Lets talk about the truck -

Year
Mods
Mileage


What failed? What cylinders?

More info please.

 

Lets talk about the truck -


Year 2005
Modsstock
Mileage47,000


What failed? injector harness
What cylinders? I don't remember the numbers (I'm thinking 1 and 6) but he said the one closest to the firewall on the right, and the one closest to the radiator on the left

More info please.

Thanks for your response

 

I just caught mine before the casing wore through. Mine was rubbing on the back right fuel fitting. I have since put a piece of thick vinyl tubing over the harness for chaffe protection. Wish I had the "elephant hide" and waxed lacing we used to use on the aircraft in the USAF.

 

The 2 most commonly affected are the # 2 and # 7,where the harness wears through..

 

X2 - #2 & #7 are the most prone to failure. Also, the harness as it comes from the factory is zip-tied to the alternator housing and will rub through. Simple fix for the alternator rub is cut the zip tie, split a piece of heater hose and wrap it around the harness, then re-zip tie it.

For #2 & #7... go buy an ice pick... then search out here and other diesel sites (Diesel Place) for the Ice Pick Fix. It's the best solution - even better than the General's fix... which has routinely been known to go bad weeks or months after being applied.

Good luck!

 

most likely its going to be #7. If you get 0207 and 2147. That means 1,4,6,7 cyl. are shut down. Try taking out the #7 plug take out the rubber grommet and replug it. do the wiggle test. wiggle the wire if it shuts down that rack then you know.

 

I agree with Randy the Hack. They make a retrofit kit and gm will put it on for you if you're stranded on the side of the road. If it's running they won't do anything. Try his fix. It's been discussed on other forums in great length.

 

I had two injectors fail on my 05 lly, took it to the dealer and they said thier was a service bulliten on the wiring harness, but no recall yet. about 300 bucks to repair.

 

I don't think it should cost you anything!!!!!!
I believe they revised it to cover 100,000 miles.
Here's the Service Bulletin:
Subject: Service Engine Soon (SES) Light On with Reduction in Engine Power, DTCs P0202 and P2149 or P0207 and P2146 Set (Install Revised 90 Degree Injector Connector with Harness Support Bracket Service Kit) #05-06-04-047B - (03/14/2006)



Models: 2004-2005 Chevrolet Silverado

2004-2005 Chevrolet Kodiak C4500/C5500 Series

2004-2005 GMC Sierra

2004-2005 GMC Topkick C4500/C5500 Series

with 6.6L Duramax™ Diesel Engine (VIN 2 - RPO LLY)




--------------------------------------------------------------------------------

This bulletin is being revised to add additional warranty information. Please discard Corporate Bulletin Number 05-06-04-047A (Section 06 -- Engine/Propulsion System).


--------------------------------------------------------------------------------

Condition
Some customers may comment on the Service Engine Soon light becoming illuminated along with a severe reduction in engine power (limp home mode). Upon investigation, the technician may find DTCs P0202 and P2149 or P0207 and P2146.

Cause
The injector connector circuits on cylinders 2 and 7 are not fully supported near the connector and are more susceptible to terminal breakage from engine vibration.

Correction
If published diagnostics lead to an injector connector, install the revised 90 degree connector and the harness support bracket from the service kit, P/N 98017958, using the following repair procedures.

Repair Procedure for Left Bank Cylinder Number 2
Disconnect the negative battery cables. Refer to Service Information (SI) for the Battery Negative Cable Disconnect/Connect Procedure (Single Battery) and Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery).
Remove the left wheelhouse panel. Refer to Service Information (SI) for the Wheelhouse Panel Replacement.
Remove the left charge air cooler inlet pipe. Refer to Service Information (SI) for the Charged Air Cooler Hoses/Pipes Replacement (Left).



Disconnect cylinder number 2 and cylinder number 4 fuel injector harness connectors.



Remove the cylinder number 2 glow plug connector nut and remove the cylinder number 2 glow plug harness connector from the glow plug.



Remove the fuel injector harness bracket bolt.



Cut the tape to remove the fuel injector harness bracket and discard the bracket.



Cut cylinder number 2 fuel injector connector off the engine harness approximately 38.1 mm (1.5 in) away from the base of the connector.
Important: It is not necessary to maintain the same polarization of the injector circuits.

Strip approximately ¼ inch of insulation from both fuel injector circuits and, using the supplied Duraseal® connectors, crimp the new 90 degree fuel injector connector to the engine harness.
Use an Ultra Torch, or equivalent, to shrink the tubing and set the glue in the Duraseal® connectors.
Secure the Duraseal® connectors with electrical tape.



Position the new injector harness bracket to align with the bracket bolt hole and secure to the harness with electrical tape.
Install the new injector harness bracket and original bolt.
Tighten
Tighten the fuel injector harness bracket bolt to 10 N·m (89 lb in).





Install the cylinder number 2 glow plug harness connector and nut.
Tighten
Tighten the glow plug harness connector nut to 2 N·m (18 lb in).

Connect the cylinder number 2 and cylinder number 4 fuel injector harness connectors.
Install the left charge air cooler inlet pipe. Refer to Service Information (SI) for the Charged Air Cooler Hoses/Pipes Replacement (Left).
Install the left wheelhouse panel. Refer to Service Information (SI) for the Wheelhouse Panel Replacement.
Repair Procedure for Right Bank Cylinder Number 7




Remove the fuel filter assembly bolts.



Position the fuel filter assembly out of the way.



Disconnect cylinder number 7 fuel injector harness connector and cut the number 7 fuel injector harness connector wires directly at the base of the connector.
Important: It is not necessary to maintain the same polarization of the injector circuits.

