TELORVEK III WIRING INSTRUCTIONS FOR LT-40 LT-1 Fuel Injection System Page #1 Thank you for purchasing the absolute finest of wiring kits for the General Motors fuel injection. We have taken considerable time to work out the circuitry so that you, the customer will understand at least some of what this is all about. We ask that you follow our instructions closely. We recommend an high pressure in tank fuel pump. Custom installations are available from Tanks (320-558-6882), Inc and Rock Valley (800-344-1934). There are some valuable HOW-TO s on our website (www.thedetailzone.com) under PROJECTS that can help you with your install. Should you eliminate a sensor, your injection system will not work at its peak and will probably be in some variation of back up mode. There are many factors that will keep you from a trouble free start up that you must consider. Use only the 1992-3 Corvette ECM and CCM. You will need all stock parts and sensors. The back page of the instructions is a list of optional accessories we offer and some of the General Motors part numbers you may need. STARTING INSTALLATION Since there are so many individual circuits to complete, we recommend that you connect them in the order that we prescribe. Disconnect the battery before starting and do not reconnect until instructed. Plug the computer (ECM) and Body Computer (CCM) to the TELORVEK III panel. Mount them in an ACCESSIBLE LOCATION. For safety, now disconnect both computers until finished the installation. Under the dash, under the seat or in the trunk are good. There are a lot of wires so allow room to work. A poor installation will result in a poor running car. The number referred to from this point on will be the location on one of the terminal blocks located on the TELORVEK III panel. For appearance, all wires can be kept under the black covers on the TPI unit itself. After all wires are in place, wire tie them together or use Zip loom to protect them. This can be done before any connections are made to the panel. Since all wires are marked, running the entire group to the panel at one time is fine. Some terminals on the panel may not be used! Any sensor that is difficult to hook-up should not be eliminated. All sensors are important if you desire your conversion to run as good as a factory engine. Eliminating any part of this kit WILL cause some portion of the EFI to work improperly. Important! We have supplied two sizes of terminals for your use on the panels itself. The Blue, used for the larger sizes wires and red for the bulk of the smaller wires. Each individual bag instructions will be marked as to when to use the blue terminals. All others will use the red terminals. The Detail Zone has made every effort to assure a quality product and can assure you that this system works well in your application. Once you have confirmed proper installation and set the timing, any trouble you experience will be a defective part or seat of the pants repair. Your unit can be tested at any General Motors Dealership with no difficulty.
Page #2 The Detail Zone fuel injection wire harnesses are ALL designed to follow the electronic circuitry of the vehicle your engine was removed from! Following this simple procedure allows our fuel injection harness customers to have their vehicles diagnosed by ANY GM dealer or reputable repair facility familiar with diagnosing fuel injection electronic systems. The Detail Zone does not re-engineer electronic circuitry that a vehicle manufacturer has spent millions of dollars on testing and designing. Our goal is to allow an easy, neat, pain free installation through quality installation instructions and a state of the art wiring kit. If your vehicle experiences starting or runability problems, 99% of the time it is some sort of mechanical, NOT A WIRING PROBLEM. Fuel injection engines still run similar to carbureted engines, the difference being that the engine computer receives inputs from various sensors throughout the engine. The computer then uses this information to calibrate fuel delivery and engine timing. Diagnosing a NO SPARK situation is the same on a computer controlled fuel injection engine as it is on a carbureted engine. Spark control, even though it may be done slightly different depending on engine year and make, is still essentially the same. A rotor is turned allowing spark to be provided to the plugs, the same as in a carbureted engine. Thank you for purchasing our products!
