A Painless Wiring Harness System

Remove the main power lead between the firewall and battery.

Inside, the instrument panel is removed first. The headlamp switch, wiper switch, and ignition switch are disconnected. The wiper motor is unplugged, as is the stereo. Behind the dashboard is the main wiring loom, which means there is a lot to disconnect. Everything must be disconnected, including the taillamp wiring loom.

With the main wiring loom plugs removed at the firewall, we are ready to prepare the openings for the Painless main wiring loom. Painless provides a template that enables you to modify these openings for the new bulkhead plugs. John Da Luz lays the template over the firewall passage and grinds the opening for a perfect fit. There are two firewall passages--one midway across the firewall and another in the corner by the master cylinder.

As you can see, each firewall passage needs massaging to make way for the Painless bulkhead connections.

The corner passage near the master cylinder is identical to the passage mid-firewall. John has laid down the template and will modify this opening the same way.

Each of the Painless wiring looms must be wrapped and protected from chafing. John has chosen to wrap each loom with electrical tape. Flexible, plastic anti-chafe may also be used to protect the wiring. Never leave the wiring exposed.

The new Painless main wiring loom is fed into the dashboard as shown. The bulkhead connector is fitted through the firewall. Then, the underhood wiring loom is connected to the main wiring loom at the firewall. The main wiring loom's connector clicks into place at the firewall. This becomes a secure connection.

The underdash main wiring loom is inspected, with destination points determined before the wiring is wrapped. Each connection is routed to a switch or accessory, just to get started. Once the main wiring loom is positioned, we determine how switches, accessories, and lighting are connected.

Like the bulkhead connector mid-firewall, the bulkhead connector in the left-hand corner of the firewall is inserted into the passage, then connected to the underhood wiring loom to the headlamps.