WNIN: Validate the kit contents with the component list included on this page, before proceeding. This kit is intended to be used in a modified vehicle. Please read this page thoroughly and be sure that you understand everything explained on it prior to opening any of the enclosed packages, or before attempting to install any of the components. Once this kit has been opened or a component installed, the kit is not returnable. 1. This new upgraded W wiring system should typically be used in a OII application only. 2. This kit includes the wiring to support the use of a factory heater only system and/or aftermarket heater and / systems. This kit does not include the wiring for the factory original / system. or 1974-76, aftermarket / systems only are supported. or 1977-78 factory / Harnesses, call merican utowire for your application. 3. This kit supports the use of a high current self-exciting 1-wire, SI series, or other style internally regulated alternator. n adapter may be necessary in some applications. The use of stock, low amperage alternators is seriously discouraged as they cannot handle the higher current requirements of most updated ignition systems, electric fans, aftermarket / systems, stereo systems, air ride suspensions, and other power hungry accessories that will ultimately create performance issues within the system. 4. W OS NOT support the use of an ammeter. ll W kits are engineered to supply the optimum charge to the battery. To achieve this performance, we route our 8ga. charge wire directly from the alternator output charge terminal to the starter battery terminal. ue to the path of the charge being altered from the stock configuration, the gauge can no longer see a charge vs. a discharge, so it may not work properly. ost stock alternator current outputs were rated at a maximum of about 37-60 amps. odified cars being built today typically utilize a 100 amp or higher output alternator. With these higher current units, ammeters, generally speaking, become a safety hazard. mmeters are usually wired in parallel to the charging circuit, are typically unfused, and can short very easily causing a fire. This wiring system has been designed to work with a voltmeter. 5. This kit IS NOT set up with a resistance wire for a standard, points type ignition system. It is wired with a full 12-volt primary ignition feed that is hot in the crank and run positions. Our system will support HI, S, other electronic ignition systems, as well as most all computerized uel Injection systems. If you wish to run a points type system, there are illustrations on the engine connection pages to do so. Primary ignition voltage in the cranking position is handled via a full 12 volt bypass wire that is routed from the starter terminals to the positive side on the coil. xtra parts (ballast resistor) that are not included in this kit will be required to complete that type of operation. - it This kit contains the following components: Part ag Number escription Quantity 500042 loor immer Switch 1 500332 Headlight Switch 1 500707 use, elay, and lasher kit 1 500708 ourtesy amp it 1 500919 Practice Terminal rimping Set 1 510684 ash Harness kit 1 H 510685 Instrument luster wiring kit 1 J 510686 ngine Wiring it 1 510687 ront ight Wiring kit 1 510688 ear ody Wiring kit 1 Validate the kit contents with this component list. If there are any discrepancies with incorrect or missing parts, stop your installation and notify the supplier you purchased the kit from before proceeding. OPYIHT 2004 merican utowire / actory-it Used with express permission of merican utowire / actory-it Page 1
STT H! PS THIS O STTIN INSTTION! This wiring kit is designed for ease of installation. Please read the guidelines below, O STTIN your installation, to guarantee a successful job. Use an appropriate crimping tool, which folds the wings of the open barrell terminals down into the wire, as shown on this page. If you use our crimping tools and correctly crimp the included terminals, soldering is not necessary. If you are unsure about a particular crimp, soldering is recommended. Our factory crimped terminations are installed by approved five ton presses, and soldering these terminations is not necessary. The terminals that we supply in our kits, utilize what is known as an crimp. The crimp, in a cross section, will look like the illustration below, when done correctly. wire core end view of un-crimped terminal proper crimp of terminal We carry the following crimping hand tools, to help with your terminal crimping. These hand tools are available, for purchase or rental. p/n 510585 O small terminal crimping tool (18-14 gauge) p/n 510586 O large terminal crimping tool (12-8 gauge) W offers a great terminal crimping video entitled Ò Proper rimping VideoÓ. It can be viewed by visiting YouTube. p/n 510587 Includes oth terminal crimping tools Type the following address into your web browser, to go directly to the video: www.youtube.com/watch?v=jgovl-co Youtube hannel: www.youtube.com/user/wiringharness Page 2 We carry many accessories for your : actory ssembly anuals 1974 p/n 43539 1975 p/n 43540 1976 p/n 43250 p/n 510703 Power Window and ock it (1974-76) If you have any questions concerning this or any of our products, please feel free to call us at 1-856-933-0801. p/n 510704 Power Window and ock it (1977-78) SI series alternator to S series alternator conversion kit p/n 37796 p/n 510701 Heated ear lass it STP 1: ISONNT YOU TTY: isconnect the battery, before installing the wiring kit, to prevent any accidental shorting caused by loose bare wire ends.