Page #3 STARTING INSTALLATION Bag #40 INTAKE AIR TEMPERATURE SENSOR: Install this sensor in the duct work between the Air Cleaner and the Plentum. Plug in the connector and run the Black wire (IAT A- > 12) to #12 and the Tan (IAT B->13) #13. Bag #41 COOLANT TEMPERATURE SENSOR: After attaching the plug to the sensor, run the two wires to the panel and connect the Yellow wire (CTS B-> 4) to #4 and Black wire CTS A-> 5 to #5. The sensor is located off to one side of the water pump. Bag #42 THROTTLE POSITION SENSOR: Plug into the sensor located on the right side of the throttle body and run Black (TPS B-> 5) to #5, Dk Blue (TPS C-> 8) to #8 and Gray (TPS A-> 9) to #9. No adjustment is required. Bag #43 IDLE AIR CONTROL: The IAC is located on the right side of the throttle body and after plugging in the connector, run Lt Green (IAC D-> 14) to #14, Lt Green (IAC C-> 15) to #15, Lt Blue (IAC B-> 16) to #16 and Lt Blue (IAC A-> 17 to #17. CAUTION! WATCH THE NUMBERS PRINTED ON THE WIRES against the terminal blocks since these wire colors are duplicated. Bag #44 MAP SENSOR: After installing the MAP (Manifold Air Pressure) sensor on top of the plentum in the holes provided by GM make sure that the nipple from the sensor is sealed were it goes through the plentum. Plug in the connector and run the Black (MAP A-> 12) to #12, Lt Green (MAP B 10 to #10 and the Gray wire (MAP C-> 11) to #11. CRITICAL! After motor is running check this sensor to make sure there is not any vacuum leaks! Bag #45 ELECTRONIC SPARK TIMING Distributor: This is the harness that is already plugged into the computer plug. We have installed an adapter on the end of this harness to address the two different styles of distributor harnesses that GM uses. Carefully uncoil the harness and run it to the distributor harness that came with the motor. If the harness will plug in as is, then do so, if not remove the short 6 inch adapter and then plug it in. IMPORTANT: THIS IS A SHIELDED HARNESS AND MAY NOT BE SHORTENED. COIL ANY EXCESS OUT OF SIGHT. Coil \ Coil Driver: Plug the black connector into the coil and the other black connector with the blue seal into the coil driver. Run the White (COIL DR B-> 40) #40, Black (COIL DR C->22) #22. Plug the Gray connector into the coil next to the Black and run the Orange (COIL-> 3) #3. The Purple wire is for the Tach. Bag #46 INJECTORS: Notice that the injector wiring cables are marked LEFT and RIGHT. Plug in all injector wires to the injectors. Run Pink wire in the Left cable to #32 and Lt Blue to #33. Run the Pink wire from the Right cable to #34 and Lt Green to #35.
Page #4 Bag #47 OIL PRESSURE SWITCH & FUEL PUMP RELAY WIRING : OIL PRESSURE SWITCH: There are two sending units that are mounted in the rear of the block. One has three terminal in it the other only one. Plug in Gray connector into the sending unit with the three terminals in it and run the Yellow (OIL SW C-> 1) #1, Tan (OIL SW D-> 37) #37. Using blue terminals supplied. The other sending unit is not used. FUEL PUMP RELAY: The relay connector is mounted in the cover of the Telorvek III panel (the housing closest to the fuses) and is prewired. Install a relay (GM Part No. 14100455) in the housing and using the blue terminals run the Tan wire (37-> FUEL PUMP) from #37 to the fuel pump. The Black (FUEL PUMP GRD) is the ground for the fuel pump. Bag #48 ENGINE OIL TEMPERATURE: Plug in the connector in the sensor which is located near the oil filter and run the Black (EOT A-> 6) #6, Dk Green (EOT B-> 7) #7. Bag #49 KNOCK SENSOR WIRING (2): These sensors will inform the computer of detonation and readjust the timing accordingly. The knock sensors must be used. These are important sensors because they advance and retard the timing. Connect the left and right sensors and run both Dk Blue wires to #31. Bag #50 OXYGEN SENSOR (2): This area of the vehicle is hot so keep the wires away from the exhaust. Two sensors are required per engine. Install each sensor as close to the block as possible. If you must install an adapter, use The Detail Zone part # OS-30. It works. The Purple wire (27->LF 02 SENSOR) runs from the left 02 sensor to #27. The second Purple wire (28->RT 02 SENSOR) runs from the right sensor to #28. Bag #51 ENGINE GROUNDS. Although some of these wires are marked ground they actually complete individual circuits that happen to be grounded. For this reason these are important wires in the kit and must be connected properly. The Black wire marked ENGINE FRONT is connected to a bolt in the front of the intake manifold and run to the number #50 on the panel. The Black wire marked ENGINE REAR is run from a rear manifold bolt to number #50 on the panel. Bag #52 SERVICE ENGINE SOON LIGHT and ASSEMBLY LINE DATA LINK. (ALDL): The Check Engine light can be any low amperage 12 volt lamp located on the dash board or where ever desired. The Brown wire (SES LIGHT-> 26) runs from the light to #26 and the Pink wire from a ignition source #32 to the light. This light is not required as the yellow light on top of the TELORVEK III Panel has the same function. The ALDL is the diagnostic link for computerized testing at your local GM dealer or a hand held scanner. We have supplied a Cover for the ALDL to dress up the appearance. Please consider a very accessible location for this important part. Connect the White wire (ALDL B-> 48) to #48 the Black wire (ALDL A-> 23) to #23 the Tan wire (ALDL M-> 49) to #49 and the Tan wire (ALDL F->43) to #43.
