It's been a while, but our recent snow has melted and I have made progress, I think.
Thanks for the comments, I did pull the ECU out and check the pins and there were signs of carbon arcing on "the one" causing issues for the injector. Cleaned up all the pins and used some 400 emery to clean off the carbon. (that alone has not solved it, BTW)
I did find out how to remove terminals from the connector [BIG THANKS to the guys at Green Diesel Engineering who gave me the "secret handshake"]. There is a pink/magenta plastic "keeper" which slides in from the bottom of the connector. Use a small pick or screwdriver to free and slide that out, at lease far enough to go past the pin/terminal(s) you want to pull. Then insert a pin or really small pick into the tiny hole right next to the big hole of the terminal you want out; this is the tiny hole right next to the hole the ECU pin goes into. Pull gently on the wire from the back as you do this. There is a little finger of metal on the terminal that your pin will compress and release. Once that finger is released, the wire starts moving out and you got it.
I have a couple of pics, but can't see how to upload them into a post here. If someone can explain that, I get them up there. But once you know how, it's fairly easy to pull wires and their terminals from the connector. Putting them back in is basically the reverse: with the keeper slide down, put the terminal in from the back and push it forwards until it clicks in. NOTE: it only works one way, with that little finger you released to get it out, on the side with that release hole. Once it is in, push the keeper back up all the way.
Anyway, when I got the terminal out there was some sort of clear "jello" in it. I suspect clear Si caulk as was used to seal up the unused holes in the connector block. Anyhow some seems to have worked its way into this terminal and was causing a bad connection to the pin on the ECU. That explains the intermittent nature of the problem and why I could make it come and go by moving this wire around. No signs of wire problems as I originally suspected/theorized. I have tried cleaning out the terminal, but there is really no good way to clean or even see the metal surfaces which make electrical contact. So while I will try a few solvents, I've also ordered some new terminal ends and plan on replacing this one, even if the cleaning seems to work (still waiting for some contact cleaner which removed corrosion before giving it a try again, but it would be nice to be able to use the Jeep while waiting on the new terminals to arrive).
_________________ 2006 KJ CRD
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