STP 2: STT INSTIN IT: This kit is broken down into individual sections, that are identified by a letter printed on the enclosed sheets, visible through each bag. The order of installation and the pages with their installation instructions, are shown below: Table of ontents: ags: H Pages: 4-9 10-13 14-15 Sections: ash Harness - This is the main harness in the kit and contains: - Starter solenoid connections. - Wiper motor connections - rake light switch connection. - Neutral safety switch connection. auge luster Harness - This Harness contains: - auge connections for aftermarket and factory gauges. ear ody Harness - This Harness contains: - Tail light, turn signal, reverse light, and running light connections. - uel pump connections. PS THIS HPU INSTTION TIP, O OIN NY UTH! Prior to installing the ash/ain harness in your dashboard, plug all of the fuses, Hazard lasher and Turn lasher into the use lock (see detailed picture below) and the Horn elay into this harness (see detailed picture below). 10 30 10 15 10 10 15 10 10 15 20 20 30 5 10 30 30 30 Y 1 16-18 ront ight Harness - This Harness contains: - Headlight, turn signal, running light connections. - Windshield washer connection. - lectric fan relay trigger. - / compressor connections. J 19-21 ngine Harness - This Harness contains: - Temperature, oil pressure, tachometer wiring. - Ignition system / U power. - lternator connections. - rake fluid level wiring. Horn elay Page 3
ash/ain harness installation instructions: Shown below, are the supplied misc. terminals, plastic connector bodies, hardware, jumpers and extensions, included in the ash/ain Harness and oose Piece bags, that will be used to complete your ash/ain harness connections. They are itemized and referred to on this page, just as they are on the following pages of this ash/ain instruction set. H J N P (Pack-on 14-way male connector, 1 pc.) H J (1979-80 dimmer extension - reference, 1 pc; NOT US IN THIS IT) (heater harness - reference, 1 pc) P (1980 neutral safety switch jumper - reference, 1 pc; NOT US IN THIS IT) (1974 kickdown switch extension - reference, 1 pc) (Pack-on male terminal, 15 pcs.) (1974-75 heater light extension - reference, 1 pc) T (1980 pulse wiper extension - reference, 1 pc; NOT US IN THIS IT) (Screw, 3, use ox, 2 pcs) (56 series single female terminal, 6 pcs.) (1976 heater light extension - reference, 1 pc) U (1979-80 automatic console indicator lamp extension - reference, 1 pc; NOT US IN THIS IT) (56 series double female terminal, 6 pcs.) V (56 Series double male connector, 1 pc) (56 Series double female connector, 1 pc) (1977-78 heater light extension - reference, 1 pc) W (56 series single female terminal, large gauge, 3 pcs.) Page 4 (1974-78 dimmer extension - reference, 1 pc) N (1979-80 heater light extension - reference, 1 pc; NOT US IN THIS IT)
ash/ain harness installation instructions: ccessory onnector See page 7 for accessory connections. Horn elay headlight switch cluster onn cluster connections onn H J cluster accessory 1980 pulse wiper switch P ON onn (electric speedo) tach speedo radio connections 10 15 15 30 5 30 10 10 10 20 20 15 30 10 10 10 30 30 Y 1 H ctsy lamp (see page 9) neutral safety switch jumper (leave plugged-in for all years) brake switch wiper switch turn signal switch (see page 7) ignition switch P N J H neutral safety switch jumper (see page 8) console back-up switch rear body brake warning switch dimmer switch (see page 8) 1974 kickdown switch (see page 9) Page 5 1974-78 dimmer extension (see page 8) 1974 kickdown switch extension (see page 9)
ash/ain harness installation instructions: gauge lights ( ally gauges) uel gauge ( ally gauges) Volt eter ( ally gauges) switch & lamp s heater light (see page 8) heater and / feed (see page 8) cigar lighter light cigar lighter glove box light glove box light trunk release 1974-75 heater light extension (see page 8) H ctsy lamp (see page 9) heater harness (see page 8) 1976 heater light extension (see page 8) J 1977-78 heater light extension (see page 8) Page 6
