Installing the Painless #10102 Harness in an early Fiat
Contents
1. 7861K53 will fit over butt splices 74965K64 fits over blue and red terminals Always use the smallest diameter tubing possible to achieve the tightest fit Use fully insulated terminals where the plastic insulation completely covers the connection point as shown here http www mcmaster com catalog 114 0734 Use wire suitable for an oily and greasy environment Machine tool wire from this same vendor is good What s with all the colors Simple Red colored terminals are used only on 20 18 ga Wire Blue all blue types ring butt spade etc for 16 14 ga Yellow for 12 10 ga Some very large terminals including some shipped with your harness are also red but they are so large there can be no question what size wire they fit Using the proper terminal for the wire size in the proper die of a ratcheting crimping tool assures you of a perfect long lasting connection Want proof Try pulling apart a connection you ve made with scrap wire if performed correctly you won t be able Adhesive on the inside walls of the heat shrink tubing described here will melt at a temperature slightly below the point where the tubing begins shrinking The adhesive is mechanically forced around the wire strands and terminal by the collapsing tubing A little of it oozes out of each end of the tubing when properly shrunk making the joint virtually waterproof when cool The tubing also provides additional mechanical strength to the union of wire2. and terminal At the very least use this product in your under hood and under fender locations but you will have added peace of mind if you use it everywhere Chassis preparation disconnect both battery cables pull choke On prevents loss of carb nuts down the carb throat remove entire air cleaner assembly detach master cylinder bracket remove left footwell vent if so equipped LJ Remove the 4 or 5 screws on the clamshell covers fitted to the steering axle and gently remove covers Pry off the horn bezel Tabs are located at 10 2 and 7 o clock Bag and tag all parts Now would be a good time to clean your horn ring with Scotch Brite or steel wool so that your horn works every time Remove 24mm nut Mark the steering axle and wheel with a scribe line or paint to assure your wheel will point straight at the conclusion of the project E Remove the steering wheel with a wheel puller or place the small end of a ball peen hammer in the depression of the steering axle Strike the hammer face with another hammer while an assistant yanks on the wheel c Remove the instrument cluster by unscrewing the four thumbscrews After a few inches the cluster will be stopped by the speedo cable Unscrew this collar nut There is a short intermediate harness which connects the cluster to the Fiat chassis harness Save this Now would be a good time to rejuvenate your instruments by disassembling them and c
3. Installing the Painless 10102 Universal Street Rod Harness in early Fiat Spiders Bernie Seneway June 1 2009 Rev C Acknowledgements Thanks to John Erskine at the Fiat Rescue League chesapeakespiders verizon net for salvage parts Rick Trawick at http www carsandplaces com for his British automotive electrical assistance Dennis Diehl at Painless Performance Products and Brad Artigue http www artigue com page id 58 for his extensive Fiat wiring diagrams and for hosting this article Errata Many Fiat Spiders manufactured by Pininfarina have wiring schematics colors and codes different than described in factory service manuals Please keep this in mind when wiring your car Your input will help make this article more accurate and helpful to other Spider owners Please contact me with any errors and omissions Bernard Seneway All rights reserved To add to your site contact me at bernie pennstar com Installing the Painless 10102 Harness in an early Fiat Spider Many reliability complaints about the Fiat Spider relate to electrics Most of these complaints can be attributed to shoddy repairs modifications at the hands of previous owners However even unmodified well maintained early Spiders still have an outdated electrical system design and 30 40 year old components This wiring modification retains most of the OEM functions and controls Upon completion your electrical system will now operate like a modern Amer
4. NK 931 INT BRN 932 INT ORN 933 15 54 RED 934a 30 1 RED 934b 30 PUR 919 50 10 Cut and discard PNK and WHT key buzzer wiring No need to cap the ends they carry no voltage Cut em flush Wire the starter and solenoid per the Painless manual Don t forget the Maxi Fuse If your Spider is a 1972 or newer model you can reuse the emissions switch on the clutch as a starter safety switch as in contemporary vehicles Place this switch inline between the fuse panel and ignition key of PUR 919 The starter will not engage unless the clutch pedal is depressed Install 3 relays in the space vacated by the OEM units Label them Lo Hi and Fan The horn relay is incorporated into the new fuse panel Sockets make installation easier but you lose the Painless wire color coding and nomenclature Your choice Connect relays as follows Relay Pinout Pin Function Description 86 trigger 901 908 or 909 In depending on relay function 85 relay ground splice 3 leads together connect to chassis ground 30 BNE from starter terminal splice 3 leads together use wow excess 916 wire trimmed from solenoid installation 87 relay out to headlight Lo beam Hi beam and Fan 87a remove or insulate terminal which is hot when lights etc are Off May arc to ground otherwise 12 E Complete Engine Section wiring to lights horn etc The Pa
