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TC-195A: Fuel Injection Pump Timing Failure

NOTE: Fuel injection pump timing failure DTC (P0216) is monitored with ignition on. DTC may be stored when Engine Control Module (ECM) senses engine speed is more than 300 RPM and fuel command and timing control are within predetermined parameters. Possible causes are: defective fuel injection pump, fuel injection pump gear improperly aligned, restricted fuel filter or restricted transfer pump inlet line.
  1. Turn ignition on with engine off. Using scan tool, check for DTCs. If DTC SPECIFIC GOOD TRIP counter is not equal to zero, go to next step. If DTC SPECIFIC GOOD TRIP counter is equal to zero, go to step  3.
  2. Using scan tool, check for DTCs and record FREEZE FRAME data. Try to duplicate conditions recorded in FREEZE FRAME data. Using scan tool, check for DTCs. If DTC SPECIFIC GOOD TRIP counter changes to zero, go to next step. If DTC SPECIFIC GOOD TRIP counter does not change to zero, test is complete.
  3. Using scan tool, check for DTCs. If DTC P0336: CRANKSHAFT POSITION (CKP) SENSOR SIGNAL, DTC P1287: FUEL INJECTION PUMP CONTROLLER SUPPLY VOLTAGE TOO LOW or DTC P1690: FUEL INJECTION PUMP CKP SENSOR DOES NOT AGREE WITH ECM CKP SENSOR is present, perform DTC P0336: CRANKSHAFT POSITION (CKP) SENSOR SIGNAL, DTC P1287: FUEL INJECTION PUMP CONTROLLER SUPPLY VOLTAGE LOW, or DTC P1690: FUEL INJECTION PUMP CKP SENSOR DOES NOT AGREE WITH ECM CKP SENSOR test. If none of DTCs listed exist, go to next step.
  4. Check for proper fuel injection pump timing and alignment of fuel injection pump drive gear. See FUEL INJECTION PUMP TIMING in ON-VEHICLE ADJUSTMENTS - TRUCKS - DIESEL article. If proper fuel injection pump timing and alignment of fuel injection pump drive gear exists, go to next step. If fuel injection pump timing and alignment of fuel injection pump drive gear is not correct, adjust as necessary. Perform TEST VER-5A.
  5. Fuel pressure drop across fuel filter should be checked. Ensure area around protective caps at inlet and outlet fuel pressure test ports on fuel filter/water separator is clean. See Fig 1. Remove protective caps from inlet and outlet fuel pressure test ports on fuel filter/water separator. Install Fuel Pressure Gauge (6828) on inlet fuel pressure test port.
    Fig 1: Locating Inlet & Outlet Fuel Pressure Test Ports
    G00005738Courtesy of DAIMLERCHRYSLER CORPORATION
  6. Start engine and allow engine to idle. Record fuel pressure. Fuel pressure should be at least 10 psi (.70 kg/cm2 ) at idle. Shut engine off. Remove fuel pressure gauge from inlet fuel pressure test port. Reinstall fuel pressure gauge on outlet fuel pressure test port. Start engine and allow engine to idle. Record fuel pressure. Shut engine off. Remove fuel pressure gauge and reinstall protective caps. Fuel pressure at outlet fuel pressure test port should not be more than 5 psi (.35 kg/cm2 ) less than fuel pressure obtained at inlet fuel pressure test port. If fuel pressure is as specified, go to next step. If fuel pressure is not as specified, replace fuel filter/water separator. Perform TEST VER-5A.
  7. Turn ignition off. Fuel supply line should be checked for restrictions. See FUEL SUPPLY RESTRICTION TEST under FUEL TRANSFER PUMP under FUEL SYSTEM in BASIC DIAGNOSTIC PROCEDURES - TRUCKS - DIESEL article. If fuel supply line is not restricted, replace fuel injection pump. Perform TEST VER-5A. If fuel supply line is restricted, repair or replace fuel supply line as necessary. Perform TEST VER-5A.
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