H
C
D
E
G
sheet 1
Classic Update Series
F
J
K
L
510575
92970865 Rev 1.0 2/6/2018
Classic Update Series
ENGINE KIT
J
bag
1976-86 JEEP CJ
M
P
Q
N
www.americanautowire.com 856-933-0801
(56 series single female connector, w/notch, 2 pcs.)
(56 series single female connector, w/lock wedge, 10 pcs.)
(56 series single male connector, 4 pcs.)
(56 series 2-way female connector, w/notches, 1 pc.)
(56 series single female HEI tach connector, 1 pc.)
(56 series single female HEI power connector, 1 pc.)
(small ring terminal for smaller gauge wire, 5 pcs.)
(small ring terminal for larger gauge wire, 2 pcs.)
(small rubber sleeve, 5 pcs.)
(large rubber sleeve, 2 pcs.)
(smaller 56 series single female terminal, 11 pcs.)
(smaller 56 series double female terminal, 7 pcs.)
(56 series single male terminal, 6 pcs.)
400
401
402
300
121
55
52
24
4
40
VSS POWER
VSS POWER
VSS POWER
ELECTRIC FAN ELECTRIC FAN ELECTRIC FAN
12V BATTERY-FUSED 12V BATTERY-FUSED 12V BATTERY-FUSED
HEAT / AIR HEAT / AIR HEAT / AIR
BACK UP LT SW --> LIGHTS BACK UP LT SW --> LIGHTS BACK UP LT SW --> LIGHTS
ALTERNATOR IGN ALTERNATOR IGN ALTERNATOR IGN
COIL --> TACH COIL --> TACH COIL --> TACH
12 V IGNITION 12 V IGNITION 12 V IGNITION
VSS SIGNAL
VSS GROUND
VSS SIGNAL
VSS GROUND
ELECTRIC CHOKEELECTRIC CHOKEELECTRIC CHOKE
39
39A
7
155
Starter Solenoid Ground Wire
Starter Solenoid Resistor Bypass Wire
STARTER SOLENOID-R
STARTER SOLENOID-R
STARTER SOLENOID-R
2F
GM “SI” Alternator Exciter Wiring Assembly
Loose Wires for Bulkhead Connector
Wiring Assemblies
Starter Solenoid Wires
Parts to be used, during Engine Harness Install
131X
4wd Light Jumper Harness
Starter Solenoid
(front view)
1980-86 -
plug wire 155, onto
terminal on back
of Starter Solenoid
(Auto Trans only)
1-wire
alternator
non-HEI
distributor
HEI
distributor
temp
sender
“BAT”
output stud,
to starter
“BAT” stud
(positive cable
attaches here also)
ballast
resistor
(resistor not included-
only used on selected
ignition systems)
oil sending
unit
1976-86 -
back-up
light switch
(manual trans)
see Figure “A”
1980-86 -
NSS/back-up
light switch
(auto trans)
see Figure “B”
optional connection
for points cars
starter solenoid ground wire
(auto trans only)
G
G
D
D
C
L
D
E
H
J
red
white
to BAT
location on coil
76-79 auto
trans kickdown
solenoid
hood
light
electric choke
see sheet 7
for electric
speedometer
connections
to TACH
location on coil
to coil + side
sheet 2
coil
yellow
apply silicone sealant
after installing terminals
white pink
to electric fan
(relay triggered)
alternator ignition wire
recommended fan relay
(not included in this kit)
brown
bulkhead connector
(mating end shown)
F
E
F
E
OR
P
K
S I
S I
402
N
E
E
M
G
G
OR
P
K
6
7
4
401
400
300
155
131
121
55
40
39A
35
2D
31
24
39
2B
3A
yellow
purple
orange/
black
dk
blue
orange
orange
dk green
dk blue
red
optional GM SI
alternator
E
2F
2B
2F
purple/white
lt green
pink
purple
pink
S I
black
All Except GM 2.5L w/Manual Transmission
tan
78-86 heater
blower motor
DG
52
orange
PART #
DESCRIPTION:
510575
1976-86 Jeep CJ
Classic Update Series
ENGINE KIT
pink
red
131X
4wd Light Jumper Harness 4wd
switch
black
relay
positive
battery
cable
(not included
with this kit)
shrink tube
shrink tube
MEGA
175A
LITTLEFUSE
MEGA
175A
LITTLEFUSE
shrink tube
6 GA. RED
(FROM 510476 KIT)
(BUSSBAR
JUMPER FROM
510476 KIT)
(Use the Mega Fuse, ring
terminals, boot and shrink
tubing from the 510476 kit.)
