OG/BK wire to ground only when the vehicle is in PARK or NEUTRAL. The BK/WH wire is the Ground circuit which also grounded throughout the harness. 8

9 28. The Light Blue wire is the signal to the computer when the brake is applied. If you ARE NOT using a 4L60E then you should terminate and tape this wire. If you ARE using the 4L60E transmission then you will have to install an electrical switch described in one of the diagrams below. The pink wire in the illustration is the wire that has power on it whether or not the brake is being applied. CAUTION FAILURE TO WIRE THIS SWITCH CORRECTLY CAN RESULT IN A BRAKE LAMP FAILURE. BRAKE SWITCH CONNECTION 29. If your vehicle has a pressure type brake switch, you may use a relay as shown in Figure 3. The 30 Amp Relay must be wired correctly or it could result in a dangerous situation with the vehicle. The torque converter may not unlock. BRAKE SWITCH RELAY CONNECTION 30. The fuel pump connector has a small gray wire at the bottom of it that terminates in a female connector. This wire is a test point for the fuel pump. After the vehicle has been wired and tested OK, terminate and tape this wire. 9

10 31. For the wires labeled VATS (Light Green/ Red & Black) are to be connected to the matching wires on the VATS module provided with the harness. 32. Fan #1 Relay Wire (Green) and Fan #2 Relay Wire (Blue) are the ground trigger wire which are controlled by the computer. NOTE: Fan #1 will come ON at 226 F and go OFF at 221 F. Fan #2 will come ON at 235 F and go OFF at 203 F 33. The wire labeled TACH (white) is the signal wire for a tachometer if used. 34. The VSS output wire is the signal wire to operate the electronic cruise control or speedometer if equipped. 10

11 UNDER-Dash Section Connections Table 2. Wire Color # of Positions in Connector Labeled Connect To: Brown (4) Red (2) 4 Air Pump Relay Relay Brown, Green/White 2 Canister Purge Canister Purge Solenoid Black, Red (2) 3 Air Pump Air Pump Gray, Green/White, Black/White, Pink 4 Fuel Relay Fuel Pump Relay Green/White VSS Output Speedometer/Cruise White Tach Tachometer Orange/Black, Black/White P/N Switch Park/Neutral Switch Pink, Light Blue/Black Brake Switch Brake Switch Pink Fuse Block B+ Ignition Power Air Pump Relay Connector Canister Purge Solenoid Air Pump Connection Fuel Pump Relay Connector 11

12 ENGINE HARNESS INSTALLATION 35. The engine harness is separated into left side (drive) and right side (passenger) sections. The right side of the engine has the connectors for the idle air control, throttle position sensor, distributor, and MAP sensor, all of which ARE labeled. 36. Locate the two BK/WH wires in the harness that have the large ring terminals and ground them to the engine. 37. Check to make sure that the wire harness has the correct distributor connector on it for your particular engine. There are two different connectors used on LT1 engines. The 92 and 93 engines used a short connector, 1 long and the 94 and up engines use a 2 connector. This harness has the 2 connector installed on it. You may reuse the original connector. 38. The pink wire labeled coil power needs to be connected to the wire that powered the coil on the original engine. ENGINE HARNESS CONNECTIONS Wire Color # of Positions in Connector Labeled Connect To: Brown, Gray 2 EGR EGR Solenoid Blue 1 Knock Knock Sensor Purple/White, Tan/White, Brown, Black 4 Drive Side Oxy Left Oxygen Sensor Purple, Tan, Brown, Black 4 Pass. Side Oxy Right Oxygen Sensor Red Ring Terminal (2) Starter B+ Starter Solenoid Gray, Light Green, Black 3 MAP Map Sensor Pink, Black 2 Inj #1 Drivers Side Front Inj Pink, Light Green/Black 2 Inj #2 Pass Side Front Inj Pink, Pink/Black 2 Inj #3 Drivers Side 2 nd Inj Pink, Light Blue/Black 2 Inj #4 Pass Side 2 nd Inj Pink, Black/White 2 Inj #5 Dirvers Side 3 rd Inj Pink, Yellow/Black 2 Inj #6 Pass Side 3 rd Inj Pink, Red/Black 2 Inj #7 Drivers Side 4 th Inj Pink, Blue/White 2 Inj #8 Pass Side 4 th Inj Gray, Black, Blue 3 TPS Throttle Position Sensor Light Green/Black, Light Green/White Light Blue/Black, Light Blue/White 4 IAC Idle Air Control Motor Yellow, Black/White, Pink 3 MAF Mas Airflow Sensor Red/Black, Pink/Black Red, Light Blue/Black 4 DIST Distributor White, black, Pink/Black, White/Black 4 IGN MOD Ignition Module Pink/White 2 Coil Ignition Coil Pink/Black, White/Black 2 Coil Ignition Coil Black/Yellow 2 ECT Engine Coolant Temp. Sensor Black/Tan 2 IAT Intake Air Temp. Sensor Black, Black/White (3) Ring Terminal (2) Ground Engine Ground Pink Coil Power Power for Coil 12