Page #5 Bag #53 PARK/NEUTRAL RELAY: This system was developed to allow a regular park / neutral switch tell the computer when the vehicle is in park, neutral or drive. Since the signals are different from normal neutral switches, we have made this small circuit that will plug into a stock GM neutral switch or splice to just about any two wire neutral switch. The signal input controls the idle air control (IAC), vehicle speed sensor diagnostics (VSS) and exhaust gas recirculation (EGR). If you are using a Ron Francis Wiring kit, this is a simple, color coded plug-in to GM Neutral Safety Switches. The regular car wiring that normally runs to the neutral safety now plugs into the P/N relay kit with the with the blue and purple wires in the black connector. The plug with the blue and black wires is connected to the original neutral safety switch. Run the black wire with the ring terminal to a good ground. NOTE: Using any other standard neutral switch requires only removing the plug and splicing. Either color wire can be used on either terminal. The black plug with the Lt Blue and Black wires is connected into your neutral safety switch. If the connector on the wires doesn't fit your application then remove it and connect the wires to the switch. The blue wire in the plug must be connected to the 12 volt supply from the ignition switch. This wire becomes hot (12 Volts) when you turn the key to crank. The purple wire is connected to the wire that runs to the starter solenoid. Run the Orange wire to #24. Install a relay (GM Part No.14100455) in the connector. Don't forget to install a relay. Bag #54 RADIATOR COOLING FANS: Both the primary and secondary fan relay connectors are mounted in the cover of the Telorvek III panel. The primary relay is located below the fuel pump relay. Install both the relays (GM Part No.14100455) in the housings. (CAUTION THE FANS WILL NOT WORK WITHOUT THE RELAYS ) The long Blue wires are connected to the Telorvek III panel. The primary fan wire (38- >PRIMARY FAN) is run from #38 to the primary cooling fan and the secondary cooling fan wire (39->SECOND FAN) is run from #39 to the secondary cooling fan. The Black wires (FAN GROUND) are connected to the fan motors and run to a good ground. Bag #55 EXHAUST GAS RECIRCULATION: Plug in the connector to the EGR solenoid. Run the Pink wire (EGR SOL A-> 20) to #20 and the Gray wire (EGR SOL B-> 19) to #19. It is important that this be working properly as the idle speed, detonation and overheating can be effected by this. Bag #56 EMISSION BAG: CANISTER PURGE: Plug the connector into the Canister Purge Solenoid and run the Pink wire (PURGE SOL A-> 20) to #20 and the Dk Green wire (PURGE SOL B-> 18) to #18. AIR BLOWER: Plug the connector into the relay mounted on the blower itself. Plug the other connector into the fuse housing mounted on the blower. Run the Red (AIR RELAY E-> 44) to #44, Pink (AIR RELAY D-> 47) to #47, Brown (AIR RELAY F-> 45) to #45, Black (BLOWER B- > 21) to #21. AIR DIVERTER SOLENOID: Plug the connector into the air diverter solenoid and run the Pink (AIR SW SOL A-> 47) to #47, Black (AIR SW SOL B-> 46) to #46.