ash/ain harness installation instructions: IN UTOWI SH HNSS ONNTION white dk green yellow purple brown dk blue lt blue black P N J H OIIN TUN SIN SWITH WIIN I - W Turn Signal Switch Wires to Stock 1974-78 Steering olumns H J N P Table W Turn Signal Switch wires to stock 1974-78 Pontiac irebird Turn Signal Switch W W Wire onnector Wire olor Printing avity W White rake SW P ark reen ight ear Turn N Yellow eft ear Turn Purple Turn Switch eed rown Turn SW Hazard ark lue ight ront Turn J ight lue eft ront Turn H lack Horn elay round None None None None None None Note: emove the original Turn Signal Switch onnector and replace it with the W 14-way connector. rimp on terminal to each of the original wires and plug them into connector (see Parts it 92971783). Use Table above to align the wires. lso, for all of the vehicles, the Steering olumn Horn utton switches for the Horn elay, which then switches power to the Horns, similar to the W design. ccessory onnector Use the provided 6-way empty connector, which is attached to the 6-way ccessory connector on the ash Harness, and terminals and to add power wires (not provided) for the following optional systems: Wire olor use lock arking use rating escription Tan Y1 30 used 12 volt SSOY feed which may be used to feed power to another accessory circuit. ark lue U 15 used 12 volt INITION feed for fuel pump (may also be used to feed power to another ignition circuit). Orange T1 20 used 12 volt TTY feed for power seats (may also be used to feed power to another battery circuit). Pink IN1 20 used 12 volt INITION feed which may be used to feed power to another ignition circuit. ed T 30 used 12 volt TTY feed (may also be used to feed power to a battery circuit). Yellow PWO WO 30 used 12 volt SSOY feed for power windows (may also be used to feed power to another accessory circuit). Page 7
ash/ain harness installation instructions: immer switch wiring (all years): dimmer switch connector from ash harness plug 1974-78 dimmer extension, into the ash harness dimmer switch connector and immer Switch 500042 immer Switch Heater wiring (all years): J these three connectors, connect to the back of the heater control panel heater and / feed brown wire and connector from ash harness pass the single-wire connector, from the J heater harness, through the original hole in the firewall, connect the connector to the blower and seat the grommet in the firewall to blower Neutral Safety switch wiring (all years): neutral safety switch purple wires and connector from ash harness neutral safety switch jumper to neutral safety switch If you have a neutral safety switch, remove the neutral safety switch jumper from the ash harness (at the same branch as the Ignition switch and turn signal switch) and plug the neutral safety switch connector from the ash harness, into the neutral safety switch Heater light wiring: (1974-75 heater light extension) heater light short gray wire and connector from ash harness Page 8 using the appropriate heater light extension for your car, plug the light socket of extension, or, into the back of your heater control panel (1976 heater light extension) (1977-78 heater light extension) plug the connector on the short gray wire, from the ash harness, into the connector of the appropriate heater light extension for your car
