WRNING: 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 MOII 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. 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. Most stock alternator current outputs were rated at a maximum of about 37-60 amps. Modified 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 I, MS, 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 R 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 1963-67 hevrolet orvette This kit contains the following components: Part ag Number escription Quantity 500042 loor immer 1 500332 eadlight 1 500684 Ignition 1 500919 Practice Terminal rimping Set 1 510145 use, Relay, and lasher kit 1 G 510613 ash arness kit 1 510614 Instrument luster wiring kit 1 510615 ngine Wiring it 1 510616 ront ight Wiring kit 1 M 510619 Rear ody Wiring kit 1 N 510620 eadlight xtension Wiring kit 1 92971437 irewall Template 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. OPYRIGT 2004 merican utowire / actory-it Used with express permission of merican utowire / actory-it Page 1
STRT R! PS R TIS OR STRTING INSTTION! This wiring kit is designed for ease of installation. Please read the guidelines below, OR STRTING 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 GM 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. end view of un-crimped terminal proper crimp of terminal wire core 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 OM small terminal crimping tool (18-14 gauge) p/n 510586 OM large terminal crimping tool (12-8 gauge) W offers a great terminal crimping video entitled Proper rimping Video. It can be viewed by visiting YouTube. Type the following address into your web browser, to go directly to the video: www.youtube.com/watch?v=govl-co Youtube hannel: www.youtube.com/user/wiringarness p/n 510587 Includes oth terminal crimping tools We carry many accessories for your. actory ssembly Manuals 1963 p/n 36337 1964 p/n 36338 1965 p/n 36339 1966 p/n 36340 1967 p/n 36341 ull vehicle ing kit p/n 500717 Optional Third Tail ight it p/n 510679 64-65 orvette Rear Mounted lower it p/n 510681 Page 2 If you have any questions concerning this or any of our products, please feel free to call us at 1-856-933-0801. STP 1: ISONNT YOUR TTRY: isconnect the battery, before installing the wiring kit, to prevent any accidental shorting caused by loose bare wire ends.
STP 2: STRT INSTING 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: PS R TIS PU INSTTION TIP, OR GOING NY URTR! Prior to installing the ash/main harness in your dashboard, plug all of the fuses (see detailed picture below), orn Relay, azard lasher and Turn lasher (see detailed picture below), into this harness. ags: Pages: Sections: G M 4-9 10-14 15-19 ash arness - This is the main harness in the kit and contains: - Starter solenoid connections. - oor jamb switches. - Wiper motor connections - Wiper module and switch connections - rake light switch connection. - efrost module and switch connections. - Neutral safety switch connection. - eadlight and fog light connections. Gauge luster arness - This arness contains: - Gauge connections for aftermarket and factory gauges. Rear ody arness - This arness contains: - Tail light, turn signal, reverse light, and running light connections. - atch connections; third brake light, license plate lights, and rear defroster connections. - uel pump connections. at - Spare 30 - T Park ights 15 - T orn 15 - T az / 15 - T Turn 15 - IGN Gauges 10 - IGN Wiper 20 - Pwr Window 30-1 2 Pwr Seats 30 - T 3 4 Stop / rtsy 15 - T 5 6 lock - T 15 - T 7 8 Pwr ocks 15 - T 9 10 uel Pump 20 - IGN 11 12 ngine an 30 - IGN 13 14 Radio 10-15 16 eat / 30-1 30 2 30 15 15 3 4 5 6 7 15 8 15 15 10 20 9 10 11 12 13 14 15 15 20 30 10 30 15 16 30 20-22 ront ight arness - This arness contains: - eadlight, turn signal, running light connections. - og lamp wiring. - Windshield washer connection. - lectric fan relay trigger. - rake fluid level wiring. use label on inside of use ox over Turn lasher azard lasher use installation orientation. 23-25 ngine arness - This arness contains: - Temperature, oil pressure, tachometer wiring. - Ignition system / U power. - / compressor connections. - lternator connections. orn Relay Page 3
