My '05 LLY with 50K miles just died. I was driving about 55mph and the engine got very loud (like a Cummings) and then no power. The engine was still running but no power. I just had it towed to the dealer.
Injectors???

Injector harness? Let us know when you find out

What sucks is I couldn't take my Edge programmer off. Hope they don't void the ext. warranty.

Your truck needs inj. Harness ends -- this is under gm war. Only if dealer will do it -- edge system !!!!!!!!!!
Most likely #7 injector end not injectors. There is a bulletin
for this repair. Good luck.

Injector harness? Let us know when you find out

ding, ding, ding, you win!
It's the harness. They told me it's not covered under warranty because it's considered "electrical" not part of the engine.
$504 for them to change it.

Can you buy the harness & do it yourself then? $504 Wow

Can you buy the harness & do it yourself then? $504 Wow

By the time I get it towed home, find a harness, and pay another day or two car rental. I probably won't save a lot.

Is there an after market harness that lasts longer?

That is BS. There is a GM bulliten (as stated before). Find it, print it, and take it to the dealer.

I would fight that one a little harder. With a TSB out on that they should fix that on their dime. I even got my $100 deductible refunding which I wasn't expecting.

Anyone have a link to the TSB?

Never mind, I found it.

TSB or not they should cover it. If the dealer won't work with you, call GM. Seen this many times on this site.

Document ID# 1785863

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

1. 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).
2. Remove the left wheelhouse panel. Refer to Service Information (SI) for the Wheelhouse Panel Replacement.
3. Remove the left charge air cooler inlet pipe. Refer to Service Information (SI) for the Charged Air Cooler Hoses/Pipes Replacement (Left).

Object Number: 1627447 Size: SH
Click here for detailed picture of above image.
4. Disconnect cylinder number 2 and cylinder number 4 fuel injector harness connectors.

Object Number: 1627457 Size: SH
Click here for detailed picture of above image.
5. Remove the cylinder number 2 glow plug connector nut and remove the cylinder number 2 glow plug harness connector from the glow plug.

Object Number: 1627467 Size: SH
Click here for detailed picture of above image.
6. Remove the fuel injector harness bracket bolt.

Object Number: 1627482 Size: SH
Click here for detailed picture of above image.
7. Cut the tape to remove the fuel injector harness bracket and discard the bracket.

Object Number: 1628077 Size: SH
Click here for detailed picture of above image.
8. 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.
9. 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.
10. Use an Ultra Torch, or equivalent, to shrink the tubing and set the glue in the Duraseal® connectors.
11. Secure the Duraseal® connectors with electrical tape.

Object Number: 1649640 Size: SH
Click here for detailed picture of above image.
12. Position the new injector harness bracket to align with the bracket bolt hole and secure to the harness with electrical tape.
13. Install the new injector harness bracket and original bolt.

Tighten
Tighten the fuel injector harness bracket bolt to 10 N·m (89 lb in).

Object Number: 1627457 Size: SH
Click here for detailed picture of above image.
14. 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).
15. Connect the cylinder number 2 and cylinder number 4 fuel injector harness connectors.
16. Install the left charge air cooler inlet pipe. Refer to Service Information (SI) for the Charged Air Cooler Hoses/Pipes Replacement (Left).
17. Install the left wheelhouse panel. Refer to Service Information (SI) for the Wheelhouse Panel Replacement.

Repair Procedure for Right Bank Cylinder Number 7


Object Number: 1628082 Size: SH
Click here for detailed picture of above image.
1. Remove the fuel filter assembly bolts.

Object Number: 1628092 Size: SH
Click here for detailed picture of above image.
2. Position the fuel filter assembly out of the way.

Object Number: 1628100 Size: SH
Click here for detailed picture of above image.
3. 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.
4. 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.
5. Use an Ultra Torch, or equivalent, to shrink the tubing and set the glue in the Duraseal® connectors.
6. Secure the Duraseal® connectors with electrical tape.

Object Number: 1628103 Size: SH
Click here for detailed picture of above image.
7. Install the new injector harness bracket to the upper valve cover.
8. Install the injector harness bracket bolts supplied with the kit.

Tighten
Tighten the injector harness bracket bolts to 20 N·m (15 lb ft).
9. Connect the cylinder number 7 injector harness connector.

Object Number: 1628107 Size: SH
Click here for detailed picture of above image.
10. Install the injector harness to the bracket as shown.
11. Install the fuel filter assembly.
12. Install the fuel filter assembly bolts.

Tighten
Tighten the fuel filter assembly bolts to 20 N·m (15 lb ft).
13. 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
Warranty Information

For vehicles repaired under warranty, use:

Labor Operation


Description


Labor Time

J7709*


Service Kit, Revised 90 Degree Injector Harness Connectors w/Harness Support Brackets - Install


0.9 hr

*This labor operation number is for bulletin use only. This number will not be published in the Labor Time Guide.
Warranty Coverage
• 2004 Model - US & Canada - Light and Medium Duty Trucks - 5 Years or 100,000 miles/160,000 kilometers
• 2005 Model - US - Light Duty Trucks - 5 Years or 50,000 miles
• 2005 Model - US - Medium Duty Trucks - 5 Years or 100,000 miles
• 2005 Model - Canada - Light and Medium Duty Trucks - 5 Years or 160,000 kilometers

I would fight that one a little harder. With a TSB out on that they should fix that on their dime. I even got my $100 deductible refunding which I wasn't expecting.