ash/ain harness installation instructions: ourtesy light wiring (all years): 1974 ickdown switch wiring: pply terminals and connector to wires of the 1974 kickdown switch extension and plug into the 1974 kickdown switch connector of the ash harness. Plug the other end of the extension into the kickdown switch onnect the (2) courtesy light harnesses to the courtesy light connectors from the ash harness: the left-hand harness at the same branch as the rake switch and Horn relay connector and the right-hand harness at the same branch as the igar lighter and Trunk release (See 500708 ourtesy ight onnection it, for (2) ourtesy ight harnesses and 92966085 instruction sheet) 1974 kickdown switch connector from ash harness courtesy light connector from ash harness to kickdown switch courtesy light harness Page 9
auge luster harness (aftermarket gauges) installation instructions: TUN SIN N HI- P ONNTIONS T TUN IN HIH IN IHT TUN IN white OI -> TH wire, if needed lt blue (H turn ind) lt green (hign beam ind) dk blue (H turn ind) _ + S + S + S + S + yellow O T wire, if needed tan S U wire, if needed brown TNTO IN wire, if needed WNIN IHT VOTS U SPO OI TP TH P ON pink 12V INITION wire, if needed brown TNTO IN wire - use for ignition warning light yellow O T wire - use for optional clock elow are some general instructions for hooking up an electric speedometer. This connector and these instructions will ONY be used in the event that you are utilizing an aftermarket electric speedometer. If your car does NOT have an electric speedometer, this connection will NOT be used and should not be plugged onto your dash harness. It is best to consult the speedometer manufacturer s instructions if you have any questions. Yellow VSS round onnect to VSS neg. -- on speedometer. Purple VSS Signal onnect to VSS input on speedometer. Purple/White speedometer. VSS Power onnect to 12V power on lack/white Speedo round onnect to on speedometer. Pink/White Speedo Power onnect to 12v power on speedometer. NOT: This wire will double onto the same stud as the purple/white VSS power wire from above. See pages 10-12 Page 10
auge luster harness installation instructions: ally Sport auges: ll years pink (12V ign) tan (brake lt) dk blue (H turn) blank lt green (high beam) black () dk blue (oil press) gray (ash lights) 8 7 6 5 4 3 2 1 ONNTO 9 10 11 12 13 14 15 16 black () blank blank yellow (clock) blank blank lt blue (H turn) dk green (water temp) tach out to negative coil (USTO PPITION ONY) water temp ash lights H turn oil press H turn gas gauge high beam to optional clock to ignition warning light 12V ign to to 12V ign brake lt black dk green dk blue lt blue lt green brown black tan gray dk blue tan yellow pink pink 9 10 11 12 13 14 15 16 plug WHIT (OI->TH) wire in H, if needed plug TN (S U) wire in H, if needed (mating end shown) plug PIN (12V INITION) wire in H, if needed plug YOW (O T) wire in H, if needed P ON (mating end shown) Page 11 dash harness connectors (bag ) plug OWN (TNTO IN) wire in H, if needed
auge luster harness installation instructions: Standard auges: 1974-76 gray (ash lights) blank (1974-75), black ( 1976) dk blue (H turn) tan (brake lt) lt green (high beam) pink (12V ign) black () blank 8 7 6 5 4 3 2 1 ONNTO 9 10 11 12 13 14 15 16 lt blue (H turn) pink (12V ign) dk blue (oil press) blank yellow (clock) tan (gas gauge) brown (lt ign) dk green (water temp) tach out to negative coil (USTO PPITION ONY) water temp ash lights H turn oil press H turn gas gauge high beam to optional clock lt ign 12V ign to to 12V ign brake lt black dk green dk blue lt blue lt green brown black tan gray dk blue tan yellow pink pink 9 10 11 12 13 14 15 16 Page 12 plug WHIT (OI->TH) wire in H, if needed plug TN (S U) wire in H, if needed (mating end shown) dash harness connectors (bag ) plug PIN (12V INITION) wire in H, if needed plug YOW (O T) wire in H, if needed plug OWN (TNTO IN) wire in H, if needed P ON (mating end shown)