Strip approximately ¼ inch of insulation from both fuel injector circuits and, using the supplied Duraseal® connectors, crimp the new 90 degree fuel injector connector to the engine harness.
Use an Ultra Torch, or equivalent, to shrink the tubing and set the glue in the Duraseal® connectors.
Secure the Duraseal® connectors with electrical tape.



Install the new injector harness bracket to the upper valve cover.
Install the injector harness bracket bolts supplied with the kit.
Tighten
Tighten the injector harness bracket bolts to 20 N·m (15 lb ft).

Connect the cylinder number 7 injector harness connector.



Install the injector harness to the bracket as shown.
Install the fuel filter assembly.
Install the fuel filter assembly bolts.
Tighten
Tighten the fuel filter assembly bolts to 20 N·m (15 lb ft).

Connect the negative battery cables. Refer to Service Information (SI) for the Battery Negative Cable Disconnect/Connect Procedure (Single Battery) and Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery).
Parts Information
Part Number
Description
Qty

98017958
Injector Connectors #2 and #7 Service Repair Kit
1
__________________

 

As stated above , #2 and #7 are the most common to failure due to the tension on the wires....and the connector. I have seen several issues with all the connectors, over time. Mostly on the 4500-5500's though. I have always replaced the connectors, and
never seen the trucks return with same issue.
Just my $0.02.

 

try Post #6 (#14)

 

I have pictures on a write up in the HOW-TOs. After 36k miles the dealers charge a $100 deductible.

 

ice pick trick

I copied this from another site, I hope it works.
It's quick and easy, and can be done on the side of the road if needed. #2 and #7 are the trouble makers. #2 is on the drivers side front, and #7 is on the passenger side rear. Both are accessible without removing anything.
The easiest way I have found to remove the harness from the injector is to apply a little pressure as if you were assembling it, then press down on the tab that my arrow points to. Once the tab is depressed simply remove the connector.
Now with the connector unplugged its time to work it up where you can get your hands on it good. Take an ice pick or a scratch awl and line it up with the slot. In the picture below I have marked each location with a cross-hair.
This next part can get you hurt, so be careful here.
View attachment 1187
Take the ice pick and force it clear through the connector. It doesn't have to poke clear out the other side, but you must be sure you went clear though the internal spade connector. This creates a new "crimp" to once again fit tight on the injector. Now simply reinstall the harness and your done.
View attachment 1188

 

Can anyone post a bigger picture of this? Thanks very much.

 

ya it should be covered we had our 05 dualy fixed for that prob.

 

dood,just dumped 600 cash on this,no new harness,just tape and rubber hose,guess Ibetter go back and have a little talk with the dealer!
Thx grnhrn

 

The TSB covered the Injector Harness until 50k miles. Unless it has been updated since mine went in. I had 56k on mine when it failed. Stealership said I was SOL and had to pay for repairs. I paid for the fix and called GM the best I could get was they sent me a check for half the cost. Too bad I hadn't found this forum yet as I would have ice picked it and been done.

 

same code again fri.night shop called today,they want 400 to fix #7 some harness repair kit,maybe I SHOULD GO BUY AN ICE PICK!ARGHHH!
Thx for the reply GRNHRN

 

The ice pick trick has fixed many trucks and it will last if done right. And it is FREE or your money back! :rof

Also check the wire harness on the passenger side of the alternator- it is tied down with a tie strap. The sharp corner of the bracket cuts into the wires and causes shorts.

 

thx all,nice to know I'm not alone.I'll try ice pikn #2

 

yes he is right, happened on lly motors 04 05 and their is a kit sold by GM for the fix for 250 bucks or you can do it manually and save some cash.cylinders 2 and 7 are on one circuit the others are on a pigtail. and there is a kit for that too. usually 2 and 7 are the culprit and will cause false code readings if truck goes into limp mode mine was misfiring on 1,4,6,7 according to our diagnostic machine. tsb number is 05-06-04-047b if youd like to take a look. once we fixed the short the engine went out of limp home mode and everything was fine it will run like crap and maybe only hit on four cylinders when it happens, loses power and has a clattering noise from under the hood.

 

06 LBZ Banks six gun injector 7 problem intermittent tried alternator harness fix was the injector wire still a problem on the LBZ

 

It was an issue on the LLY but not as much on the LBZ.

As mentioned above, you can buy new injector connectors at Rockauto.com to splice in.

 

Go to rockauto.com and just buy new injector plugs for cheap. My ice pick failed twice and left me stranded pretty far from home. Dealer fix kit is a waste of money in my opinion.

 

sub'd

 

Great info....thanks

 

This should help u little some of these guys are great with there answers Nelo

Code p0207 or p0202 code with a p2146? Well essentially on cylinders 2 and 7, the wiring is too tight and after time the engine vibration causes the crimping in the connector to go bad or pull out just enough to lose connection. You may have heard of the "ice pick" fix but if you want to make sure it gets done right or dont want to risk putting an ice pick thru your finger, here is how.
Go to any auto parts store (or Chevy/GMC dealership if you want to pay more for the same AC Delco part) get part number 88988963. You'll get a connector with pig tail wires and 2 wire connectors. If you have the patients to work in small tight spaces, soldering the wires and wrapping with heat shrink wrap would be the best option, but you shouldn't have any issues with using connectors if you do it right

 

They sell the injector connector at RockAuto Auto Parts for around $20 each, try that first

 

They sell the injector connector at RockAuto Auto Parts for around $20 each, try that first

X2

There is a GM repair kit they sell for plugs #2 and #7 (comes with new connectors, brackets, etc) but the injector connectors are also available separately from Rockauto.com

AC Delco PT2183

GM P/N 88988963 (alot more money, same part)