5. U 937 276 1661 BLU 938 Diode Hazard Switch The factory hazard switch cannot be used You must obtain a 2 or 3 pole single throw switch The switch can have internal 12 VDC illumination if you wish This illumination source would connect to BRN 930 Pick a 2 pole switch if you don t require a separate hazard warning indicator the turn signal indicator will flash with hazard ON For external indication like the factory wiring use a 3 pole switch with the third pole to Indicator 59 right side location on the panel Wire per diagram below gt 17 Hazard Switch for Fiat Spider Switch 3 Pole Single Throw On Off Radio Shack 900 6562 Allied HK254 73 to Fiat indicator 59 Splice to LT BLU wire 926 Splice to BLU wire 925 or omit if desired at column at column left front turn right front turn I used a non illuminated 2 pole DPST rocker switch epoxied into the Fiat bezel then filled with body filler and painted texture black This is a popular switch with 22 x 27mm body and 22 x 30mm cutout 18 19 Brake Switch E Wire ORN 917 and WHT 918 to the two terminals on the brake switch Route and secure wires to avoid interference with the steering wheel or pedals Radio If your car has a radio wired RED 940 to B unswitched constant to the appropriate wire on your radio to maintain clock station presets etc RED BLK 941 is B switched Either of these can also be used to power your c
6. d hazard flashers until the installation is complete Note the damaged one in the photo above L Ground BLK 961 leading from the fuse block Pass engine compartment bundle thru Fiat firewall grommet It is the perfect size for the Painless harness Add two 18 ga wires to this bundle Use two different colors Label them with masking tape on each end oil fail on one wire and brake fail on the other These wires must be long enough to reach from their respective senders to the instrument panel Make sure you have plenty of slack Create another bundle of wires for the windshield wiper and washer Two wires for the washer five for the wiper They must reach from the wiper and washer motors across the firewall thru the grommet and into the cluster area You can cut the connector from the wiper factory wiring or attach your bundle directly to the wiper motor Label both ends of each wire as follows Windshield Wiper Washer Fiat Mine Function washer washer GRY BLK BLU 905 wiper B GRY wiper Lo BLU wiper Hi BLU BLK Wiper park BLK wiper ground BLU WHT not used Note in Mine column above the colors of the wires you ve used for this bundle so that you or the next owner can troubleshoot if necessary In this new configuration wiper stalk Up is Off first click down is Lo and second click Bottom position is Hi E Attach one 276 1661 dio
7. de from Park to Lo with the stripe facing Lo Do this in the interior of the car not under the cowl Wiper Schematic Yes BLU 905 does connect to both the wiper motor and stalk Power is required at the motor to run the Park circuit to the bottom of the stroke In the firewall trough with this bundle go the following WHT 914 alternator exciter to alternator FastOn connector The instrument cluster charge lamp is spliced into this wire See p 15 RED 915 alternator to alternator output post GRN 921 water temperature sender PUR WHT 923 tachometer source to coil PNK 920 coil You need not fabricate and install High Output Wire described on Painless Page 7 and elsewhere While routing the Painless bundles and your added wires observe the hood release and emergency hood release Don t obstruct or hinder their operation Route wiring around the left footwell vent as shown L Modify handle on previously removed footwell vent to clear new panel Do not re install vent at this time Ignition Switch Wire the ignition switch as follows The Fiat switch duplicates several terminals Use any properly labeled terminal Take care in routing this bundle from the fuse panel to the cluster area Do not impede steering wheel movement or permit chafing of any wires If you wish to install a starter safety switch see next page Ignition Switch Painless Fiat P
8. ican car headlights work without the ignition key etc The reduced load on your ignition switch will add reliability in the years ahead Subject car is a 1973 Spider with a 65A Bosch alternator and integral voltage regulator The original equipment 42A Marelli alternator is marginal and if yours has unsatisfactory output replace with the 55 or 65A Bosch I chose the Painless 10102 Universal Street Rod harness which has 12 circuits more than enough for the Spider particularly when you consider that four of the Spider s nine are devoted to the headlights alone This harness does have a few deficiencies when used in this application It does not support emission equipment key or seatbelt buzzer or e Backup lights e Electric fuel pump e Oil pressure failure lamp e Hydraulic failure handbrake On lamp Windshield wiper and washer are supported by providing a single power feed no switch or motor wiring is provided Before beginning the project download a copy of the Painless installation instructions at http www painlessperformance com Manuals 10102 pdf to familiarize yourself with the procedure Don t be intimidated by Sections 7 8 and 9 they are not applicable to the Fiat installation The items you will refer to most often are pages 1 5 Figure 10 7B Table 11 2 and pages 30 31 In addition to the items recommended by Painless you will need the following tools and materials e Ratchet crimper e Automatic wire st