ash/main harness installation instructions: Shown below, are the supplied misc. terminals, plastic connector bodies, hardware, jumpers and extensions that will be used to complete your ash/main harness connections. They are itemized and referred to on this page, just as they are on the following pages of this ash/main instruction set. G M N P (Pack-con 14-way male conn, 1 pc.) M (56 series double female terminal, 9 pcs.) (cover, circuit breaker, 1 pc.) S TS S TS S TS (grommet, 2 way, 1 pc.) S TS S TS S TS (ash ight xtensons - reference, 4 pcs.) (male flat Pack-con terminal, 11 pcs.) (56 series single female terminal, 8 pcs.) (screw, 1,fuse box, 4 pcs.) N P R (circuit breaker, 1 pc.) (sleeve, long, 2 pcs.) (ring terminal, 4 pcs.) S TS S TS (Power ntenna umper - reference, 1 pc.) (ash ight andelabra umper - reference, 1 pc.) (washer, 1/4, 2 pcs.) T (sleeve, short, 4 pcs.) GG (eadlight oor umper - reference, 1 pc.) P N M G (Pack-con 11-way female conn, 1 pc.) U V (10-32 nut, 2 pcs.) (washer, 10-32, 2 pcs.) (1963 only Parking rake xtension - reference, 1 pc.) (Glove box ight xtension - reference, 1 pc.) G Page 4 (female Pack-con terminal, 11 pcs.) (single male bullet terminal, 6 pcs.) (56 series 2-way female conn, 1 pc.) (56 series single female conn, 4 pcs.) w Y (light socket, 2 pcs.) (56 series single female conn, 1 pc.) (smaller metal light socket, 1964 and up only, 1 pc.) (light socket sleeve, 1 pc.) (spring, light socket, 1 pc.) (Turn Signal umper, 1963 only - reference, 1 pc.)
1 ash/main harness installation instructions: Ground Rear ody oor amb ourtesy ight ulkhead onnector Page 5 NOT: With the wires exiting the top end of the fuse box, position the fuse box on the side wall approximately as shown. There is one mounting hole in the lower flange and three in the top flange; use the two top holes that are on either side of the wires exiting the fuse box. Mark and drill three 1/8 (.125) dia holes in your firewall. Use the three screws, item, in the 92971416 loose piece kit (for the 510613 dash harness), to attach the fuse box to your side wall. If necesarry, cut back any sound deadener or carpet, to mount the fuse box. e sure to check for clearances of any accessories that you might be adding. 30 2 30 3 15 4 15 5 15 6 15 7 15 8 15 9 15 10 20 10 11 12 30 20 13 14 10 30 15 16 30 use ox immer 500042 immer
ash/main harness installation instructions: U (2 pcs.) ccessory onnector See page 8 for accessory connections. azard lasher orn Relay Turn lasher ondenser/ apacitor eed N eadlight oor ircuit reaker GG M luster onnections (electric speedo) P ON V G (2 pcs.) use supplied nuts U and washers V, to attach 2 ring terminals to circuit breaker N. over completed circuit breaker with cover M. igar ighter Ground P N M G Turn Signal See page 8 for Turn Signal connections. Ground Ignition eadlight 500332 eadlight eadlight oor rake Parking rake See page 9 for Parking brake switch connections. (Not used for 1967; see page 19 for 1967 instructions). 500684 Ignition Page 6 1963-66: install rake terminals into (2) connectors. 1967: install rake terminals into connector; no indexing required.
