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  • InstallingthePainless#10102UniversalStreetRodHarness

    inearlyFiatSpiders

    BernieSenewayJune1,2009

    Rev.C

    AcknowledgementsThanks to JohnErskineat theFiatRescueLeague chesapeakespiders@verizon.netfor salvage parts, Rick Trawick at http://www.carsandplaces.com for his Britishautomotive electrical assistance, Dennis Diehl at Painless Performance Products,nd Brad Artiguea http://www.artigue.com/?page_id=58 for his extensive Fiatiringdiagramsandforhostingthisarticle.w

    ErrataManyFiatSpidersmanufacturedbyPininfarinahavewiringschematics,colorsandodesdifferentthandescribedinfactoryservicemanuals.Pleasekeepthisinmindcwhenwiringyourcar.Your input will helpmake this articlemore accurate and helpful to other Spiderowners.Pleasecontactmewithanyerrorsandomissions.

    Bernard Seneway. All rights reserved. To add to your site, contact me at bernie@pennstar.com

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    http://www.carsandplaces.com/http://www.carsandplaces.com/http://www.artigue.com/?page_id=58http://www.artigue.com/?page_id=58http://www.artigue.com/?page_id=58http://www.artigue.com/?page_id=58

  • InstallingthePainless#10102HarnessinanearlyFiatSpiderManyreliabilitycomplaintsabouttheFiatSpiderrelatetoelectrics. Mostof thesecomplaints can be attributed to shoddy repairs/modifications at the hands ofprevious owners. However, even unmodified, wellmaintained early Spiders stillhave an outdated electrical system design and 3040 yearold components. Thiswiring modification retains most of the OEM functions and controls. Uponcompletion, your electrical systemwill now operate like amodern American car;eadlightsworkwithout the ignition key, etc. The reduced load on your ignitionhswitchwilladdreliabilityintheyearsahead.Subject car is a 1973 Spider with a 65A Bosch alternator and integral voltageegulator. Theoriginalequipment42AMarellialternator ismarginal,andifyours

    lrhasunsatisfactoryoutput,rep acewiththe55or65ABosch.I chose the Painless #10102Universal Street Rod harness,which has 12 circuits,ore than enough for the Spider, particularlywhen you consider that four of them

    Spidersninearedevotedtotheheadlightsalone.hisharnessdoeshaveafewdeficiencieswhenusedinthisapplication.Itdoesnotuppor ipment,keyorseatbeltbuzzer,or:Ts

    temissionequ

    Backuplights

    ElectricfuelpumpOilpressurefailurelamp

    Hydraulicfailure/handbrakeOnlampindshieldwiperandwasheraresupportedbyprovidingasinglepower feed;noW

    switchormotorwiringisprovided.Before beginning the project, download a copy of the Painless installationinstructions at http://www.painlessperformance.com/Manuals/10102.pdf tofamiliarizeyourselfwiththeprocedure.DontbeintimidatedbySections7,8and9 theyarenotapplicable to theFiat installation. The items youwill refer tomostoftenarepages15,Figure107B,Table112,andpages3031.nadditiontotheitemsrecommendedbyPainless,youwillneedthefollowingtoolsndmaIa

    terials:

    Ratchetcrimperaticwirestripper

    powersupply Autom

    Lowvoltage

    VOMBulbgrease

    Brasstoothbrush

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    http://www.painlessperformance.com/Manuals/10102.pdf

  • 2or3pole,singlethrowswitch(hazard

    ) adlight)Doublepole,triplethrowtoggleswitch(he

    661 01X036

    3pcs.RadioShackdiodep/n2761orelayp/nV23234A10

    3pcs.Tyc

    adhesivelinedheatshrinktubing

    terminalsheatgun

    ,blueandyellow nd18ga.wire

    additionalred

    additional16awheelpuller

    24mmsocketWiringBasicsBecause all of the terminations in your newwiring are crimpon, it is imperativethatyouemploythepropertoolsandtechniques.Donotuseaplierstypecrimpingtool; these can over or undercrimp the connector. Obtain a ratcheting crimper,suchas thisone. Look forred,blueandyellowdieson the tool;youwillneedallthree.Makeafewpracticecrimpsonscrapwiretofamiliarizeyourselfwiththetool.Tocrimp,squeezethetoolhandlesuntiltheyreleaseandpopopen.Onlythenhaveyouappliedthepropercrimpingforce. Toabortacrimp,releasethehandleswiththesmallleverontheinsideofthehandle.StrippingmodernTXLinsulatedwireisbest performed with a stripper such as this one. You must remove the toughnsulationwithoutnickingthecopperwirestrands.Plierstypestrippersshouldnotibeused.While not absolutely necessary, I strongly recommend that you fortify each andeveryterminationandsplicewithadhesivelinedheatshrinktubing,availablefromMcMasterCarr and others. Part number 7861K53 will fit over butt splices,4965K64 fits over blue and red terminals. Always use the smallest diameter7tubingpossible,toachievethetightestfit.Usefullyinsulatedterminals,wheretheplasticinsulationcompletelycoverstheconnectionpoint,asshownherehttp://www.mcmaster.com/#catalog/114/0734Usewiresuitableforanoilyandgreasyenvironment.Machinetoolwirefromthissamevendorisgood.Whatswithallthecolors?Simple.Redcoloredterminalsareusedonlyon2018ga.Wire.Blue(allbluetypes;ring,butt,spade,etc.)for1614ga.Yellowfor1210ga.Someverylargeterminals,includingsomeshippedwithyourharness,arealsored,but they are so large there canbenoquestionwhat sizewire they fit. Using theproper terminal for thewire size, in the proper die of a ratcheting crimping tool

