Test Procedure

WARNING: This page does not describe the selected car, but rather 30 other vehicles, including the 2004 Mercury Sable, 2004 Mercury Mountaineer, 2004 Mercury Monterey, 2004 Mercury Marauder, and 2004 Mercury Grand Marquis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION table of fault code setting condition.

FAULT CODE SETTING CONDITION

Fault Code

KOEO

KOER

Continuous Memory

P0230 1 & 2

KA55

KA84

P0230 1 & 3

KA1

KA40

P0231 1 & 2

KA80

KA85

P0231 1 & 3

KA23

KA39

P0232 1 & 2

KA64

KA86

P0232 1 & 3

KA10

KA37

P1232

KA41

KA47

P1641 1 & 2

KA55

P1641 1 & 3

KA1

KA40

⁽¹⁾

For Natural Gas Engines see

⁽²⁾

F-Super Duty, Excursion, Expedition and Navigator

⁽³⁾

All other vehicles FAULT CODE SETTING CONDITION .

KA1 KOEO DTC P0230: CHECK THE VPWR VOLTAGE TO FUEL PUMP RELAY

FP Relay connector disconnected.
Key ON Engine OFF.
Measure the voltage between:

( + )FP Relay Connector, Harness Side	( - )
VPWR	Ground

Is the voltage greater than 10.5 V?

Yes	No
KEY OFF. GO to KA2.	REPAIR open circuit.

KA2 CHECK THE FUEL PUMP RELAY

REFER to the pin numbers indicated on the FP relay. There will be either a pin 1 or pin 85.
Measure the resistance between either pin 1 or pin 85 and all the other pins of the relay. One measurement must be between 40 and 120 ohms, with the other measurements being greater than 10,000 ohms.

Are all Resistance checks OK?

Yes	No
GO to KA3.	INSTALL a new FP relay.

KA3 CHECK THE FP CIRCUIT FOR A SHORT TO POWER IN THE HARNESS

PCM connector disconnected.
Key ON Engine OFF.
Measure the voltage between:

( + )FP Relay Connector, Harness Side	( - )
FP	Ground

Is the voltage less than 1 V?

Yes	No
KEY OFF. GO to KA4.	REPAIR short circuit.

KA4 CHECK THE FUEL PUMP CIRCUIT FOR A SHORT TO GROUND IN THE HARNESS

Measure the resistance between:

( + )FP Relay Connector, Harness Side	( - )
FP	Ground

Is the resistance greater than 10K ohms?

Yes	No
GO to KA5.	REPAIR short circuit.

KA5 CHECK THE FUEL PUMP CIRCUIT FOR AN OPEN IN THE HARNESS

Measure the resistance between:

( + )FP Relay Connector, Harness Side	( - )PCM Connector, Harness Side
FP	FP

Is the resistance less than 5 ohms?

Yes	No
GO to KA6.	REPAIR open circuit.

KA6 CHECK KOEO DTCS:

CHECK KOEO DTCs:

Are DTCs P0231 or P0232 present?

Yes	No
GO to KA7.	INSTALL a new PCM. REFER to FLASH ELECTRICALLY ERASEABLE PROGRAMMABLE READ ONLY MEMORY - FLASH EEPROM .

KA7 CHECK THE FP PRIMARY CIRCUIT INSIDE THE PCM

PCM connector connected.
FP Relay connector connected.
Key ON Engine OFF.
Access the PCM -FPF PID.

Is the PID state FAULT?

Yes	No
KEY OFF. INSTALL a new PCM. Refer to FLASH ELECTRICALLY ERASEABLE PROGRAMMABLE READ ONLY MEMORY - FLASH EEPROM .	GO to KA8.

KA8 CHECK THE FUEL PUMP PRIMARY CIRCUIT INSIDE THE PCM WHILE CRANKING THE ENGINE

NOTE: The scan tool must be connected to a reliable power source that is powered with the key in the START position (such as directly to the vehicle battery). Also verify that the vehicle battery is fully charged.

Access the PCM -FPF PID.
While observing the PID, carry out the following:
- Crank the engine.

Does the PID display indicate a fault during crank?

Yes	No
KEY OFF. INSTALL a new PCM. Refer to FLASH ELECTRICALLY ERASEABLE PROGRAMMABLE READ ONLY MEMORY - FLASH EEPROM .	KEY OFF. Fuel pump primary circuit is OK in the harness and PCM GO to KA9.

KA9 IS DTC P0231 PRESENT IN THE KOEO SELF-TEST?

CHECK KOEO DTCs:

Is DTC P0231 present?

Yes	No
GO to KA23.	DTC P0232 is present GO to KA10.

KA10 KOEO DTC P0232: DOES THE ENGINE START?