ash/main harness installation instructions: 402 VSS 400 401 Wiper Motor Washer ackup ight These wires and connectors will pass through the grommet, at the firewall. Glove ox ight eater Resistor eater lock eater eed oor amb ash ights See page 9 for ash ight connections. ourtesy ight Page 7 150 43 99 Radio
ash/main harness installation instructions: MRIN UTOWIR S RNSS ONNTION white dk green yellow purple brown dk blue lt blue black P N M G G M N P ORIGIN TURN SIGN SWIT WIRING IGRM - W Turn Signal Wires to Stock 1963 Steering olumns. white dk green yellow purple dk blue lt blue black horn button MRIN UTOWIR S RNSS ONNTION white dk green yellow purple brown dk blue lt blue black P N M G ORIGIN TURN SIGN SWIT WIRING IGRM - W Turn Signal Wires to Stock 1964-67 Steering olumns. G M N P Table W Turn Signal wires to stock 1963-67 hevrolet orvette Turn Signal W W Wire onnector Wire olor Printing avity W White rake SW P ark Green Right Rear Turn N Yellow eft Rear Turn M Purple Turn eed rown Turn SW azard (aftermarket only) ark lue Right ront Turn ight lue eft ront Turn lack orn Relay Ground G None None None None None None Note: 1963 only: Remove the original Turn Signal onnector and replace it with the W 14-way connector and Turn Signal umper. rimp on terminal to each of the umper wires and plug them into connector (see Parts it 92971416). 1964-67 only: Remove the original Turn Signal onnector and replace it with the W 14-way connector. rimp on terminal to each of the original Turn Signal wires and plug them into connector (see Parts it 92971416). Use Table above to align the wires. lso, for all of the vehicles, the Steering olumn orn utton switches for the orn Relay, which then switches power to the orns, 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 arness, and terminals and to add power wires (not provided) for the following optional systems: Wire olor Printing use # use lock over use rating escription Red -RIO 7 az / 15 used 12 volt TTRY feed for cruise control (may also be used to feed power to another battery circuit). Tan U PUMP 10 uel Pump 20 used 12 volt IGNITION feed for fuel pump (may also be used to feed power to another ignition circuit). Orange POWR STS 2 Pwr Seats 30 used 12 volt TTRY feed for power seats (may also be used to feed power to another battery circuit). Red POWR OS 8 Pwr ocks 15 used 12 volt TTRY feed for power door locks (may also be used to feed power to another battery circuit). Pink POWR WINOWS 15 Pwr Window 30 used 12 volt SSORY feed for power windows (may also be used to feed power to another accessory circuit). Orange 12V TTRY US 1 at-spare 30 used 12 volt TTRY feed (may also be used to feed power to a battery circuit). Page 8
ash/main harness installation instructions: gray wire from ash harness ash ight wiring: Parking rake switch wiring: or 1963: pply terminal and connector to tan wire from ash harness and plug into the parking brake switch. tan wire from ash harness Ground Using 1963 Parking rake xtension, attach the ring terminal to a good and plug the connector into the parking brake switch. If using radio illumination (such as the stock radio), double-crimp the andelabra wire with the loose ash ight xtension wire in terminal, insert it into connector and plug it into the connector with the gray wire from the ash harness. tan wire from ash harness to radio illumination or 1964-66: Power ntenna wiring: ccessory connector (at ash harness) pply terminal to tan wire from ash harness and plug into the parking brake switch. ccessory plug T Using the three ash ight xtension wires that have a terminal at one end, slide on light sockets W and (also light socket sleeve at socket ), cut to length and apply T sleeves and terminals to the other end, then plug into andelabra connector. Power ntenna Page 9 Power ntenna switch w w pass through hole, eater light lock lights near Power ntenna
Gauge luster harness installation instructions: Shown below, are the supplied misc. terminals, plastic connector bodies, light sockets and hardware that will be used to complete your Gauge luster harness connections. They are itemized and referred to on this page, just as they are on the following pages of this Gauge luster instruction set. 1. Pass wire through spring and socket 2. rimp terminal to wire ow to install lamp sockets and lamp socket terminals. 1. Pass wire through socket 2. rimp terminal to wire 3. When complete pull wires back through to seat in socket (light socket, 13 pcs.) M (spring, smaller metal light socket, 1 pc.) 1. rimp terminal to wire oes not require spring 2. Insert into bulb socket G (spring, plastic light socket, 1 pc.) (terminal rivet, 20 pcs.) (terminal, plastic light socket, 2 pcs.) (plastic light socket, 1 pc.) (56 series single female terminal, 8 pcs.) (splice clip, 3 pcs.) N P R T (56 series 2-way female conn, 2 pcs.) (56 series 2-way female conn, 1 pc.) (56 series 2-way female conn, 1 pc.) (56 series 1-way female conn, 3 pcs.) ow to use the splice clip to join multiple wires. elow is just an XMP of how to use the splice clip and shrink tubing; see your specific application on the following pages for actual splice information. 1 XMP ONY fter routing wires to be spliced, slide heat shrink tube onto wires OR installing splice clip. Shrink Tubing Splice lip XMP ONY (shrink tubing, 3 pcs.) (reflector, smaller metal light socket, 1 pc.) (smaller metal light socket, 1 pc.) (insert, plastic light socket, 1 pc.) Page 10 U V (56 series 3-way female conn, 1 pc.) (small ring terminal for smaller gauge wire, 1 pc.) 2 3 * eep away from heat while soldering splice clip Shrink Tubing Splice lip rimp and Solder XMP ONY When finished, heat the shrink tubing to seal the splice connection. Shrink Tubing
Gauge luster harness (aftermarket gauges) installation instructions: TURN SIGN N I-M MP ONNTIONS T TURN IN IG M IN RIGT TURN IN lt blue ( turn ind) lt green (hign beam ind) dk blue (R turn ind) _ + S + S + S + S + R WRNING IGT VOTS U SPO OI TMP T P ON WIPR-WSR GROUN WIPR-O SP GROUN WIPR-I SP GROUN 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 Ground 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 Ground 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. Page 11 See pages 12-14.