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    assuresyouofaperfect, longlastingconnection. Wantproof? Trypullingapartaconnectionyouvemadewithscrapwireifperformedcorrectly,youwontbeable.Adhesiveontheinsidewallsoftheheatshrinktubingdescribedherewillmeltatatemperature slightly below the point where the tubing begins shrinking. Theadhesive is mechanically forced around the wire strands and terminal by the

    http://www.harborfreight.com/cpi/ctaf/displayitem.taf?itemnumber=97420http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=36810http://www.mcmaster.com/#catalog/114/782

  • collapsing tubing. A littleof itoozesoutofeachendof the tubingwhenproperlyshrunk,makingthejointvirtuallywaterproofwhencool. Thetubingalsoprovidesadditionalmechanicalstrengthtotheunionofwireandterminal.Attheveryleast,sethisproductinyourunderhoodandunderfenderlocations,butyouwillhaveddedpeaceofmindifyouuseiteverywhere.uaChassispreparation

    disconnectbothbatterycablesfcar

    bnutsdownthecarbthroat)pullchokeOn(preventslosso

    removeentireaircleanerassemblydetachmastercylinderbracket

    removeleftfootwellvent,ifsoequipped

    Remove the4or5screwson theclamshell covers fitted to the steeringaxle,andgentlyremovecovers.Pryoffthehornbezel.Tabsarelocatedat10,2and7oclock.Bagandtagallparts.Nowwouldbeagoodtimetoclean yourhorn ringwith ScotchBrite or steelwool, so that yourhornworkseverytime.Remove24mmnut.Markthesteeringaxleandwheelwithascribelineorpainttoassureyourwheelwillpointstraightattheconclusionoftheproject.

    - 4 -

  • Removethesteeringwheelwithawheelpuller,orplacethesmallendofa ballpeen hammer in the depression of the steering axle. Strike thehammer face with another hammer, while an assistant yanks on thewheel.

    Remove the instrument cluster by unscrewing the four thumbscrews.After a few inches, the cluster will be stopped by the speedo cable.Unscrew this collarnut. There is a short intermediateharnesswhichconnectstheclustertotheFiatchassisharness.Savethis.

    owwouldbeagoodtimetorejuvenateyour instrumentsbydisassemblingthemndcleaningtheglassfaces.Youmightaswellreplaceall14lampsatthistime,too.Na

    Removethesteeringcolumnswitchassemblebylooseningtheonebandnutandpullingtheassemblytowardyou.Notetheassemblyiskeyedandwillonlyseatproperlyinoneorientation.

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  • Younowmustdecideifyouwishtoretaintwofailurepronefactoryitemsonyourcar;intermittentwipersandpanellampdimmer.Mycarisafairweatheritem,soI dont need the former. Ive also relamped and cleaned my instruments, andithoutthedimmer,myclusterilluminationisjustright.Theseinstructionsassumeourescrappingthesetwoitems.Ifyourekeepingthem,adjustaccordingly.wyPreparethePainlessHarnessUnwraptheharness,andseparatethethreemainbundles;engine,cockpitandtail.Noticetheexceptionallengthofthisharness.ItfitsfullsizeAmericancarstwicetheizeofyourroadster. Resistthetemptationtoshortenanyofthethreebundlesathistime.st

    Remove BLU/WHT #9021 from engine section, cut and cap near fuseblock.(Cappingwireneatlycanbeaccomplishedwithashortsectionofheat shrink tubingallow of tubing toextendbeyond thewire,thenpinchitwhilehot.)

    Move ORN #917 and WHT #918 from the engine bundle and looselyassociateitwithcockpitbundle.

    RemoveRED#954fromenginesection,unlessyourealreadyconvertedtoanelectricchokecarb.Capandcoilunderdriverscarpetforlaterusebyyouorthenextowner.

    Go to Page 27 of the Painless manual. Draw a line thru the followingwires;theyareunusedornotincludedinthiskit:902,903,910,911,912,913,942,943,944,946,947,956,957and958.

    Relabel BLK/WHT #904 fuel pump if your car is equipped with anelectricfuelpump.Joinwithtailsectionbundle.Cutandcapotherwise.

    RemovetheFiat fuseblock,relaysandallwiring. Donotdiscardorcutthe Fiat intermediate cluster harness, or any of the wires on theinstrument column switch assembly. Observe the hood release,emergency hood release and other items throughout the carwhich arenotwires;dontcutthem!Saveandreusesenderboots.

    1 Colors are shown in their three-letter abbreviation. In the case of multi-color wires, the first color is the body, the second is the stripe. All Painless wire numbers are three-digit beginning with the numeral 9. Any references to Fiat wiring in this article will follow the same color conventions.

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  • Installyournewfusepanelinthespacevacatedbytheold. Ishortenedthetwotopmountingpostsonthenewpanel,andbentslightly forwardthemetaldashflangetomountthePainlesspanel.

    Youmayfindithelpfultojackupthesideofthecaryoureworkingon;yourbackillthankyouattheendoftheday.Besuretousejackstands,wheelchocks,and

    cuthere

    wotherappropriatesafetymeasures.ont install the fragile tu