auge luster harness installation instructions: Standard auges: 1977-80 pink (12V ign) dk blue (H turn) lt green (high beam) black () 8 7 6 5 4 3 2 tan (brake lt) black () blank blank 1 ONNTO 9 10 11 12 13 14 15 16 tan (gas gauge) gray (ash lights) lt blue (H turn) pink (12V ign) dk blue (oil press) dk green (water temp) brown (lt ign) yellow (clock) tach out to negative coil (USTO PPITION ONY) water temp ash lights H turn oil press H turn gas gauge high beam to optional clock lt ign 12V ign to to 12V ign brake lt black dk green dk blue lt blue lt green brown black tan gray dk blue tan yellow pink pink 9 10 11 12 13 14 15 16 plug WHIT (OI->TH) wire in H, if needed plug TN (S U) wire in H, if needed (mating end shown) plug PIN (12V INITION) wire in H, if needed plug YOW (O T) wire in H, if needed P ON (mating end shown) Page 13 dash harness connectors (bag ) plug OWN (TNTO IN) wire in H, if needed
ear ody harness installation instructions: Shown below, are the supplied misc. terminals, plastic connector bodies, clamps and wire extensions, included in the ear ody Harness and oose Piece bags, that will be used to complete your ear ody harness connections. They are itemized and referred to on this page, just as they are on the following pages of this ear ody instruction set. (56 Series single female terminal, 7 pcs) (56 Series double female terminal, 9 pcs) H (H tail, stop & directional light extension - reference, 1 pc) (56 Series single male connector with clip, 1 pc) J (tail light extension - reference, 2 pcs) (metal clamp, J style, 5 pcs) (back-up light extension - reference, 2 pcs) (clip, conduit, 1 pc) (side marker light extension - reference, 2 pcs) (license plate light extension - reference, 2 pcs) (56 Series single male terminal, 2 pcs) N (dome light extension - reference, 1 pc) P (fuel gauge extension - reference, 1 pc) Page 14 (H tail, stop & directional light extension - reference, 1 pc) ( daisy chain extension - reference, 2 pcs)
ear ody harness installation instructions: ear ody (at ash harness, near kick panel) to dome light N to 3rd brake light P to fuel sending unit H J J Page 15
ront ight harness installation instructions: Shown below, are the supplied misc. terminals, plastic connector bodies, clips, grommets, pigtails and wires, included in the ront ight Harness and oose Piece bags, that will be used to complete your ront ight harness connections. They are itemized and referred to on this page, just as they are on the following pages of this ront ight instruction set. (56 Series double female connector, 2 pcs) (1977-80 high-beam headlight pigtails - reference, 2 pcs) (56 Series single female connector, 2 pcs) N (1974-76 H park/turn light pigtail - reference, 1 pc) (59 Series double female terminal, 9 pcs) (59 Series single female terminal, 4 pcs) P (1974-76 H park/turn light pigtail - reference, 1 pc) (56 Series single female terminal, 7 pcs) (headlight pigtails - reference, 2 pcs) (56 Series double female terminal, 5 pcs) T (VSS wire - reference, 1 pc) (wedge base single female terminal, 4 pcs) U V (VSS signal wire - reference, 1 pc) (VSS power wire - reference, 1 pc) H (56 Series single female connector, 2 pcs) W Y (transmission kickdown solenoid - reference, 1 pc) (air conditioning feed for factory /; see page 1 for existing / wiring - reference, 1 pc) J (clip, 8 pcs) (1977-78 park/turn pigtails - reference, 2 pcs) (grommet, 1 pc) (1979-80 H park/turn light pigtail - reference, 1 pc; NOT US IN THIS IT) Page 16 (light socket, wedge base, 2 pcs) (1979-80 H park/turn light pigtail - reference, 1 pc; NOT US IN THIS IT)
ront ight harness installation instructions: 1974-76 to auto trans kickdown solenoid W V V U T S (wiring end shown) U T S U U T S to VSS power T V U T S VSS signal and VSS wires, are to remain twisted together their entire length to VSS signal to VSS electric fan recommended fan relay (not included) N P horn horn Page 17