Gauge luster harness installation instructions: rake Warning eadlight Warning ash ight igh eam ash ight P N Right Turn Temperature ash ight Tachometer (Mechanical) ash ight Speedometer eft Turn ash ight uel from Gauge luster harness connector V Ground ash ight ash ight 1965-67 ONY ash ight 1965-67 ONY ash ight from Gauge luster harness connector Ignition Oil (Mechanical) ighter see View Wiper mmeter (NOT SUPPORT) ight or proper wire locations, refer to etail View Page 12 View M see instructions on page 10 etail View (mating end shown) see instructions on page 10 Gauge luster harness connectors Oil pressure sender wire, if used ash harness luster connectors G etail View (mating end shown) Tach wire, if used
Gauge luster harness installation instructions: rake Warning eadlight Warning ash ight igh eam ash ight Right Turn ash ight ash ight Speedometer eft Turn ash ight Temperature Tachometer (Mechanical) uel Ground ash ight ash ight 1965-67 ONY ash ight 1965-67 ONY ash ight mmeter (NOT SUPPORT) Ignition Oil (Mechanical) ighter T Wiper ight ondenser/ apacitor eed R U 1963-66: Use terminals and connectors in box, to the left, to connect Gauge luster harness to the wiper switch. from ash harness (page 6) luster onnections 1963-66 wiper switch connections 1967 wiper switch connections 1967: Use terminals and connectors in box, to the left, to connect Gauge luster harness to the wiper switch. Page 13 from ash harness (page 6) from ash harness (page 6) (mating end shown) ash harness luster connector Tach wire, if used
Gauge luster harness (optional aftermarket functions) installation instructions: aftermarket gauge only rake Warning eadlight Warning ash ight igh eam ash ight Right Turn ash ight ash ight Speedometer eft Turn ash ight Temperature Tachometer uel aftermarket gauge only V Ground Ignition ash ight Oil ash ight 1965-67 ONY ighter Wiper ash ight 1965-67 ONY Voltmeter ash ight ight for a gauge that has been converted to a voltmeter or aftermarket gauge only see instructions on page 10 12 V IGNITION wire Page 14 etail View (mating end shown) Gauge luster harness connectors Oil pressure sender wire, if used ash harness luster connectors G etail View (mating end shown) Tach wire, if used or proper wire locations, refer to etail View
Rear ody harness installation instructions: Shown below, are the supplied misc. terminals, plastic connector bodies, boots and wire extensions that will be used to complete your Rear ody harness connections. They are itemized and referred to on this page, just as they are on the following pages of this Rear ody instruction set. (56 series single male terminal, 6 pcs.) (56 series 1-way male conn, 2 pcs.) (56 series double male terminal, 3 pcs.) (splice barrel, 1 pc.) (56 series single female terminal, 10 pcs.) M (heat shrink, 1 pc.) (56 series double female terminal, 5 pcs.) N (parking brake wire, 1967 only, - reference, 1 pc.) (56 series 1-way female conn, 3 pcs.) P (license plate light extension - reference, 1 pc.) (56 series 2-way female conn, 2 pcs.) G (56 series 2-way male conn, 2 pcs.) R (tail, license and back-up light, extensions - reference, 4 pcs.) (boot, 6 pcs.) (bullet terminal, 4 pcs.) Page 15
1963-65 without back-up lights Rear ody (at ash harness, near rear kick panel) to dome light Rear ody harness installation instructions: 3rd brake light pass through hole (grommet not supplied) G G M license plate light Page 16
1963-66 with back-up lights Rear ody (at ash harness, near rear kick panel) to dome light Rear ody harness installation instructions: 3rd brake light pass through hole (grommet not supplied) G G M license plate light Page 17
1967 Rear ody (at ash harness, near rear kick panel) to dome light Rear ody harness installation instructions: 3rd brake light pass through hole (grommet not supplied) G G M back-up light Page 18 license plate light