Page #6 Bag #57 CENTRAL CONTROL MODULE: The Central Control Module (CCM) communicates through the serial data link with the Electronic Control Module (ECM). This communication allows a scan tool to be connected to the ALDL connector so any trouble shooting can be done. By installing the CCM you will also be able to use all factory General Motors parts. The CCM performs many functions however only a few can be utilized on a street rod application. Battery & Ignition Connections to the CCM: Plug in the Lt Green connector into the CCM. Uncoil the wires and run the Yellow wire (F1->BATTERY) to a 12 volt (Hot All The Time) source. Run the Orange wire (E5->IGNITION) to a ignition source that is hot (12 Volts) with the key on and in the crank position. Run the Red wire (E4->ACC IGNITION) to the accessory side of the ignition switch. This wire must be hot (12 Volts) with the key in the run position but turn off in the crank position. Ground, Serial Data: Run the Black wire (E16->GROUND) to ground. Run the Tan Wire (E13->49) to terminal #49 on the Telorvek panel. This wire allows the CCM to communicate with the ECM. Install the black connector into the CCM. Run the Black wire (C1->GROUND) to ground. Run the Yellow wire (D6->ALDL G) to the ALDL connector and install it in terminal (G) using the terminal provided. Extra care should be taken in making sure this wire is installed in the right slot. VEHICLE SPEED SENSOR (VSS): A VSS signal input is needed on all General Motors TPI engines. If the ECM does not see that input a CODE 24 WILL SET. The VSS input helps control some of the EGR and IAC functions. You need to provide this input and prevent this code one of two ways. Using a 700 R4 Transmission The first is most 700 R4 transmissions have the factory pulse generator located in them. This can be connected into the computer to provide this signal. For the 700 R4 transmission that has a speedometer cable connector we have developed a pulse generator (part #PG6A) that installs in line on the cable to provide the speed signal into the computer. This transmission also requires a torque converter lock-up signal which is given by the ECM from the input it receives from the pulse generator. The Detail Zone s transmission wiring kits includes the wiring for the TCC lock-up and the correct connectors to plug into the factory pulse generator to make this connection easy. Other Transmissions A speed signal into the computer can done simply by purchasing the PG-6A pulse generator. It installs into the speedometer cable and following the instructions will wire into the harness.
Page #7 FINISHING UP Connect the large prewired Orange wire to the ignition circuit of your ignition switch. This is an ignition feed that is controlled by the ignition switch. This is not an accessory feed and must remain hot even when the engine is cranking. Connect the large prewired Yellow battery feed wire to a battery feed. This is a battery feed that must remain hot even with the key off. Make sure this is a good connection. If you have a Master Disconnect switch, install this wire on the battery side of the switch so it will remain hot with the Disconnect off. The Black ground wire from the TELORVEK III Panel runs direct to the battery. Do not consider grounding the battery to the frame and then the engine to the frame. Run the battery ground directly to the engine. STARTING THE ENGINE You have now made all of the connections necessary to TRY to start your car. If you try now, you will be disappointed since you did not hook up the battery. You can do so now. If you turn the key on but do not crank engine, you will hear the fuel pump for about 2 to 4 seconds before it stops. This will indicate the pump is ready. During normal operating it is best if you do not wait till the pump stops as this is not an indication that the pressure is up. There is no need to "pump" the throttle on fuel injected cars. TROUBLE CODES: Connecting a jumper wire from terminal A to terminal B of the ALDL connector (white and black wires) will allow the computer to "flash" trouble codes in the "CODES" light mounted on the TELORVEK III panel or dash board. Each code will flash 3 times. Each number is flashed separate. Example: Thirteen is flashed as a single flash followed by three flashes. This will repeat three times before moving on to any addition codes. Since the engine must be stopped for this test, code 12 will always flash first. 