9. igarette lighter depending on whether you want constant or switched power to this outlet Horn The Spider horn contacts have polarity Examine the steering column switch assembly The contact nub closest to the axle is which goes to BLK 953 the other Accessories Wire the heater fan courtesy lamp and other accessories to ORN BLK 955 Testing Power your car only from the battery charger while you test individual circuits per the Painless manual Pull the Coil fuse from the block so as to avoid burning the ignition points during prolonged testing The area of greatest uncertainty is the cluster so leave it out of its nacelle and clamshell covers off while you test wipers lights etc Don t forget to reattach the speedo cable before securing the cluster When reinstalling the column switch assemby slide the assembly toward you so that the turn signal defeat pin mates with the hole in the steering wheel slip ring Save these instructions for future reference and future owners 20
10. inless kit contains new headlight sockets use them I routed the right side lighting in a bundle tie wrapped to the front valence An alternate is to go rearward from the relays across the firewall trough and up the right side Grounding Many Fiat electrical difficulties arise from faulty grounds While you rewire your car take care to provide adequate electrical grounds in multiple locations visible to yourself and future owners Inspect and repair if necessary the engine to body ground cable Tail Section E Add one 16 ga and one 18 ga wire to the tail section bundle Label both ends Lo Fuel 18 ga and Backup Lights 16 ga Fuel wire should reach from cluster area to fuel tank backup lamps are attached to a switch in the transmission There are two transmission switches one for emissions and one reverse switch Consult a service manual for switch identification for your model year PNK 939 fuel sender goes to the forward terminal on the tank Your Lo Fuel wire goes to the rearward terminal Both stop lamps are powered by ORN 950 Ensure a good electrical connection to individual lamps by brushing their terminals with a brass toothbrush You might as well replace all these bulbs too Clean sockets thoroughly with sandpaper and brass toothbrush Apply a film of lamp grease on both the bulb and socket as well as terminals Inspect and repair or replace if necessary the black ground harness on each tail lamp as
11. ion Observe the charge lamp during your daily startup procedure WHT 914 WHT 914 Alternator 15 Headlight Dimmer Switch Test Car Function Painless My Car BLU GRY RED B BLU YEL 907 GRN2 Lo beam TAN 909 GRN2 Hi beam Lt GRN 908 Splice the intermediate harness to the Painless cluster wires Before cutting any wires plug in the intermediate harness to the instruments to avoid cutting the wrong end Notice the wiring colors often change from the intermediate harness to individual instruments Label with Painless numbers the freshly cut intermediate harness wires Then detach from the cluster and wire the car You will find that there are significantly fewer wires with your new installation plus these wires are smaller diameter and much more flexible than those you ve removed This will allow you to provide a little more slack to this assembly making subsequent relamping a lot easier Cut and cap unused wires from the column switch assembly and intermediate harness same color different circuits Note this harness does not support flash to pass momentary Hi beam stalk up for Lo beam down for Hi beam headlight 16 Turn Signal Indicator Your Fiat uses one indicator serving both right and left lamp sets Wire this indicator as follows a an Indicator Bulb Stripe Points Towards Indicator Bulb Left Turn Right Turn Signal Wire Radio Shack Signal Wire Lt BL
12. leaning the glass faces You might as well replace all 14 lamps at this time too c Remove the steering column switch assemble by loosening the one band nut and pulling the assembly toward you Note the assembly is keyed and will only seat properly in one orientation You now must decide if you wish to retain two failure prone factory items on your car intermittent wipers and panel lamp dimmer My car is a fair weather item so I don t need the former I ve also re lamped and cleaned my instruments and without the dimmer my cluster illumination is just right These instructions assume you re scrapping these two items If you re keeping them adjust accordingly Prepare the Painless Harness Unwrap the harness and separate the three main bundles engine cockpit and tail Notice the exceptional length of this harness It fits full size American cars twice the size of your roadster Resist the temptation to shorten any of the three bundles at this time E Remove BLU WHT 902 from engine section cut and cap near fuse block Capping wire neatly can be accomplished with a short section of heat shrink tubing allow 1 4 of tubing to extend beyond the wire then pinch it while hot LJ Move ORN 917 and WHT 918 from the engine bundle and loosely associate it with cockpit bundle i Remove RED 954 from engine section unless you re already converted to an electric choke carb Cap and coil under driver s carpet for la