13 Exhaust Gas Recirculation (EGR) Solenoid Knock Sensor Oxygen (O2) Sensor Manifold Absolute Pressure (MAP) Sensor Injectors 1, 3, 5, 7 Injectors 2, 4, 6, 8 13

14 Throttle Position (TP) Sensor Idle Air Control (IAC) Solenoid Mass Airflow (MAF) Sensor Distributor Ignition Module Coil 14

15 Engine Coolant (ECT) Sensor Intake Air Temp (IAT) Sensor REAR HARNESS CONNECTIONS 39. If you ARE NOT USING a 4L60E transmission, Tape off and store the Light Blue/ Black and Pink (brake switch) wires in the under-dash harness and the 13-position (transmission) round connector. 40. If you ARE USING a 4L60E transmission: You MUST have a two-position vehicle speed sensor (VSS) and the correct brake switch which are necessary to make the transmission work correctly. The brake switch should be closed (electronically connected) when the brakes ARE NOT being applied and open (not electronically connected) when the brakes ARE being applied. This is the opposite of a standard brake light switch. If you are using a pressure brake switch, a SPDT relay must be installed to unlock the converter when the brakes are applied. The vehicle speed sensor is used to determine shift schedule. NOTE: Regardless of whether you use the 4L60E or not, the vehicle speed sensor (VSS) and park/neutral indicator switch must be used as the computer uses it to command the emissions control devices on the engine. This part is necessary if you want your car to be street-legal. 41. Route the GRAY wire to the fuel pump being certain to keep it clear from the exhaust system or any moving parts. Use the included zip ties to secure this out of the way. This is the power wire for the fuel pump. 42. Route the connector for the Vehicle Speed Sensor (VSS) and connect it at this time. 15

16 Rear Harness Connections Wire Color # of Positions in Connector Labeled Connect To: Purple, Yellow 2 VSS Speed Sensor Gray Fuel Pump Fuel Pump Light Green, White, Light Blue/White Tan/Black, Brown, Pink, Yellow/Black Red/Black, Pink/Black, Blue, Red Yellow/White, Black 13 Tans Transmission Vehicle Speed (VSS) Sensor TROUBLESHOOTING Transmission Connector If you are having trouble with your engine running badly or not running at all, first ensure that you are using the correct parts (Table 1), check for faulty connections, blown fuses, connection of VATS module, spark, timing, fuel pressure, etc.), then see if the computer has stored a trouble code in its memory. Panel Identification CHECK ENGINE LIGHT Normally the check engine light should illuminate when the ignition is turned on, and will turn off after a few seconds once the engine starts running. If it reappears, or stays on while the engine is running, the computer has detected a fault and a Default Trouble Code (DTC) has been set, and is held in the computer s memory. OBTAINING TROUBLE CODES FROM THE COMPUTER 43. Identify the found code to those found in the DTC Chart to determine which circuit the computer has detected a problem in. Keep in mind, that a fault code does not necessarily identify a faulty part, but rather a problem with that particular circuit, which may or may not be caused by a bad part. 44. Before performing any extensive corrective actions for any trouble codes, make sure that all connections on the indicated circuit, INCLUDING THE COMPUTER, are clean and tight. 16