ront ight harness installation instructions: 1977-78 to auto trans kickdown solenoid (400 trans only) W Y V U V U T S (wiring end shown) U T S U T S to VSS power T V U T S VSS signal and VSS wires, are to remain twisted together their entire length to VSS signal to VSS / feed or 1977-78 factory / Harnesses, call merican utowire for your application electric fan recommended fan relay (not included) horn H H horn Page 18
ngine harness installation instructions: Shown below, are the supplied misc. terminals, sleeves, plastic connector bodies and wires, included in the ngine Harness and oose Piece bags, that will be used to complete your ngine harness connections. They are itemized and referred to on this page, just as they are on the following pages of this ngine instruction set. (56 Series single female terminal, 12 pcs) (1974-77 56 Series single female connector, 3 pcs) (56 Series double female connector, 1 pc) (56 Series single female connector, 2 pc) N (1975-77 56 Series double female connector, 1 pc) (56 Series single female connector, 1 pc) (rubber boot, 1 pc) P (1979-80 56 Series double female connector, 1 pc; NOT US IN THIS IT) ( SI jumper harness - reference, 1 pc) (ring terminal, 5 pcs) (large sleeve, 4 pcs) (fusible link - reference, 1 pc) (1975-77 56 Series double female connector, 1 pc) (1980 pulse wiper extension - reference, 1 pc; NOT US IN THIS IT) (ring terminal, 2 pcs) T (56 Series single male connector, 1 pc) (electric choke wire - reference, 1 pc) H (56 Series single female connector, 1 pc) (56 Series single female connector, 1 pc) U V (59 Series single female connector, 1 pc) (59 Series single female terminal, 2 pcs) HH JJ (coil-tach wire - reference, 1 pc) (1974-77 brake light/switch wire - reference, 1 pc) (1978-80 brake pressure differential warning switch jumper - reference, 1 pc) J (56 Series double female terminal, 6 pcs) W (1978-80 56 Series 3-way female connector, 1 pc) (fusible link - reference, 1 pc) Page 19 (ring terminal, 6 pcs) (small sleeve, 5 pcs) Y (56 Series double female connector, 1 pc)
ngine harness installation instructions: to TH location on coil W X Y Z J positive battery cable (not included with this kit) distributor oil sending unit to T location on coil see View Ò Ó see View Ò Ó H O J temperature sending unit O bulkhead connector X Y Z X Y Z W X Y Z (wiring end shown) from bulkhead connector coil Optional connection for points cars. This yellow wire is not supplied. View Ò Ó optional connection for points cars (resistor not included - only used on selected ignition systems) ballast resistor T starter solenoid S from bulkhead connector W offers an Ò SIÓ series W alternator offers an to Ò SIÓ SÓ series series alternator alternator to Ò SÓ conversion series alternator kit 37796 conversion (see page kit 2) 37796 (see page 2) HH (1974-77) O JJ (1978-80) alternator (SI) T electric choke Page 20
ngine harness installation instructions: bulkhead connector (wiring end shown) W X Y Z X Y Z X Y Z Y N W X Y Z wiper - lo speed wiper - hi speed wiper - washer wiper feed wiper feed 1974 Wiper/Washer N W Page 21 1975-77 Wiper/Washer 1978 Wiper/Washer
STP 3: ONNT YOU TTY: When you have completed the installation and are ready to reconnect the battery, make sure that the following electrical system s are in place:. attery is ed to the NIN O.. attery is ed to the frame.. ngine block is ed to the frame.. ody is ed to the frame. STP 4: H TI UNTIONS: ny non-functioning items should be checked for proper installation. ny problems with your wiring and electrical circuit functions, should be addressed to merican utowire Systems, Inc. as soon as possible, to avoid any warranty problems. If you have any questions concerning this or any of our products, please feel free to call us at 1-856-933-0801. Page 22