shrink tube
6 GA. RED
(FROM 510476 KIT)
92970865 Rev 1.0 2/6/2018
sheet 3
optional
1-wire
alternator
2B
Starter Solenoid
non-HEI
distributor
HEI
distributor
temp
sender
ballast
resistor
(resistor not included-
only used on selected
ignition systems)
oil sending
unit
back-up
light switch
(manual trans)
see Figure “A”
optional connection
for points cars
G
G
D
D
C
L
D
E
H
J
red
white
to BAT
location on coil 78-86 heater
blower motor
electric choke
see sheet 7
for electric
speedometer
connections
to TACH
location on coil
to coil + side
coil
yellow
apply silicone sealant
after installing terminals
white pink
alternator ignition wire
brown
bulkhead connector
(mating end shown)
F
E
F
E
OR
P
K
402
D
E
G
G
OR
P
K
6
7
4
401
400
300
121
52
39A
35
2D
31
24
39
3A
yellow
purple
dk
blue
orange
orange
dk green
dk blue
red
GM SI
alternator
E
2F
2B
2F
purple/white
lt green
pink
purple
pink
GM 2.5L w/Manual Transmission
tan
PART #
DESCRIPTION:
510575
1976-86 Jeep CJ
Classic Update Series
ENGINE KIT
BAT
RS
pink
red
hood
light
NM
40
orange
4wd
switch
EG
131
131X
4wd Light Jumper Harness
black
to electric fan
(relay triggered)
recommended fan relay
(not included in this kit)
relay
shrink tube
shrink tube
MEGA
175A
LITTLEFUSE
MEGA
175A
LITTLEFUSE
shrink tube
6 GA. RED
(FROM 510476 KIT)
(BUSSBAR
JUMPER FROM
510476 KIT)
(Use the Mega Fuse, ring
terminals, boot and shrink
tubing from the 510476 kit.)
shrink tube
positive
battery
cable
(not included
with this kit)
6 GA. RED
(FROM 510476 KIT)
92970865 Rev 1.0 2/6/2018
sheet 4
PART #
DESCRIPTION:
510575
1976-86 Jeep CJ
Classic Update Series
ENGINE KIT
Be sure that the Engine Harness 20-way Bulkhead Connector is in position near the Dash Harness Firewall Connector before routing and cutting of any wires. See the Front Light Kit Instructions for connecting the Bulkhead Connectors together.
Wire Color Printing Description
1. Hood Light
Orange 12V BATTERY-FUSED If you have a Hood Light, obtain the loose orange “12V BATTERY-FUSED) wire (circuit 40), see sheet 1, and plug it into the Bulkhead connector, as shown on sheets 2 or 3. Route the loose end of the wire to the Hood Light, cut to length,
crimp on terminal “N”, insert into connector “M”, and connect to your Hood Light.
2. Heater Blower Motor
Orange HEAT/AIR If you have a 1976-77 vehicle, the Heater Blower Motor is inside the vehicle (see the Dash Harness Instructions for connections).
For the 1978-86 vehicles, obtain the loose orange “HEAT/AIR” wire (circuit 52) and plug it into the Bulkhead connector (see sheet 2 or 3 for location). Route the loose end of the wire to the Heater Blower Motor, cut to length, install
terminal “D” and insert into connector “G”. Attach the connector directly to the Heater Blower Motor.
3. 4WD Switch
Black no printing Obtain the “4WD Light Jumper Harness” (circuit 131X) and attach the molded connector to the 4WD Switch which is attached to the Transfer Case.