17 Inspect the wiring in the circuit for any broken, shorted or exposed wires and insure all ground wires are clean and secure. 45. If a trouble code is detected and the problem has been fixed, clear the codes by first making sure the ignition is off then disconnecting the NEGATIVE battery cable for a minimum of 3 minutes. Diagnostic Trouble Codes (DTC) Chart Diagnotic Trouble Code (DTC) DTC 11 DTC 13 DTC 14 DTC 15 DTC 16 DTC 18 DTC 21 DTC 22 DTC 23 DTC 24 DTC 25 DTC 26 DTC 27 DTC 28 DTC 29 DTC 32 DTC 33 DTC 34 DTC 36 DTC 37 DTC 38 DTC 41 DTC 42 DTC 43 DTC 44 DTC 45 DTC 46 DTC 47 DTC 48 DTC 50 DTC 51 DTC 53 DTC 55 DTC 58 DTC 59 DTC 61 DTC 63 DTC 64 DTC 65 DTC 66 DTC 67 DTC 68 Specific Problem Circuit Malfunction Indicator Lamp Bank 1 (left) Heated Oxygen Senor (HO2S) Open Circuit Engine Coolant Temperature (ETC) Sensor Circuit (Signal Voltage Low) Overheated Engine Coolant Temperature (ETC) Sensor Circuit (Signal Voltage High) Engine cold Distributor Ignition System (Low Resolution Pulse) Injector Circuits Throttle Position (TP) Sensor Circuit (Signal Voltage High) Throttle Position (TP) Sensor Circuit (Signal Voltage Low) Intake Air Temperature (IAT) Sensor Circuit (Signal Voltage High) Cold Intake Air Vehicle Speed Sensor (VSS) Circuit Intake Air Temperature (IAT) Sensor Circuit (Signal Voltage Low) Hot Intake Air Evaporative Emission (EVAP) Canister Purge Solenoid Valve Circuit Exhaust Gas Recirculation (EGR) Vacuum Control Solenoid Valve Circuit Transmission Range (TR) Pressure Switch Assembly Fault Secondary Air Injection (AIR) Pump Circuit Exhaust Gas Recirculation (EGR) Manifold Absolute Pressure (MAP) Sensor Circuit (Signal Volts High, Low Vacuum) Manifold Absolute Pressure (MAP) Sensor Circuit (Signal Volts Low, High Vacuum) Distributor Ignition System (Faulty High or Extra Low Resolution Pulse Detected) Brake Switch Stuck ON Brake Switch Stuck OFF Ignition Control (IC) Circuit (Open Circuit) Ignition Control (IC) Circuit (Shorted or Grounded Circuit) Knock Sensor (KS) Circuit Bank 1 (Left Heated Oxygen Sensor (HO2S) Circuit (Lean Exhaust Indicated) Bank 1 (Left Heated Oxygen Sensor (HO2S) Circuit (Rich Exhaust Indicated) Pass-Key Circuit Knock Sensor (KS) Module Circuit or Module Missing Mass Air Flow (MAF) Sensor Circuit System Voltage Low EEPROM Programming Error System Voltage High Fuel Lean Monitor Transmission Fluid Temperature (TFT) Sensor Circuit Low (High Temp Indicated) Transmission Fluid Temperature (TFT) Sensor Circuit Low (Low Temp Indicated) A/C System Performance Bank 2 (Right) Heated Oxygen Sensor (HO2S) Circuit (Open Circuit) Bank 2 (Right) Heated Oxygen Sensor (HO2S) Circuit (Lean Exhaust Indicated) Bank 2 (Right) Heated Oxygen Sensor (HO2S) Circuit (Rich Exhaust Indicated) A/C Refrigerant Pressure Sensor Circuit (Open or Shorted) A/C Refrigerant Pressure Sensor Circuit (Pressure Sensor or A/C Clutch Problem) A/C Relay Circuit (Shorted Circuit) 17

18 DTC 69 DTC 70 DTC 71 DTC 72 DTC 73 DTC 74 DTC 75 DTC 77 DTC 79 DTC 81 DTC 82 DTC 83 DTC 83 DTC 84 DTC 84 DTC 85 DTC 90 DTC 91 DTC 97 DTC 99 A/C Clutch Circuit A/C Clutch Relay Driver Circuit A/C Evaporator Temperature Sensor Circuit (Open or Shorted) Vehicle Speed Sensor Loss (Automatic Transmissions Only) Pressure Control Solenoid (PCS) Circuit (Current Error) Traction Control Circuit (TCS) Circuit Low Transmission System Voltage Low Cooling Fan Relay Control Circuit Transmission Fluid Temp Too High Transmission 203 Shift Solenoid Circuit Transmission 1-2 Shift Solenoid Circuit Reverse Inhibit System (Manual Transmission) TCCPWM Solenoid Circuit Fault (Automatic Transmission) Automatic Transmission 3-2 Control Solenoid Circuit Skip Shift Solenoid Circuit (Manual Transmission) Transmission TCC Stuck ON Transmission TCC Solenoid Circuit (Manual Transmission) Skip Shift Lamp Circuit VSS Output Circuit Tach Output Circuit NOTE REGARDING EMISSION DEVICES: This harness has provisions for 3 emission devices, specifically the EGR solenoid, the Air Pump relay and Canister Purge solenoid. The canister purge solenoid wiring and air pump wiring can be removed if these items are not going to be used, but be aware that the check engine light may illuminate. These circuits do not necessarily need to be fully functional, but to prevent the check engine light from coming on you will need to plug in a canister purge solenoid and air pump relay to the appropriate wires labeled as such, because the computer is monitoring these circuits. 18