He's absolutely right, GM has to fix this. Let us know how it goes!

There is the big red flag issue with the edge system installed!!!!

Had both number 2 and 7 harness fixed at a dealership in New Mexico with my Edge installed and monitor sitting on the dash. The tech told me that the issue of the harness was in no way connected with the Edge and warranty was not voided. Now...if it was a smoked transmission....LOL

But, to be safe, I would remove the programmer. All dealerships are not as forgiving.

I had the same problem on my LLY, no way I was gonna take it to stealer, they would've just laughed at me when I popped the hood anyway.

I disconnected the #2 harness connector, and shoved a small piece of foil down in the connector. (The #2 connector is known for the terminals breaking and mine did, foil restored the continuity) Rigged but it's worked for about a year now with no problems!:)

:grd:

:grd:

That's what I call custom:D Hey it works and until it doesn't I can spend $504 on something new for my truck!

just had mine repaired on monday. had edge hooked up on mine too and they had no issues with it. and a buddy had his do the same thing a day later. both of ours fixed under warr. just a $100 deduct.

sure doesnt make you want to buy a dodge does it. driving three miles like that listening to that crap drove me nuts.

Well I just picked it up. I took a copy of the TSB with me, showed it to the service manager. I told him about all the other people that have had theirs repaired under warranty. He made a phone call, came back and told me they would cover it. I had to pay a $100 deductable. They even paid for the tow truck. So instead of $564 it was $100.

Thanks for the advise.

Nice work and another chunk of change saved by Diesel Place.

Mine just did the exact same thing today, glad to here it is nothing more serious. I left it at the dealer and had to get a ride home.

Did anyone notice at the bottom of the TSB that the warranty for harness failure on 2005 models is only good for 5 years or 50,000 miles, while on other models it's good up to 100,000 miles.

Sure glad I have a GMPP ZERO deductible warranty for for 111,000 miles!

Where can I find this TSB that evryone is talking about???

On post #13 on this very thread?.?.?.?......

Just had mine die again!!!!! This time it was the #2 that went out. Dealer says I have to wait a week to get it back since they have to get the harness from the factory. Got them to waive my $100 deductable, but i'm confused since in the TSB is says its covered up to 100,000 miles or 5 years. I have 45000 miles on my truck.

First harness with #7 went out at 34000 miles at my house, then last night at McDonalds drive thru second harness with #2 went out. I'm not sure why they didn't do both the first time.

I'm not sure why they didn't do both the first time.

It depends on the codes pulled up. Most likely u had a Group 1 code the first time, so they only replaced 1 & 7 injector ends.

U probaly have a code for Group 2 injectors

Is it the wires that are the problem or the injectors? I was reading awhile back about the wires rubbing on something and I did the mod they recommended. I put a piece of hose under it, so is this the same problem or a different one

http://www.alldata.com/tsb/General-M..._05-06-04-047/ (http://www.alldata.com/tsb/General-Motors/1122966000000_1128582000000_05-06-04-047/)

E-mail me what you need i have many spare parts for sell
:)

can someone post the link for how to keep the harness from rubbing thru?

Is it the wires that are the problem or the injectors? I was reading awhile back about the wires rubbing on something and I did the mod they recommended. I put a piece of hose under it, so is this the same problem or a different one
Different one. You are thinking of the alternator bracket rubbing. This is right in the end of the electrical connector on the injector.

:rant:
I am so fed up with my 2004 Duramax LLY that I could just park it at a dealer and call GMC and tell them to go pick it up. I've treated it like gold, serviced on time, everything right and yet I keep having problems. Fuel gel problems, cracked hubs, front end total rehaul ($2000) and now, I'm out in the boonies of Virginia on a Saturday night driving to try to get to see my family in NC for a mini reunion after my flight was cancelled due to the "Noreaster" and my truck dies 3/4 of the way there. All of a sudden clanking noise, loss of power/could only go 30 MPH and it sounds like someone has a hammer in my engine and is going to town. No dealers are open on a Sunday and I am wondering if it is this wire harness thing. I am tempted to not buy GM again because of this and all the other probs I've had. 79k miles on this beauty (on the outside) yet I feel like I am driving a Ford or something with all the problems. GM Customer Care toll free number isn't even open on Sundays. Can anyone give me direction? I'm at my wits end and about ready to go look into, dare I say it, a DODGE or FORD :mad: I know but that's how ticked I am right now...

Very well could be injector harness issue. IIRC, it occurs on the driver's side front, but don't take my word on it, do a search.

If you have a "harness box" tuner on it, remove it, and look at all pins before reconnecting.

You need to find out what codes are being thrown.

The #2 and #7 connections are surprisingly easy to get to. They say that you can wiggle the connections to re-establish connection to limp it to your destination.

Just had this happen to me as well, Dealer installed new harness. 98017958. Text says he installed new injector harness repair kits (plural) per bulletin. Is it a fair assumption that this fixes both #7 and #2?

Is this something than the dealer will fix BEFORE it actually goes bad???????

I agree Thats BS, fight it.

Is this something than the dealer will fix BEFORE it actually goes bad???????
Yea this is my question too!!!!!!!!!!!!!!!!!!!!!!!

Only if you pay for it.

"Only if you pay for it."
Well..... Thats no good.