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Duramax Second Generation: 2004.5-2005 (LLY) Discuss the second generation (2004.5-2005 LLY) of the 6.6L Duramax diesel engine & associated components. 2006 LLY engine discussion belongs in Third Generation forum due to the differences of the 2006 LLY and the 2004.5-2005 LLY. Engine related discussion ONLY.

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Old 11-09-2017, 12:16 PM   #1 (permalink)
Trodrig
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FICM Connector Problem?

Hi folks! I'm on a road trip and having intermittent problems with my 2004 LLY. It's throwing codes P0202, 0203, 0205, 0208, and P2149. I've spent a good bit of time searching the forum and have found the descriptions on the wire bundle that's zip tied to the alternator bracket. I've pulled these bundles apart and all of the wires appear fine. There are a couple of spliced connections. These must be factory original because I'm the only owner of this truck and have never been into this wire bundle before. So far, it does not look like chafing of the wires there at the alternator is the problem. In fact, wiggling these wires individually with the engine running did not reproduce the fault.

What DID reproduce the fault was wiggling the plugs where they go into the FICM. Is this another problem point for these trucks? I'm in a hotel right now and about to go back out to the truck to see if I can remove these connectors from the FICM to inspect. If anyone knows of something specific to look at on these two connection blocks, please let me know.

Thanks!
Thomas

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Old 11-09-2017, 07:48 PM   #2 (permalink)
G2GBY
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Glad you found the source of your bad connection.
Fix that and you should be good to go

Bulletin No.: 06-06-04-026A

Date: December 08, 2006

TECHNICAL
Subject:
LLY Intermittent SES/MIL Lamp Illuminated, Reduced Engine Power, Fuel Injector Driver Circuit DTCs P0201, P0202, P0203, P0204, P0205, P0206, P0207, P0208 and Cylinder Bank Shut Down DTCs P2146 or P2149 (Replace Affected Injector Connector Pigtail Harness)

Models:
2004-2005 Chevrolet Kodiak C4500/C5500 Series, Silverado Models
2004-2005 GMC Sierra Models, TopKick C4500/C5500 Series

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

Supercede:

This bulletin is being revised to update the Kent Moore tool number used on inspecting the injector connections. Please discard Corporate Bulletin Number 06-06-04-026 (Section 06 - Engine/Propulsion System).

Condition

Some customers may comment that the Service Engine Soon lamp is illuminated and/or intermittent along with a significant reduction in engine power (limp home mode). Upon investigation, the technician may find one or multiple injector driver circuit diagnostic trouble codes (DTCs) P0201, P0202, P0203, P0204, P0205, P0206, P0207, P0208 and bank shut down DTCs P2146 or P2149.

Correction

If the published diagnostics lead to an injector connector on cylinders 2 and 7, the 2 and 7 cylinder injector connectors must be repaired and supported as per bulletin 05-06-04-047B.

If the published diagnostics lead to an injector connector on cylinders 1, 3, 4, 5, 6 or 8, replace the affected injector connector pigtail harness with P/N 88988963 using the following repair procedure.

Complete normal SI diagnosis for the trouble codes set.

Injector circuit or injector coil tests may be normal until the engine reaches operating temperature. Recheck circuit/injector resistance readings with a warm engine.

Dealer technicians are to repair wire chafes at the Fuel Injection Control Module (FICM) as needed. Follow the correct SI wiring repair procedures. Insulate the harness from the aluminum retaining bracket with suitable material (electrical conduit or heater hose) so the harness will not chafe again.

When diagnostics are being completed for Injector Driver Fault codes, the dealer technician may notice the Fuel Injection Control Module (FICM) connector is wet or has a wet residue on it. The FICM connectors do have a type of dielectric grease that may be mistaken for diesel fuel. The FICM should not be replaced if this type of wet residue is found. Clean and dry the connectors as needed. No extra dielectric grease needs to be added to the FICM connectors.

Inspect for wire harness chafes on the Fuel Injection Control Module (FICM) wiring harness retaining bracket. This is an aluminum bracket very close to the FICM connectors. If any part of the taped portion of the harness is touching the FICM wiring harness retaining bracket, then you must look for chaffing on the wiring harness. It must be disconnected from the FICM and bent back towards the engine. Look for any chafes into the tape. If necessary peel the tape from the area and look for any chafes into the wires. Some of these chafes are very small, possibly the size of a pen tip, but could still cause injector circuit concerns.

If diagnosis is inconclusive, inspect the injector connections on all related cylinders. Pin drags and terminal tension can be checked with Kent Moore tool number J 35616-35.

Clear the trouble codes and then wiggle test the related injector connectors to see if the trouble codes can be induced. If the vehicle had only injector circuit codes for P0202 or P0207 (with bank shutdown P2146 or P2149), and the wiggle test induces a P0202 or P0207 to reset, use bulletin number 05-06-04-047B to repair the injector connectors and install the injector harness support kit.

If the trouble codes or customer concern is induced during the wiggle test on any other cylinders (other then P0202/P0207), replace the affected injector connector pigtail with P/N 88988963. This replacement pigtail can be used to repair any cylinder except number 2 and number 7. The 2 and 7 cylinder connectors must be repaired and supported as per bulletin 05-06-04-047B.

GM Part :88988963 ACDelco PT2183 Pigtail Harness, Fuel Injector Connector


Last edited by G2GBY; 11-09-2017 at 08:05 PM.
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Old 11-14-2017, 09:37 AM   #3 (permalink)
CHEVYJEFF
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Lone Star Diesels Member

read thru this thread on my search for my ficm harness short. hopefully the photobucket pics show up.

https://www.dieselplace.com/forum/63-...t-non-typ.html
__________________
2004.5 lly, Silver Birch Metallic w/ dark charcoal leather interior.

6" RCD lift w/ bilstiens, cognito tie rods, pitman/idler braces, roller bearing idler arm mount, uca's and sway bar links. New oem pitman and moog idler arm, new design ISS, 2" muffler clamp and "NO ISS CLUNK".

All stock LLY except LBZ MP, egr blocker w/ fingerstick, PCV re-route and a 4" magnaflow exhaust combined w/ a MBRP cat delete down pipe.

Rolls on Raceline 17x9 wheels w/ 35X12.5X17 Toyo open count mt's, AMP electric steps, t-rex billet grill, frontier grill guard, Avalanche roof rack and escalade door handles
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