P0205: How to Diagnose & Fix — Injector Circuit/Open - Cylinder 5
7 vehicles · 5 makes · $30-$6,500 repair
How to diagnose and fix P0205: most-reported vehicles
Ranked by owner reports. Each card gives the symptoms, how to confirm the cause, the fix, parts and sources for that vehicle.
Ford Transit · 2017–2023
The 2017-2023 Ford Transit with the 2.0L EcoBlue diesel engine (available in some markets) and the 3.5L EcoBoost V6 experience fuel injector failures causing rough running, misfires, poor idle, reduced performance, and excessive smoke on cold start. Ford issued a service action for 2.0L EcoBlue vehicles built between February and September 2019 after a batch of high-pressure fuel injectors (reported as Continental-supplied) failed to meet quality standards, causing misfire and reduced engine performance. FordTransitUSAForum.com documents injector failure on 3.5L EcoBoost Transit models as well, where direct injection fuel deposits cause injector spray pattern degradation. RepairPal estimates individual injector replacement between $266 and $627 depending on Transit model, but multiple injectors often need replacement simultaneously, and contaminated fuel systems can cost significantly more.
Common Symptoms
- Rough running and engine misfires
- Poor idle quality
- Excessive blue or black smoke on cold start
- Reduced engine performance and power
- Check engine light with injector or misfire codes
- Engine stalls immediately after starting
- High fuel consumption
- Engine hesitation under acceleration
How to Fix
For Transit 3.5L EcoBoost: replace failed injectors ($100-200 per injector, 3-4 hours labor). Consider replacing all 6 injectors if the vehicle has over 100k miles - if one has failed, others are likely close behind. For EcoBlue diesel: Ford issued a service action for Continental injector failures - check with dealer for coverage. Use only Top Tier gasoline and change fuel filters per schedule. Professional fuel system cleaning every 50,000 miles can extend injector life.
Sources for this issue (3)
GMC Sierra 2500HD · 2001–2004
The 2001-2004 6.6L Duramax RPO LB7 uses injectors buried under the valve covers that are notorious for failing well before 150,000 miles. GM's own analysis attributed the failures to fuel injector body cracks, ball seat erosion, and high-pressure seal extrusion. A leaking injector dumps unburned diesel into the cylinder and past the rings into the crankcase, raising the oil level and diluting it. Owner reporting on duramaxforum.com and silveradosierra.com consistently puts first failures in the 100k-150k range, and because the injectors sit under the valve covers the labor to reach them is far higher than on the later LLY/LBZ engines, where injectors are accessible from the top. This is an LB7-only failure mode - the LLY and later injectors were redesigned and do not share it.
Common Symptoms
- White or blue smoke at idle once warmed up
- Strong raw fuel smell from the exhaust
- Engine oil level rising between changes and smelling of diesel
- Rough idle and misfire, especially cold
- Hard starting
- Knocking/rattle under load
How to Fix
Replace all eight injectors as a set (replacing one at a time invites repeat teardown labor), along with the injector return lines and valve cover gaskets. GM issued a Special Policy extending injector coverage to 7 years/200,000 miles for qualifying trucks after a dealer balance-rate test - that program has long expired, so repairs are now owner-paid. Reman Bosch or new injectors plus the required ECM injector-code programming is the correct repair; change the oil immediately afterward because of the fuel dilution.
Sources for this issue (3)
GMC Sierra 3500HD · 2015–2024
The fuel injectors on the Duramax LML (Bosch piezoelectric) and L5P (Denso solenoid) engines can fail due to contaminated fuel, high-mileage wear, or internal electrical faults. A failed injector causes white smoke on startup, rough idle, misfires on the affected cylinder, and fuel dilution of the engine oil. The high fuel rail pressures (about 29,000 PSI on the L5P) stress the injectors over time. Contaminated fuel from bulk diesel stations accelerates injector wear.
Common Symptoms
- White or gray smoke on cold start
- Rough idle or misfire on one or more cylinders
- Fuel smell in engine oil (fuel dilution)
- Check engine light with injector circuit codes
- Reduced power and poor fuel economy
- Hard starting in cold weather
How to Fix
Diagnose the failed injector with a relative compression test and injector balance rate scan using a Tech 2 or equivalent scan tool. Replace the failed injector(s) — OEM injectors are $300-$500 each, and labor is 2-4 hours per injector ($300-$600). Always replace the injector hold-down clamp and fuel return line seals. If one injector fails at high mileage, consider replacing all 8 as the others are likely near end of life. Use a quality fuel additive like Stanadyne or Hot Shot Secret to protect remaining injectors.
Sources for this issue (2)
Land Rover Defender · 1999–2006
Chevrolet Silverado 2500HD · 2001–2016
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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?
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.
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?
Repair costs for P0205 range from $30 to $6,500, depending on the vehicle and root cause.
Which vehicles are affected by P0205?
Au7o has documented P0205 across 7 vehicle models from 5 manufacturers: Audi, Chevrolet, Ford, GMC, Land Rover.
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Content compiled with AI assistance using NHTSA complaints, TSBs, and owner reports. May contain errors. Always verify with your vehicle's service manual.