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2003 2004 2005 Cummins Diesel Engine Harness 5.9L - Manual Transmission Only By Painless Performance

P/N 60250

2003 2004 2005 Cummins Diesel Engine Harness 5.9L - Manual Transmission Only

       
 

  • Application
  • Specs
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Year: 2003 - 2005
Make: Dodge
Model: 2500HD or 3500HD
Engine: 5.9L CRD Cummins
Trans.: Manual Transmission Only
American Made

 

Take a look at just some of the great features we have designed into the 60250 harness.

 

 

The first aftermarket harness to facilitate the transplant of a Cummins diesel engine, this harness will fit 2003 - 2005 5.9L common rail diesel Cummins engines using standard transmissions.  Professionally manufactured by Painless Performance with all new components that meet factory specifications for durability and performance this harness is the product of an 18 year tradition of Painless ingenuity.

 

Created with a rugged Bussman weatherproof electrical center at its heart, this harness is ready for the harsh environment of a diesel engine compartment.  Integral fuse block circuits include 40 amp relays for fuel pump, fuel heater and ignition circuits.  B+ and ignition circuits are short circuit protected by the 10 mini ATC fuses.

 

 

 

Built with pneumatically crimped, gold plated terminals for a positive connection between the PCM and all of the engine sensors. 

 

Internal harness wire splices are pneumatically crimped and then sealed with weather proof heat shrink.

  

Extra 20 amp fused output wire included to power anything from a CB radio to a ColdShot water methanol injection system.

 

Connectors included for all three styles of accelerator pedal position sensors.  These three types being; 2003 bell crank mounted to the front of the intake manifold, 2004 APPS factory mounted under the driver side battery tray and 2005 APPS mounted to the accelerator pedal inside the cab.

 

Have a bad sensor; find out which one is causing your problem by retrieving diagnostic trouble codes and live engine data through using the OBD2 connector that is wired into the harness.  You will notice we don't have a check engine light attached to the OBD2 connector pictured to the right.  Chrysler builds their late model trucks with a digitally controlled check engine light.  The ECM does not have a driver to turn a light on.  Instead, it communicates serially to the instrument cluster control module which controls the check engine light.

 

 

 

Got a 2003-4 Cummins and ECM but want to run an aftermarket lift pump; no problem.  The 60250 harness gives you the ability to operate a 40 amp relay (pre-mounted and wired into the fuse block) with a 2003-4 fuel pump drive circuit from your ECM.  It is as simple as swapping one inline connector to the next.  See picture below.

We recommend checking the online manual for the full list of required mating parts prior to ordering.  

 

Number of Circuits: 10 Fuses with 2 Ignition, 1 Fuel Heater & 1 Accessory Relay
Harness Length: 4 Feet Between Engine and ECM
Fuse Type: Mini Blade
Firewall Passthrough: Grommet
Color Code Based: 2005 2500HD Dodge Truck
Circuit Designations: Printed Wire Tags on all Connectors and Open Ended Wires

You will need the following components in addition to this harness for a successful installation:

1. ECM- This must be a factory ECM flashed for a manual transmission.  This harness only fits ECMs from 2003-2005 Dodge trucks with the 5.9L Cummins engine.
2. IAT heater relays- This harness provides ECM output wires in order to turn on factory style IAT heater relays.  You must purchase these relays or get them from a salvaged vehicle.  
3. APPS- This harness supports the 2003 early Accelerator Pedal Position Sensor that was mounted on the front of the engine to the intake, the 2004 APPS mounted under the battery box and the 2005 late model Accelerator Pedal Position Sensor that was mounted on the accelerator pedal.  You must use which ever APPS your ECM is programmed for.  All APPS units are available from your local Chrysler dealer.
4. CTS- This harness only supports the late model style coolant temperature sensor.  
5. LIFT PUMP- There are several options when choosing a lift pump.  This harness provides a 30 amp power wire.  It is relayed and ECM controlled.
A.      Use a factory style lift pump; this may be a good budget minded option if this Cummins motor is transplanted into a vehicle that already had a diesel engine.  Be sure to check volume and pressure from your factory lift pump if going with this option.
B.      2003-2004.5 Cummins engines had lift pumps mounted to the back of the fuel filter/water separator.  
C.      Use an aftermarket lift pump.
6. RADIATOR FAN DRIVE- This is factory mounted to the fan shroud and controls the speed of the mechanical radiator cooling fan.  This part can be taken from the donor vehicle or purchased new.  If you may also choose to use aftermarket radiator fans.
7. VSS SIGNAL WIRE- This wire needs to receive a 5 Volt square wave signal from an ABS module or VSS signal modification module. 