Rear ody (at ash harness, near rear kick panel) to parking brake (1967 only) Rear ody harness installation instructions: pass through hole (grommet not supplied) GROUN 12V IGNITION (small pin connector) GS GUG (large pin connector) Page 19
ront ight harness installation instructions: Shown below, are the supplied misc. terminals and plastic connector bodies, 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 single female terminal, 10 pcs.) G (56 series 3-way female conn, 2 pcs.) (56 series double female terminal, 2 pcs.) (56 series single male terminal, 10 pcs.) (56 series 3-way female conn, 2 pcs.) (56 series 3-way male conn, 2 pcs.) (terminal cover, 4 pcs.) (56 series single female connector, 2 pcs.) (female terminal, right angle, 5 pcs.) (56 series 2-way female conn, 2 pcs.) Page 20
ront ight harness installation instructions: eadlight xtension harness 510620 NOT: If you have a 1963 car with original fiberglass / buckets, all 22 inches of the loom will be used as-is. If your 1963-67 car has metal / buckets, cut the loom down and use about 10 inches of it. The 1963 fiberglass buckets also utilized a grommet. That grommet is not included in this kit. The cars with the metal buckets did not use any type of grommet. (wiring end shown) bulkhead connector loom loom G G eadlight xtension harness 510620 eadlight xtension harness 510620 W offers the following Parking ight repair kits: 40059 (1963-66) 40060 (1967) Page 21
ront ight harness installation instructions: (wiring end shown) bulkhead connector horn horn limit switch headlight door motor headlight door motor limit switch Note that the indexing of these is opposite of each other. Page 22
ngine harness installation instructions: Shown below, are the supplied misc. terminals, sleeves, plastic connector bodies and wires, 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, 8 pcs.) (small ring terminal for smaller gauge wire, 4 pcs.) (56 series single female connector, 2 pcs.) M (small rubber sleeve, 3 pcs.) (56 series single female connector, 2 pcs.) N (56 series single male terminal, 3 pcs.) (rubber boot, 1 pc.) P (56 series 1-way male conn, 1 pc.) (small ring terminal for larger gauge wire, 1 pc.) R (56 series single female connector, 2 pcs.) (large rubber sleeve, 2 pcs.) T STRTR SONOI - R G (large ring terminal, 1 pc.) U TRNTOR IGN V TRI N (56 series single female connector, 2 pcs.) W STRTR SONOI - S (56 series single female connector, 2 pcs.) Y rake Page 23 (56 series double female terminal, 4 pcs.)
ngine harness installation instructions: to T location on coil to T location on coil V U (wiring end shown) distributor see View bulkhead connector positive battery cable (not included with this kit) oil sending unit see View R OR M temperature sending unit R OR M R T S T starter solenoid G from bulkhead connector View W offers an SI series alternator to S series alternator conversion kit 37796 (see page 2) alternator (SI) Page 24 M optional connection for points cars coil (resistor not included - only used on selected ignition systems) M ballast resistor from bulkhead connector electric fan recommended fan relay (not included)
ngine harness installation instructions: from neutral safety switch if there is no neutral safety switch, plug these two connectors together Y to brake warning switch if applicable N heater blower N P washer wiper motor VSS backup ight switch bulkhead connector (wiring end shown) cut off original heater blower wire and replace with terminal N and connector P starter solenoid R T S W Page 25
STP 3: RONNT YOUR TTRY: 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 NGIN O.. attery is ed to the frame.. ngine block is ed to the frame.. ody is ed to the frame. STP 4: TRI 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 26