12 Distributor not operating (turning) 13 Left Oxygen Sensor Circuit 14 Coolant Temperature Sensor (High Temp. Indicated) 15 Coolant Temperature Sensor (Low Temp. Indicated) 16 Opti-Spark Ignition (Low Resolution Pulse) 21 Throttle Position Sensor (Signal Voltage High) 22 Throttle Position Sensor (Signal Voltage Low) 23 Intake Air Temperature Sensor (Low Temp. Indicated) 24 Vehicle Speed Sensor 25 Intake Air Temperature Sensor (High Temp. Indicated) 26 Quad-Driver Module (#1 Circuit) 27 Quad-Driver Module (#2 Circuit) 28 Quad-Driver Module (#3 Circuit) 32 Exhaust Gas Recirculation Circuit 33 Map Absolute Pressure (High Voltage Low Vacuum) 34 Map Absolute Pressure (Low Voltage High Vacuum) 36 Opti-spark Ignition (Faulty High Resolution Or Extra Low Pulse Detected) 41 Electronic Spark Timing (Open Or Shorted) 42 Electronic Spark Timing (Grounded Circuit) 43 Electronic Spark Control (Knock Sensors) 44 Left Oxygen Sensor (Lean) 45 Left Oxygen Sensor (Rich) 51 MEM-CAL (Replace Prom) 52 Engine Oil Temperature (Low Temp. Indicated) 53 System Over-voltage (Check Alternator) 55 Fuel Lean Monitor 62 Engine Oil Temperature Circuit (High Temp. Indicated) 63 Right Oxygen Sensor Circuit (Open Circuit) 64 Right Oxygen Sensor Circuit (Lean) 65 Right Oxygen Sensor Circuit (Rich)
Page #8 LT-1 Cooling Systems General Motors has Installed quite an elaborate recovery system in the 92 Corvette to handle their new reverse cooling system. This system is in place to handle AIR POCKETS that may stop coolant flow through the entire motor. EXTRA care should be taken to bleed (burp) all the air out of the motor. There is a bleed valve on the thermostat housing for this purpose. Care should be taken to be sure the air bleed line from the back of the engine is correctly plumbed. If not done exactly like the Corvette, You may need an extra connection in the top of the radiator. Install a water temperature gauge and keep a close eye on it during testing and the first 500 miles. Optional Accessories GM Part No. The Detail Zone Part # Electronic Control Module 16159278 EC-54 Prom (Mem-Cal) Auto Trans 16171697 PR-19 Prom (Mem-Cal) Manual Trans 16171690 PR-20 Central Control Module (C.C.M) 16159188 CM-54 Fuel Pump Relay 14100455 FP-25 Cooling Fan Relay 14100455 FP-25 Park Neutral Relay 14100455 FP-25 Pulse Generator (Speed Sensor) Torque Converter Lock-Up Wiring (Stand Alone Unit) Torque Converter Lock-up Wiring (Round Five Pin Trans Connector) Computer Controlled (Pulse Generator Required) Torque Converter Lock-up Wiring (Four Pin Trans Connector) Computer Controlled (Pulse Generator Required) PG-6A TC-70 TC-62 TC-60 Copyright 1992-2001 The Detail Zone
Page #9 General Motors EFI Connections 1) (NOT USED) 2) (NOT USED) 3) Coil Driver Connector 13) Coolant Temperature Sensor 14) Canister Purge Solenoid 4) (NOT USED) 5) EGR Solenoid 6) ALDL Connector 15) Male Distributor Test Connector 16) Female Distributor Test Connector 7) Oxygen Sensor 8) Injectors 9) Knock Sensor 17) Oil Switch Connector 18) Throttle Position Sensor / Engine Oil Temp Sensor 10) Manifold Air Pressure Sensor 19) Fuel Pump, Fan, Park/Neutral Relay 11) Idle Air Control 20) Intake Air Temp Sensor 12) Air Divert Solenoid 15 16 17 18 19 20
Page #10 Copyright Infringement The Detail Zone has taken the extra effort to produce a quality, easy to understand instructions. We will aggressively prosecute any other harness supplier who attempts to copy this material!!