Dark Blue no printing Obtain the dark blue wire (circuit 131) which is already plugged into the Bulkhead connector and route this wire to the “4WD Light Jumper Harness”. Cut to length, crimp on terminal “E”, and insert into connector “G”. Connect this wire to
the “4WD Light Jumper Harness”.
4. Back-up Lights – Manual Transmission (see Figure “A” on sheet 6)
Pink 12V Ignition
Light Green Back UP LT SW --> LIGHTS The Back-up Light Switch is located on the transmission. Obtain the loose pink “12V IGNITION” wire (circuit 39) and the loose light green “BACK UP LT SW --> LIGHTS” wire (circuit 24) and plug into the Bulkhead connector (see sheets 2
or 3). Now route these wires to the Back-up Light Switch (See photos #1 and #2, on sheet 6) and cut to length.
Manual Transmission Figure “A” Option I Slide a sleeve “K” over the pink and light green wires, crimp on a ring terminal “P” to each wire, and slide the sleeve “K” onto the ring terminal “P”. Attach the two ring terminals to the Backup Light Switch, polarity does not matter.
Manual Transmission Figure “A” Option II Crimp on terminal “E” to the pink and light green wires and insert into connector “Q”, polarity does not matter. Now connect to the Backup Light Switch.
Manual Transmission Figure “A” Option III Obtain a 2-wire Aftermarket Jumper Harness (not included in this kit) available for this Backup Light Switch and crimp on a terminal “N” to each wire of the Jumper Harness and insert into connector “M”. Crimp on terminals “E” to the pink
and light green wires from the Engine Kit and insert into connector “G”. Now you can connect both connectors “G” to the Jumper harness.
5. Backup Lights/Neutral Safety Switch – Automatic Transmission (see Figure “B” on sheet 6)
Pink 12V Ignition
Light Green Back UP LT SW --> LIGHTS
Black no printing For the 1976-79 vehicles with an Automatic Transmission, the Back-up Light/Neutral Safety Switch is located on the Steering Column (see the Dash Harness instructions (510574) for this connection).
For the 1980-86 vehicles, the 3-pin Backup Light/Neutral Safety Switch is located on the transmission. Obtain the loose black no printing “Starter Solenoid Ground Wire” (circuit 155). This wire will provide ground for the Starter Solenoid during crank. The center pin of the Backup
Light/Neutral Safety Switch goes to ground in Park or Neutral. Attach the female bullet end of the black (circuit 155) wire to the back of the Starter Solenoid (see sheet 2). Route the loose end of the black wire to the 3-pin Backup Light/Neutral Safety Switch on the Automatic Transmission.
Obtain a 3-wire Aftermarket Jumper Harness (not included in this kit) available for this Backup Light/Neutral Safety Switch, crimp on three terminal “N’s” to each wire of the Jumper Harness and insert each terminal into a connector “M”, (see Figure “B” on sheet 6). Crimp on terminals “E”
to the light green (circuit 24), black (circuit 155), and pink (circuit 39) wires from the Engine Kit and insert each into a connector “G”. Now connect all three connectors “G” to the Jumper Harness (See photo #3, on sheet 6). Note: the black wire (circuit 155) from the Engine Kit must be
connected to the center pin of the Backup Light Switch.
6. Auto Trans Kick Down Solenoid
Orange/Black no printing For the 1976-79 Automatic Transmission vehicles, there is a Kick-Down Solenoid located near the valve body of the Automatic Transmission. Obtain the loose orange/black stripe no printing wire (circuit 55) and plug this wire into the
Bulkhead connector (see sheet 2). Route this wire to the Automatic Transmission (near the valve body) and connect to the Automatic Transmission Kick-Down Detent Solenoid. Use the original wiring connector, for this connection.
7. Main Fuse Panel Feed
Red 12V BATTERY Route this wire from the Engine Harness to the MegaFuse supplied with the 510476 kit and cut to length, apply ring terminal, and shrink tubing and connect as shown on
pages 2 and 3.
8. Coil Power
Pink IGNITION FEED For an HEI Distributor equipped vehicle, obtain the large pink “Ignition Feed” wire (circuit 3A) which is already plugged into the Bulkhead connector, and route this wire to the
battery terminal of the HEI Distributor, cut to length, install terminal “D” and insert into connector “J”. Connect to the distributor.