Does the engine start?

Yes	No
GO to KA11.	For F -150 Heritage 5.4L SC GO to KA48. For All Others GO to KA17.

KA11 VERIFY THAT FUEL PUMP IS OFF

Key ON Engine OFF.
Wait for 5 seconds.
The fuel pump is located above the fuel tank. Listen for the sound of the fuel pump operating which can be heard from outside the vehicle.

Is Fuel Pump OFF with the key on?

Yes	No
GO to KA13.	GO to KA12.

KA12 CHECK FOR FUEL PUMP RELAY CONTACTS ALWAYS CLOSED

FP Relay connector disconnected.
Key ON Engine OFF.

Is Fuel Pump OFF with the key on?

Yes	No
INSTALL a new FP relay.	REPAIR short circuit to PWR. (FPPWR/FPM ckt)

KA13 CHECK THE FPM CIRCUIT FOR AN OPEN IN THE HARNESS

PCM connector disconnected.
FP Relay connector disconnected.
Measure the resistance between:

( + )FP Relay Connector, Harness Side	( - )PCM Connector, Harness Side
FPPWR	FPM

Is the resistance less than 5 ohms?

Yes	No
GO to KA14.	REPAIR open circuit. (fault is between splice and PCM)

KA14 WAS KOEO DTC P0231 PRESENT?

CHECK KOEO DTCs:

Is DTC P0231 present?

Yes	No
INSTALL a new PCM. REFER to FLASH ELECTRICALLY ERASEABLE PROGRAMMABLE READ ONLY MEMORY - FLASH EEPROM .	For F -150 Heritage 5.4L SC GO to KA16. For All Others GO to KA15.

KA15 CHECK THE FPM PRIMARY CIRCUIT INSIDE THE PCM

PCM connector connected.
FP Relay connector connected.
Key ON Engine OFF.
Access the PCM -FPM PID.

Is the PID state OFF?

Yes	No
KEY OFF. The fault is not present at this time The FPM circuit is OK in the harness and PCM. Disregard DTC P0232 at this time. Concern is elsewhere. RETURN to SYMPTOM CHARTS - CNG, FLEX-FUEL & GASOLINE for further direction.	INSTALL a new PCM. REFER to FLASH ELECTRICALLY ERASEABLE PROGRAMMABLE READ ONLY MEMORY - FLASH EEPROM .

KA16 CHECK THE FPM PRIMARY CIRCUIT INSIDE THE PCM

PCM connector connected.
FP Relay connector connected.
Key ON Engine OFF.
Access the PCM -FPM PID.

Is the PID state OFF?

Yes	No
KEY OFF. GO to KA46.	INSTALL a new PCM. REFER to FLASH ELECTRICALLY ERASEABLE PROGRAMMABLE READ ONLY MEMORY - FLASH EEPROM .

KA17 CHECK IF INERTIA FUEL SHUTOFF TRIPPED

Is IFS tripped?

Yes	No
Reset Switch	GO to KA18.

KA18 CHECK THE INERTIA FUEL SHUTOFF

IFS connector disconnected.
Measure the resistance between:

( + )IFS Connector, Component Side	( - )IFS Connector, Component Side
FPPWR-A - Pin 2	FPPWR-B - Pin 1

Is the resistance less than 5 ohms?

Yes	No
GO to KA19.	INSTALL a new IFS.

KA19 CHECK THE FP PWR CIRCUIT FOR AN OPEN IN THE HARNESS

FP Relay connector disconnected.
Measure the resistance between:

( + )IFS Connector, Harness Side	( - )FP Relay Connector, Harness Side
FPPWR-A - Pin 2	FPPWR

Is the resistance less than 5 ohms?

Yes	No
GO to KA20.	REPAIR open circuit. CHECK for an open circuit between IFS and FPM splice REFER to the wiring diagram.

KA20 CHECK THE FUEL PUMP GROUND CIRCUIT FOR AN OPEN IN THE HARNESS

FP connector disconnected.
Measure the resistance between:

( + )FP Connector, Harness Side	( - )
FPGND	Ground

Is the resistance less than 5 ohms?

Yes	No
GO to KA21.	REPAIR open circuit.

KA21 CHECK THE FP PWR CIRCUIT FOR AN OPEN IN THE HARNESS

Measure the resistance between:

( + )FP Connector, Harness Side	( - )IFS Connector, Harness Side
FPPWR	FPPWR-B - Pin 1

Is the resistance less than 5 ohms?

Yes	No
GO to KA22.	REPAIR open circuit.

KA22 CHECK THE INTERNAL RESISTANCE OF FUEL PUMP

Measure the resistance between:

( + )FP Connector, Harness Side	( - )FP Connector, Harness Side
FPPWR	FPGND

Is the resistance less than 10 ohms?