 

The Fuse Block Protects The Following Circuits:

  • Accessory
  • DLC B+
  • ECM B+
  • ECM B+
  • ECM B+
  • ECM Key-On
  • Fuel Heater
  • Fuel Pump
  • Ign Key-On
  • Wastegate & Fan
  • 40 Amp Fuel Pump Relay
  • 40 Amp Fuel Heater Relay
  • 40 Amp Ignition Relays

 

 

This harness includes connections for the following components:

  • 20 Amp Output
  • 2003 - 2004 Fuel Pressure Drive
  • 2005 Fuel Pressure Drive
  • Accelerator Pedal Position Sensor
  • Alternator Regulator
  • APPS 2004
  • APPS Early
  • APPS Late
  • Battery
  • Battery Temperature
  • Brake Switch #1
  • Brake Switch #2
  • Camshaft Position Sensor
  • Coolant Temperature Sensor
  • Crankshaft Position Sensor
  • Cruise Control
  • CTS Early Signal
  • CTS Late Signal
  • CTS Signal
  • Data Link Connector 
  • ECM
  • Fuel Control Acutator
  • Fuel Heater
  • Fuel Pressure Relay
  • Fuel Pump
  • Fuel Rail Pressure
  • Harness 12v Activation
  • IAT Heater Relay Activation #1
  • IAT Heater Relay Activation #2
  • Injectors
  • MAP / Intake Air Temperature
  • Oil Pressure
  • Park/Neutral Safety Switch
  • Pre-Turbo IAT/Pressure
  • Radiator Fan Drive
  • VSS Signal
  • Wastegate Control Solenoid
  • Water-In-Fuel Sensor

 

 2003 2004 2005 Cummins Diesel Engine Harness 5.9L - Manual Transmission Only By Painless Performance

 

 

ECM Flash Program

 

 

This is a basic start and run tune that we only recommend for a near stock application. We will only change the following parameters: delete VATS/PASS-KEY security, cooling fan on/off temperatures, rear end gear ratio, tire size, speed limiter, rpm limiter, idle rpm, and we will adjust the check engine light parameters. If your setup requires any other parameters tuned you will need to locate a local tuner. All ECMs are left unlocked to allow easy access for your tuner.

Step 1: Purchase one of the qualifying part numbers. See below for that list.


Step 2: If your part number is highlighted RED proceed to step 3B. If your part number is highlighted BLACK, proceed to step 3A.


Step 3A: If you have arrived at this step, your harness does not come with an ECM and you must provide one to be flashed. Please reference the manual with your harness to confirm the ECM part number required.


Step 4A: Once you have received your harness, please cut the Barcode label from the box as shown in the picture below.


Step 5A: Package and mail your ECM along with the Barcode label, a copy of your purchase receipt, and your ECM form that you are about to complete. (The address will be provided after you complete the form). We will pay for return ground shipping*. If you request a faster service, you will need to provide a return label.


Step 3B: If you have arrived at this step, your purchase comes with an ECM. You must fill out our ECM form BEFORE your purchase will ship. Proceed to Step 6.


Step 6: Click the “Start Here” button below to fill out our ECM questionnaire.


Step 7: Once we have the ECM, we will use the data from the form to flash the ECM. Then, once it has been flashed we will package the ECM and ship it back to you. If we encounter a question, we will contact you. This process can take 1-3 days.


Step 8: Once you receive your ECM, it is ready to go.

 

*Note: Our free return shipping is ONLY good for the lower 48 states, via ground UPS. If you are outside of those states, you must provide a return shipping label with your order. If your purchase comes with an ECM, the shipping will be covered via the retailer you purchased from.

 

 

Click the Start Here button below to get your FREE ECM Flash!

Click Here To Start The ECM Reflash Process

 

End Panel


APPLICABLE PAINLESS PART NUMBERS

60008

   

60522

60009

   

60523

60017

   

60524

60026

   

60526

60217

   

60608

60218

   

60617

60221

   

60700

60508

   

60701

60509

   

60702

60520

   

60710