With age, our much loved 6.0 Powerstroke wiring harnesses have taken some wear. As they wear over time, signal quality can become a concern. One of the more commonly replaced items is the injector connectors.  It's a fairly simple procedure. Use this guide to help you get the job done.

Thanks to Alliant Power for all the information here. 

When replacing the AP0040 G2.8 Injector Connector on the injector harness, you will need the following:

- AP0040 G2.8 Injector Connector (which includes the following:)

• Connector Body
• Orange Lock
• Seals   

- Small Pick

Note: Alliant Power does not recommend replacing the terminals if broken. Cutting the wires to replace terminals will make the harness too short.

Replacing a Damaged Connector:

1.  Pull out the orange lock inside the connector with a pick.

2.  Use the pick to pull back or break the inner terminal clips and release the terminal from the connector body.

3.  Pull the wires out of the connector.

4.  Install wires into the corresponding holes in the new connector and verify each wire is in the correct pin location.

5.  Push the wires into the new connector body until you hear or feel the click of the terminal going past the terminal clip.

6.  After each wire has been inserted, hold the connector with one hand and gently pull on the wire with the other to verify that the terminal is properly locked into the connector.

7.  Push the new orange lock down until it clicks. The lock is keyed and can only be inserted one way. The top of the lock should be flush with the inside of the connector.

8.  Check the wires again by holding the connector and gently pulling down on the wires. The terminals should not slide down past the orange lock.