13. ripper e Low voltage power supply e VOM e Bulb grease e Brass toothbrush e 2or3 pole single throw switch hazard e Double pole triple throw toggle switch headlight e 3 pcs Radio Shack diode p n 276 1661 e 3 pcs Tyco relay p n V23234 A1001 X036 e adhesive lined heat shrink tubing e heat gun e additional red blue and yellow terminals e additional 16 and 18 ga wire e wheel puller e 24mm socket Wiring Basics Because all of the terminations in your new wiring are crimp on it is imperative that you employ the proper tools and techniques Do not use a pliers type crimping tool these can over or under crimp the connector Obtain a ratcheting crimper such as this one Look for red blue and yellow dies on the tool you will need all three Make a few practice crimps on scrap wire to familiarize yourself with the tool To crimp squeeze the tool handles until they release and pop open Only then have you applied the proper crimping force To abort a crimp release the handles with the small lever on the inside of the handle Stripping modern TXL insulated wire is best performed with a stripper such as this one You must remove the tough insulation without nicking the copper wire strands Pliers type strippers should not be used While not absolutely necessary I strongly recommend that you fortify each and every termination and splice with adhesive lined heat shrink tubing available from McMaster Carr and others Part number
14. sembly Headlight Switch This harness uses a double pole triple throw DP3T switch You cannot use the Fiat switch with this harness I found it difficult to find an OFF ON ON configuration but several manufacturers make an ON ON ON type Simply don t use the first set of contacts and cap them off by pushing empty FastOn connectors onto them You don t need a monster switch here as all the large headlight current is handled by relays 5A 28VDC rating is sufficient One terminal pair is active when parking lights are selected and these terminals are maintained when the second pair headlamps is selected Here is one switch source http shop willyselectronics com browse cfm 4 4898 html Use your VOM to determine the terminal locations and switch orientation Remember that Up in Fiats is Off Wire switch as follows Instrument Panel Before beginning this final section you must discern the color code for your car s cluster and column switch assembly Use a wall wart or similar low power DC power supply and VOM to fill in the table below Do this in a clean well lit area seated comfortably not squatting on the garage floor Test car s info is shown for reference but you must perform this step on yours too Cross out the Test Car info when finished so you don t use this data by mistake Take your time errors here Headlight Switch Painless Function RED BLK 928 input bridge two
15. ter use by you or the next owner LJ Go to Page 27 of the Painless manual Draw a line thru the following wires they are unused or not included in this kit 902 903 910 911 912 913 942 943 944 946 947 956 957 and 958 E Re label BLK WHT 904 fuel pump if your car is equipped with an electric fuel pump Join with tail section bundle Cut and cap otherwise LJ Remove the Fiat fuse block relays and all wiring Do not discard or cut the Fiat intermediate cluster harness or any of the wires on the instrument column switch assembly Observe the hood release emergency hood release and other items throughout the car which are not wires don t cut them Save and reuse sender boots 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 L Install your new fuse panel in the space vacated by the old I shortened the two top mounting posts on the new panel and bent slightly forward the metal dash flange to mount the Painless panel You may find it helpful to jack up the side of the car you re working on your back will thank you at the end of the day Be sure to use jack stands wheel chocks and other appropriate safety measures Don t install the fragile turn signal an
16. terminals input BRN 927 929 930 parking tail lights instrument lamps BLU YEL 907 head lights can take many hours to troubleshoot and correct Wiper Washer Switch Test Car Function Painless My Car BLU washer BLU 905 BRN washer not provided YEL BLK wiper common BLU 905 RED wiper Lo not provided GRY wiper Hi not provided 14 Instrument Cluster Test Car Function Painless My Car GRY YEL oil sender Lt BLU BLK 922 GRY oil fail none add BLU BLK charge lamp el ea PUR BLK charge lamp ae re WHT PNK inst lighting BRN 930 YEL RED lights on BRN 930 BLU WHT turn indicator see p 17 WHT BLK inst ground BLK 961 YEL BLK inst power ORN BLK 955 GRY RED low fuel none add BLU YEL fuel sender PNK 939 GRN WHT water sender Lt GRN 921 GRY WHT tach sender PUR WHT 923 Charge Lamp Circuit Fuse Panel When the ignition key is On and the alternator is not charging current flows from the fuse panel to the excitor terminal on the alternator which is grounded in this state The charge lamp illuminates When the alternator has sufficient output the voltages present at the fuse panel and alternator are nearly equal so no current flows thru the lamp Ifthe Charge Lamp bulb is missing or defective the circuit is broken and the alternator will not charge nor will you have any indication of this malfunct
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