92970865 Rev 1.0 2/6/2018
sheet 5
PART #
DESCRIPTION:
510575
1976-86 Jeep CJ
Classic Update Series
ENGINE KIT
Wire Color Printing Description
For Prestolite BID Systems, route this pink wire directly to the “+” side of the coil and connect.
For Aftermarket Systems, such as MSD, Accel, etc. connect per the manufacturers recommendations.
For a vehicle that requires resistance in the feed to the Ignition Coil (such as a Duraspark or points-type Ignition System) route this wire to the Ballast Resistor (not provided in this kit). Crimp on terminal “D” and insert into connector “G”. You can now connect to the Ballast Resistor, polarity
does not matter.
9. Resistor Bypass
Yellow STARTER SOLENOID-R
Pink IGNITION FEED (cutoff portion) The yellow Starter Solenoid Resistor Bypass Wire is provided if you are using an Ignition System with a Ballast Resistor. Obtain the loose yellow “STARTER SOLENOID – R’ wire (circuit 7). Connect the ring terminal to the “I”
terminal of your Starter Solenoid, see sheet 2, or the “R” terminal of your Starter Solenoid, see sheet 3 (for the GM 2.5L vehicles). Route the other end of the yellow wire to the Ballast Resistor, cut to length. Obtain the cutoff
section of the large pink “Ignition Feed” wire (circuit 3A from step 8) and double it with the yellow wire (circuit 7) and crimp on terminal “D” and insert into connector “G”. You can now connect this connector “G” to the Ballast
Resistor. The other end of the large pink wire can be routed and connected to the (+) side of your Ignition Coil (see sheets 2 or 3).
10. Starter Solenoid
Purple STARTER SOLENOID-S Obtain the large purple “STARTER SOLENOID – S” wire (circuit 6). This wire is already plugged into the Bulkhead connector. Route to the Starter Solenoid, cut to length, slide sleeve “L” onto the wire, install ring terminal “C”. Slide
sleeve “L” over the terminal and attach to the Starter Solenoid’s “S” terminal (see sheet 2 or 3).
11. Alternator Output Power
Red no printing Use the 6ga red wire, MegaFuse, ring terminals, and shrink tubing from the 510476 kit. Route 6ga red wire from MegaFuse to the alternator and cut to length, apply ring terminal and connect as shown on pages 2 and 3.
12. Alternator Regulator
Brown ALTERNATOR IGN If you have a GM “SI” Alternator, plug the loose brown “ALTERNATOR IGN” wire (circuit 4) into the Bulkhead connector as shown on sheet 2 or 3. Route the other end of the wire to the GM “SI” Alternator, cut to length and install
terminal “E”. Insert the brown wire (circuit 4) into the 2-way white connector of the “GM “SI” Alternator Exciter Wiring” jumper harness next to the red wire that is already in the white connector. Now plug this white connector into
the Alternator.
13. Electric Choke
Tan ELECTRIC CHOKE For vehicles equipped with an Electric Choke, obtain the loose tan “ELECTRIC CHOKE” wire (circuit 39A) and plug it into the Bulkhead connector. Route the other end of the wire to the Electric Choke, cut to length, install terminal
“E” and insert into connector “G”. You can now connect to the Electric Choke.
14. Water Temp Sender
Dark Green WATER TEMP SENDER Obtain the dark green “WATER TEMP SENDER” WIRE (circuit 35) which is already plugged into the Bulkhead connector. Route this wire to the Water Temperature Sender, cut to length, install terminals “E” or “P” (install sleeve
“K” first if using terminal “P”), plug into connector “F” (if using terminal “E”) and connect to the Water Temperature Sender (see sheet 2 or 3).
15. Oil Pressure Sender
Dark Blue OIL PRESSURE SENDER Obtain the dark blue “OIL PRESSURE SENDER” wire (circuit 31) which is already plugged into the Bulkhead connector. Route this wire to the Oil Pressure Sender, cut to length, install terminals “E” or “P” (install sleeve “K” first if
using terminal “P”), plug into connector “F” (if using terminal “E”) and connect to the Oil Pressure Sender (see sheet 2 or 3).
