LLY Injector Harness Fix!

[RickDLance]

Well, I've seen a few people asking so I thought I would put something together. Sideswiper from the DP was up the other day and we took a few pictures. I'll talk about his method and Gm's.

Let's talk about sideswiper's way first. 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 picture below shows the #2 injector.

http://dmaxcentral.com/forum/attachment.php?attachmentid=35&d=1211731502

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.

http://dmaxcentral.com/forum/attachment.php?attachmentid=36&d=1211731513

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.

http://dmaxcentral.com/forum/attachment.php?attachmentid=37&d=1211731518

[RickDLance]

This next part can get you hurt, so be careful here.

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. Thanks Scott AKA sideswiper!!

http://dmaxcentral.com/forum/attachment.php?attachmentid=40&d=1211731813

http://dmaxcentral.com/forum/attachment.php?attachmentid=41&d=1211731820

http://dmaxcentral.com/forum/attachment.php?attachmentid=42&d=1211731827

http://dmaxcentral.com/forum/attachment.php?attachmentid=43&d=1211731833

[RickDLance]

Now lets talk about GM's fix, harness service kit part # 980117958.

Below is the kit as it comes from the General. The replacement harness at the top of the picture is for #7 and the one at the bottom right is for #2. Also the larger bracket on the left is for #7, and the smaller one on the right is for #2.

http://dmaxcentral.com/forum/attachment.php?attachmentid=44&stc=1&d=1211736225

Lets talk about #7 first. Start by removing the inner fenderwell, but taking the filter mount off and moving the filter out of the way will make it a little easier.

The bracket bolts on to the valve cover in existing holes using the two new bolts. Now plug the new harness in to the injector. It has plastic plugs that snap into the holes in the new bracket. This supports the harness completely. After the bracket and harness are installed simply cut the wires and use the butt connectors provided. All but the wire splicing I did from the top. I also soldered and shrink wrapped mine. I did it several months ago so the parts are a little dirty in the picture.

http://dmaxcentral.com/forum/attachment.php?attachmentid=45&stc=1&d=1211736225
#2 is even easier.

I removed the red electrical junction box marked battery(+) and it's mounting bracket from in front of the valve cover. Once again I connected the new harness to the injector first, then bolted the new support bracket to the existing hole using the existing bolt that supported the old harness. Wire tie the harness to the bracket and make your wire connection the way you prefer.

http://dmaxcentral.com/forum/attachment.php?attachmentid=46&stc=1&d=1211736225

Reinstall all the parts. That's it, your done!

[LarryJewell]

The dealer repaired mine at my request as preventative maintenance :D

[James Hess]

did you connect your new harnesses by completely cutting the old wires off and cutting back the sleeve to solder the new harness to the old one, or did you just cut back the sleeve enough to "splice" in? and how much did this kit cost from GM?

[RickDLance]

The new harness, IIRC, comes with crimp on butt splices. I like solder, but the vibration may be an issue??

[stacks04]

yes they are butt style, but are the ones with the shrink ends on them so they seal also. just cut, crimp, and heat.

[James Hess]

i seal would definatly be nice, thats why i like soldering because its easier to use heat shrink.

[dirtymax6600]

Hey guys im new on the site.. I have an 04.5 LLY with the # 2 and #7 wiring harness messed up... is this just from heating up and melting? or from wires rubbing on somethin..
?? I gotta have the truck back ASAP! :(

[RickDLance]

The ice pick will likely fix it. Follow sideswipers method and you should be good. Careful though, those ice pics are sharp!:)

[chevman]

The ice pick will likely fix it. Follow sideswipers method and you should be good. Careful though, those ice pics are sharp!:)

The pictures were great. first time I really understand what to do. thanks
chevman:hello:

[blksmok]

The pictures were great. first time I really understand what to do. thanks
chevman:hello:

Welcome to the site! :Handshake:

[RoadRunnerTR21]

Those were the ones I used way back when. Excellent visual guide!

[SEA04DMAX]

Alot easier to understand...Thanks Rick.:thumb:

[shiftnutz1]

Thank god for the pictures worked great runs like a top!!! :thumb:

[blksmok]

Thank god for the pictures worked great runs like a top!!! :thumb:

:welcome:

[bluebowtie]

cant u just splice in a inch or two of wire with sodder and shrink tube instread of buying the $250 kit?

[RickDLance]

No, then you don't get the connector. That is where the problem is.

[bluebowtie]

I thought the problem was the wires where too short witch put stress on the connector.

[RickDLance]

The kit comes with wires and brackets to support the connectors. I think vibration is the actual cause.

[2005]

Fix works saved the day thank you Rick iPhones and google :thumb:

[blksmok]

Fix works saved the day thank you Rick iPhones and google :thumb:

:welcome:

[1953drtelco]

Great info before I start my weekend drives to Havasu/Parker through the desert

[PLODMAX]

Hi Rick,
Thanks for posting this for us DIY guys, unfortunately my truck is already at the shop getting "fixed" before I found this site. Driving back from Golden Colorado to Upland, CA and Broke down in Saint George, Utah. Got Quoted 550 to fix the bad injector harness. Left a message with the service manager to keep the parts box because only injector 2 harness went bad. I will see if they replaced both, or if they are trying to keep the #7 harness. Thanks for posting the Ice Pick method, I will keep one in my truck in case this happens again. Breaking down in 116 heat and a pregnant wife was not fun, but luckily we were close to a dealer and were able to limp in.

[Scrapemaker]

will this work on the lb7

[RickDLance]

will this work on the lb7

Welcome!! :hello:

The LB7 doesn't suffer from this normally. The wires for the injectors on them actually go into the valve covers and attach via eyelets, studs, and nuts.

[Fingers]

5 hours from home on I-70 I got the honor of doing this while pulled over on the shoulder of I-70. Thought a piston was going to come out the side of the block. I already had an Idea what to do, but mobile phone internet helped.

Thank you again Rick for the DIY on this. :thumb:

[hugot]

ice pick method worked great for me
I thought I had blown the engine, sounded awful
thanks...

[RickDLance]

ice pick method worked great for me
I thought I had blown the engine, sounded awful
thanks...

Welcome!! :hello:

Good to hear it's working for everyone. A friend of mine came up with it.

[burntmushu]

well i'm from nashville tn. and i had a trip upto montreal and while heading back through toronto got #7 acting up on me. hopefully this will fix it. P0207. thanx for the pixs. will post back if this works.

[JOHN70]

Thanks Rick and Sidewinder, I inlarged the pictures of the ice pick method you can definetly see how far to push the ice pick. Ice Pick in the tool box now

[JOHN70]

Sideswiper, sorry for my srewup

[burntmushu]

well i got another tip if you're off the side of the road and you're looking at this with a smartphone and you don't have any tools...here's a really short temp fix. all i had was a paper clip. when you remove the pigtail and look dead at it you will see six holes.
-- stick paper clip in these hole and try prying down.
-- where the acutal pigtails are.
-- stick paper clip in these hole and try prying up for a temp fix.
when i write up and down i mean try prying it so it goes to the middle of where the pigtails are. all you're doing is hoping it'll squeeze those clips to close up a little atleast until you can get to a part store and get a pick to pierce through the plastic. after doing this temp fix it got me 50 miles down the fwy to a walmart where i was able to buy something sharp enough to pierce through the plastic.