I have an '04 LLY, with 180K mi. that has been great except for a couple hiccups. I had to replace the 2 connectors at both far ends of the harness due to lack of strain relief, and repeated discontinuity. I bought replacement connectors, which had longer wires, and after installing them, (soldered & shrink tubed), I thought that would be the end of the problem. It has been several years since I did this, and the truck has run flawlessly, until this past weekend. The truck went into "safe mode" while I was in the middle of nowhere, and I limped it into my destination, (many hours later than planned). When I put the code reader on it, it gave me a 0201 fault, (#1 fuel injector). I did my best to make sure that it was connected, cleared the fault, and it was fine for about 20 miles on the return trip, before going into "safe mode" again. My question is what is the best fix for this? Does someone make an aftermarket fuel injector wiring hardess? I would like to replace them all so that I don't have this problem recur.

Double check the fit bit happened to run across a you tube video on the subject. Don’t remember who did it though.


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While #2 and #7 are notorious, it's the same connector on all cylinders, so any of them can go bad (i.e., loosen for a bad connection). Looks like #1 for you now. I would just replace that one for now. You can replace all of them, although some are very hard to get to. Unless you have other harness issues (usually rub-throughs), I wouldn't replace it.

I used the cheap knock-offs over 4 years ago (4 for $16 back then, but I see they're now 8 for $16 but I don't if they're the same), from Amazon. I only did #2 and #7 and they're still good. My day for others may come.

 

Thanks for the info Jake. I had previously replaced #2 & #7, with the lower cost straight plugs. The issue with them seemed to be that there was a strain on them which eventually caused a disconnect. The replacements came with longer wires, which enabled me to give them some slack. Unfortunately now #1 is the problem and I'm guessing #8 will be next. I guess I'll replace both of them. They should have been engineered with right angle plugs, like those that come with the expensive "fix" kit for upwards of $300. GM still says that there is no recall, or service letter for this debacle, yet they sell the kit to fix it! It's all about the $$$!

 

I might add that I soldered 2-way connectors to the harness, and then made a bunch of pigtails with a 2-way on one end and an injector connector on the other. I keep the spare pigtails under the back seat. The idea is that if a connector goes bad, I can just pop off the old pigtail and plug in a new one. For some reason, Amazon calls the 2-way connectors "Workman TP-2 CB Radio Polarized Quick Disconnect 2 pin 12" 16 Gauge". I also zip-tied the wires in an attempt to provide strain relief.

And of course, I won't leave home without an OBDII scanner so I can tell which connector goes bad, although this hasn't happened.

 

My pigtails...