P0205 on Chevrolet: How to Diagnose & Fix
Injector Circuit/Open - Cylinder 5
1 Chevrolet model · 1 documented issue · $100-$800 repair
P0205 on Chevrolet by model: symptoms, diagnosis and fix
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)
P0205 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 P0205 mean on a Chevrolet?
P0205 stands for "Injector Circuit/Open - Cylinder 5." P0205 is a fuel-system code meaning the engine computer detected an electrical problem (an open circuit or out-of-range condition) in the fuel injector circuit for cylinder number 5. The PCM controls each injector with a precise electrical pulse, and it monitors that circuit for proper current flow. When the cylinder 5 injector circuit doesn't respond as expected — typically an open or a wiring fault — this code sets. It generally causes a misfire on that cylinder, rough idle, hesitation, reduced power, and possibly hard starting, since cylinder 5 isn't being fueled correctly. On Chevrolet it is documented across 1 model: Silverado 2500HD.
What are the most common causes of P0205?
The most common causes of P0205 are: Failed or open fuel injector on cylinder 5, Open or shorted wiring in the injector control circuit, Corroded, loose, or damaged injector connector, Poor power feed or driver fault from the PCM/injector circuit, Chafed or broken injector harness, Blown fuse feeding the injector bank (where applicable), PCM injector driver failure (less common). The specific cause varies by vehicle.
How much does it cost to fix P0205 on a Chevrolet?
Published repair estimates on Chevrolet range from $100 to $800 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 P0205 on a different make?
View P0205 across all makes →Join 700+ subscribers following Au7o for vehicle insights and updates.
Content compiled with AI assistance using NHTSA complaints, TSBs, and owner reports. May contain errors. Always verify with your vehicle's service manual.