16. Tachometer Signal
White COIL --> TACH NOTE: This kit does not support the use of an original factory Tachometer (see the Warning Page).
If you wish to use an aftermarket Tachometer or have your original Tachometer reconfigured: Obtain the loose white “COIL --> TACH” wire (circuit 121) and plug into the Bulkhead connector, as shown, on sheets 2 or 3.
Route the other end of the wire to the negative (-) side of the Ignition Coil or to an aftermarket Ignition Module and connect. See the aftermarket Ignition Module Manufacturer’s recommendations for connection.
If you have an HEI Distributor: Route the loose end of circuit 121 to the HEI Distributor, cut to length, install terminal “E” and insert into connector “H”. This connector can now be installed into the TACH location of the HEI
Distributor (see sheets 2 or 3).
17. Electric Fan
Orange ELECTRIC FAN If you wish to add an Electric Cooling Fan to your vehicle, obtain the loose orange “ELECTRIC FAN” wire (circuit 300) and plug into the Bulkhead connector, as shown,
on sheets 2 or 3. This circuit is provided to feed the Ignition trigger wire of your Electric Fan Relay (not available with this kit). See the Electric Fan Manufacturers
recommendations for the relay electrical hook-up.
Note: Circuit 300 is a keyed hot feed.
92970865 Rev 1.0 2/6/2018
sheet 6
PART #
DESCRIPTION:
510575
Photo
#1
Photo
#2
Photo #3
Aftermarket Jumper Harness
Aftermarket
Jumper Harness
Engine wiring
Engine wiring
Engine wiring
Engine wiring
1976-86 Jeep CJ
Classic Update Series
ENGINE KIT
M
M
MN
N
G
G
E
E
E
E
E
Q
G N
M
M
N
G
E
EG N
K P
P
K
Back-up light
switch/neutral
safety switch
(A-904, A-999)
Back-up
light switch
(T18)
BACK UP LT SW --> LIGHTS
BACK UP LT SW --> LIGHTS
BACK UP
LT SW
--> LIGHTS
BACK UP
LT SW
--> LIGHTS
12V
IGNITION
12V IGNITION
24
brown/yellow
black
purple/black
black
pink
lt green
pink
lt green
12V
IGNITION pink
lt green
39
24
39
12V IGNITION pink
lt green
24
39
24
39
155
Back-up
light switch
(SR4, T4, T5)
Back-up
light switch
(T-170, T176,
T177)
Option I
Option II
Option III
black
purple
FIGURE “B”
1980-86
Back-up Light Switch/Neutral Safety Switch
Automatic Transmission
FIGURE “A”
1976-86
Back-up Light Switch
Manual Transmission
92970865 Rev 1.0 2/6/2018
(VSS Ground (-)
(VSS Signal)
(VSS Power)
NOTE: These wires should
be twisted for the entire length.
TYPICAL VEHICLE SPEED SENSOR CONNECTIONS
Below are some general instructions for hooking up a Vehicle Speed Sensor for an electric speedometer. These instruc-
tions will ONLY 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 you will not need to plug these wires into the
bulkhead. It is best to consult the speedometer manufacturer’s instructions if you have any questions.
Yellow VSS Ground Plug into bulkhead in the location shown below, route to VSS, cut to length
and connect to VSS neg. “--”.
Purple VSS Signal Plug into bulkhead in the location shown below, route to VSS, cut to length
and connect to VSS input.
Purple/ VSS Power Plug into bulkhead in the location shown below, route to VSS, cut to length
White and connect to 12V power on VSS.
402
401
400
yellow
purple
purple/white
bulkhead
connector
sheet 7
PART #
DESCRIPTION:
510575
1976-86 Jeep CJ
Classic Update Series
ENGINE KIT
92970865 Rev 1.0 2/6/2018
sheet 8
PART #
DESCRIPTION:
510575
1976-86 Jeep CJ
Classic Update Series
ENGINE KIT
THIS PAGE, INTENTIONALLY
LEFT BLANK.
92970865 Rev 1.0 2/6/2018
/
