Fix P0216: Mechanic’s solutions that WORKED

The code P0216: Injection Timing Control Circuit Malfunction points out a fault in the engine’s fuel injection timing, and most likely is caused by a failing injection pump or issues with fuel supply. Accurate injection timing is crucial for optimal engine performance and fuel efficiency.

P0216 quick overview

Meaning	P0216: Injection Timing Control Circuit Malfunction
Is it serious?	Yes, this code is serious as it can lead to poor vehicle performance, increased emissions, and potential damage to the engine if not addressed promptly.
Possible causes	– Faulty injection pump – Low fuel pressure or volume from the lift pump – Clogged fuel filter or lines – Contaminated or poor-quality diesel fuel – Faulty sensors affecting fuel timing, like the camshaft position sensor
How to diagnose?	Check Fuel Volume and Pressure: Ensure the lift pump provides adequate volume and maintains proper pressure. Inspect Injection Pump: Look for signs of wear or failure in the injection pump. Verify Fuel Quality: Check for contaminated or poor-quality diesel. Examine Fuel Lines and Filter: Ensure there are no clogs or restrictions. Assess Sensor Signals: Confirm proper operation of sensors that could affect injection timing.

How to fix P0216 – learn from mechanics

I looked into P0216 service cases at iatn.com website where in the private forums the mechanics seek advice from other mechanics. I looked up a bunch of cases to help you decide how to fix your issue and see what would a real mechanic do to solve it.

Case #1: Ram

Vehicle Information:
2000 Dodge Ram 2500 5.9L

Issue + Repair History:

• Experiencing surges while driving at around 55 MPH with no load or trailer.
• Recently replaced TPS and fuel supply pump.
• Struggles to maintain speed on flat or small hilly roads, but not at 70 MPH.

Other OBD2 Codes + Test Results:

• PO216: Injection timing control

Suggestions to Fix Issue:

• Monitor engine/transmission speed and shift points with a scanner.
• Consider the role of injection timing in maintaining torque and RPM.
• Acknowledge that a failing injector pump can cause intermittent power loss.

Final Fix:

• Replaced the injector pump after experiencing hesitation upon acceleration.
• The replacement resolved the issue, improving the truck’s performance even on steep hills.

Case #2: Chevrolet

Vehicle Information:
1997 Chevrolet K3500 6.5L

Issue + Repair History:

• Experiencing poor idle quality and excessive smoke.
• Required gas pedal to be floored to start and then ran as if overloaded.
• Cooling system tested and found okay, indicating smoke is not from coolant.

Other OBD2 Codes + Test Results:

• PO216: Ignition timing control
• Stepper motor coil resistance at 45 ohms for both coils

Suggestions to Fix Issue:

• Check injectors for pressure holding and spray pattern.
• Consider replacing the injection driver module.
• Verify fuel pressure (minimum 6 psi) and inspect for metal shavings in fuel indicating a bad lift pump.
• Check the EGR valve for sticking issues causing black smoke.
• Consider potential issues with the pressure rod in the Stanadyne pump used by GM.

Final Fix:

• Replaced the injector pump with a remanufactured one.
• Required a Tech 2 to reset the TDC timing to avoid trouble codes PO216 or 1214.
• After resetting, the truck ran well with no excessive smoke.

Case #3: Dodge

Vehicle Information:
2001 Dodge Ram 2500 5.9L

Issue + Repair History:

• Came in for check engine light and intermittent stalling.
• Initially had a P0216 code indicating injector pump timing failure.
• Fuel pressure was low at idle and at 2500 RPM.
• No cam sensor signal was detected on the scanner.
• Replaced the lift pump and cam sensor but the stalling persisted.

Other OBD2 Codes + Test Results:

• P0216: Injector pump timing failure

Suggestions to Fix Issue:

• Check cam sensor harness for faults.
• Ensure the transfer pump is functioning correctly.
• Consider the possibility of a failing PCM impacting sensor signals.
• Replace the injection pump, particularly if fuel pressure was previously low.

Final Fix:

• Replaced the injection pump due to the P0216 code and low fuel pressure issues.
• Required a tech to reset the TDC timing to avoid further trouble codes.
• After the replacement, the truck ran well, and the customer was satisfied.

Case #4: Dodge

Vehicle Information:
2000 Dodge Ram 2500 5.9L

Issue + Repair History:

• Experiencing excessive emissions, poor idle quality, hesitation, surges, and lack of power.
• Previously had an injection pump rebuild and transfer pump update.
• Displayed codes P1693 and P0216, indicating potential injection pump timing failure.

Other OBD2 Codes + Test Results:

• P1693: MIL fault in companion module
• P0216: Injection pump timing failure

Suggestions to Fix Issue:

• Replace the injection pump, particularly if there’s a history of low fuel pressure.
• Check fuel pressures and lift/transfer pump performance.
• Ensure the new injection pump is not dumping fuel on the return side.
• Inspect the wastegate actuator for any seizing.
• Consider the fuel’s specific gravity to rule out contamination or incorrect fuel type.
• Verify if the vehicle has any aftermarket power adders that could increase fuel demands.

Final Fix:

• Replaced the injection pump with a Bosch rebuilt unit that comes with pre-calibrated mixture computer.
• Updated the transfer pump.
• The truck showed improved performance with no more smoke and good power post-repair.

Case #5: Dodge

Vehicle Information:
2002 Dodge Ram 3500 5.9L

Issue + Repair History:

• Experiencing hesitation, poor power, excessive emissions, and the MIL lamp on.
• Previous updates include a transfer pump update.
• Found a clogged pump with debris and replaced it but still faced low fuel pressure and performance issues.
• Continues to set P0216 code indicating injector pump timing failure.

Other OBD2 Codes + Test Results:

• P0216: Injector pump timing failure
• P177: Water in fuel
• P0230: Transfer pump circuit out of range
• P1693: DTC detected in ECM
• P0217: Reduced engine performance from overheat
• P0500: No vehicle speed signal

Suggestions to Fix Issue:

• Verify fuel volume is at least 45oz when starter is bumped; low fuel can cause P0216 and damage the injection pump.
• Replace the injection pump if the fuel volume test is passed.
• Check for any debris or restriction in the fuel line.
• Consider installing an oil pressure sensor in the pressure line as an early warning for transfer pump failure.
• Recheck fuel supply for debris or restriction due to the slightly low fuel volume.

Final Fix:

• Replaced the injection pump with a Bosch rebuilt unit.
• Updated the transfer pump and ensured proper fuel volume.
• The truck showed improved performance post-repair.

Advice	Brief Description of Diagnostic Step
Check Fuel Volume	Ensure the transfer pump outputs at least 45oz of fuel when the starter is bumped, indicating sufficient fuel supply to the injection pump.
Inspect Injection Pump	Consider replacing the injection pump, especially if P0216 sets immediately after addressing fuel supply issues.
Monitor Fuel Pressure	Verify that the fuel pressure does not drop below the specified level under load; low pressure can damage the injection pump.
Check for Fuel Contamination	Inspect the fuel for debris or contamination that could clog the pump or affect fuel flow.
Update Transfer Pump	Ensure the transfer pump is functioning correctly and consider upgrading if it’s an older model.
Perform Fuel Restriction Test	Check fuel restriction with a gauge at the lift pump inlet to identify any clogs or restrictions in the fuel line.