P0204 on Chevrolet: How to Diagnose & Fix
Injector Circuit/Open - Cylinder 4
1 Chevrolet model · 2 documented issues · 1 critical · $100-$4,000 repair
P0204 on Chevrolet by model: symptoms, diagnosis and fix
Bosch fuel injectors on early Duramax engines develop internal leaks causing rough running, white smoke, and hard starts. LB7 generation (2001-2004) most affected with class action settlement history.
Common Symptoms
- Rough idle
- White smoke from exhaust
- Hard cold starting
- Fuel knock or miss
- Reduced fuel economy
- Fuel in oil
How to Fix
Replace failed injectors. Consider replacing all 8 as preventive measure. Use updated Bosch injector part numbers. Replace injector return lines and cups at same time.
Sources for this issue (1)
The fuel injector wiring harness on the Duramax diesel routes across the top of the engine under the valve covers. The harness rubs against the valve cover and rocker arms, causing the insulation to wear through and the wires to short or open. When an injector wire is damaged, the affected cylinder misfires, the engine runs rough, and white smoke pours from the exhaust. The chafing is accelerated by engine vibration and can affect multiple cylinders over time. GM released updated harness routing clips but the fundamental design has the harness in a high-wear location.
Common Symptoms
- Engine misfires on one or more cylinders
- White smoke from exhaust
- Rough idle that develops gradually
- Check engine light with injector circuit codes
- Engine runs on fewer than 8 cylinders
- Intermittent misfires that come and go
How to Fix
Remove the valve covers and inspect the injector harness for chafing (requires 2-3 hours labor). Damaged sections can be repaired with heat-shrink tubing and solder ($100-$300 for repair). If the harness is severely damaged in multiple places, a complete replacement harness costs $200-$500 and takes 3-5 hours to install. Add additional harness routing clips and protective loom to prevent recurrence. Some diesel specialists reroute the harness outside the valve cover (external harness conversion) to eliminate the chafing issue permanently.
Sources for this issue (1)
P0204 code reference
General diagnostic-code context. The code alone does not confirm a cause for your vehicle; use the applicable issue card and its sources.
Frequently asked questions
What does P0204 mean on a Chevrolet?
P0204 stands for "Injector Circuit/Open - Cylinder 4." This code means the Engine Control Module detected an electrical problem (open circuit or out-of-range resistance) in the fuel injector control circuit for cylinder 4. The ECM controls each injector through its own circuit and monitors it to confirm proper operation. P0204 indicates the computer isn't seeing the expected electrical response from cylinder 4's injector, so that cylinder may not be getting the correct fuel. You'll often notice a misfire, rough running, and a loss of power tied to cylinder 4. On Chevrolet it is documented across 1 model: Silverado 2500HD.
What are the most common causes of P0204?
The most common causes of P0204 are: Damaged or corroded injector connector at cylinder 4, Open or shorted wiring in the injector control circuit, Failed (electrically open) fuel injector on cylinder 4, Loose or backed-out connector pin, Poor ground or power feed to the injector, Faulty injector driver inside the ECM/PCM, Chafed harness causing intermittent open. The specific cause varies by vehicle.
How much does it cost to fix P0204 on a Chevrolet?
Published repair estimates on Chevrolet range from $100 to $4,000 depending on the model and root cause. If an issue mentions a recall or campaign, check your VIN with the manufacturer or NHTSA and confirm eligibility and coverage with a dealer.
Looking for P0204 on a different make?
View P0204 across all makes →Content compiled with AI assistance using NHTSA complaints, TSBs, and owner reports. May contain errors. Always verify with your vehicle's service manual.