Yes	No
The Fuel Pump circuit is OK in the harness and PCM. Disregard DTC P0232 at this time. Verify the test step results Reconnect all the disconnected components. RETURN to QT: STEP 1: PCM QUICK TEST and CONTINUE diagnosis as directed.	INSTALL a new FP.

KA23 KOEO DTC P0231: WAS KOEO DTC P0230 ALSO PRESENT?

CHECK KOEO DTCs:

Is DTC P0230 present?

Yes	No
GO to KA1.	GO to KA24.

KA24 DOES THE ENGINE START?

Does the engine start?

Yes	No
GO to KA13.	GO to KA25.

KA25 CHECK IF IFS TRIPPED

Is IFS tripped?

Yes	No
Reset Switch	GO to KA26.

KA26 CHECK THE B+ CIRCUIT VOLTAGE TO THE FP RELAY

FP Relay connector disconnected.
Measure the voltage between:

( + )FP Relay Connector, Harness Side	( - )
B+	Ground

Is the voltage greater than 10.5 V?

Yes	No
For F-150 Heritage 5.4L SC GO to KA28. For All Others GO to KA27.	B+ circuit fault. CHECK the condition of the related fuse/fuse links. If OK, REPAIR the open circuit. If the fuse/fuse link is damaged, CHECK the circuit for short to ground before replacing.

KA27 CHECK THE FP PWR CIRCUIT FOR AN OPEN IN THE HARNESS

Measure the resistance between:

( + )FP Relay Connector, Harness Side	( - )
FPPWR	Ground

Is the resistance less than 10 ohms?

Yes	No
INSTALL a new FP relay.	REPAIR open circuit. (The open is between the splice and the FP relay) NOTE: Some applications may have the IFS in this part of the circuit. First verify the IFS is set.

KA28 CHECK THE VPWR & IFS CIRCUIT TO THE IFS RLY

IFS Relay connector disconnected.
Key ON Engine OFF.
Measure the voltage between:

( + )IFS Relay Connector, Harness Side	( - )IFS Relay Connector, Harness Side
VPWR - Pin 1	IFS - Pin 2

Is the voltage greater than 10.5 V?

Yes	No
GO to KA34.	GO to KA29.

KA29 CHECK THE VPWR CIRCUIT TO THE IFS RLY

Measure the voltage between:

( + )IFS Relay Connector, Harness Side	( - )
VPWR - Pin 1	Ground

Is the voltage greater than 10.5 V?

Yes	No
KEY OFF. GO to KA30.	REPAIR open circuit.

KA30 CHECK IF INERTIA FUEL SHUTOFF SWITCH TRIPPED

Is Inertia Fuel Shutoff tripped?

Yes	No
Reset Switch	GO to KA31.

KA31 CHECK THE GROUND CIRCUIT TO INERTIA FUEL SHUTOFF SWITCH

IFS connector disconnected.
Measure the resistance between:

( + )IFS Connector, Harness Side	( - )
GND	Ground

Is the resistance less than 5 ohms?

Yes	No
GO to KA32.	REPAIR open circuit.

KA32 CHECK THE IFS SWITCH

Measure the resistance between:

( + )IFS Connector, Component Side	( - )IFS Connector, Component Side
IFS	GND

Is the resistance less than 5 ohms?

Yes	No
GO to KA33.	INSTALL a new IFS.

KA33 CHECK THE IFS CIRCUIT FOR AN OPEN IN THE HARNESS

Measure the resistance between:

( + )IFS Relay Connector, Harness Side	( - )IFS Connector, Harness Side
IFS - Pin 2	IFS

Is the resistance less than 5 ohms?

Yes	No
The fault is not present at this time Disregard DTC P0232 at this time RETURN to QT: STEP 1: PCM QUICK TEST and CONTINUE diagnosis as directed.	REPAIR open circuit.

KA34 CHECK FP PWR CIRCUIT CONTINUITY

Measure the resistance between:

( + )FP Relay Connector, Harness Side	( - )IFS Relay Connector, Harness Side
FPPWR	FPPWR-A - Pin 3

Is the resistance less than 5 ohms?

Yes	No
GO to KA35.	REPAIR open circuit.

KA35 CHECK THE FUNCTIONALITY OF IFS RLY

Connect a 5 amp fused jumper wire between the following:

Point A IFS Relay Connector, Component Side	Point B Vehicle battery
VPWR - Pin 1	Positive terminal

Connect a 5 amp fused jumper wire between the following:

Point A IFS Relay Connector, Component Side	Point B Vehicle battery
IFS - Pin 2	Negative terminal

Measure the resistance between:

( + )IFS Relay Connector, Component Side	( - )IFS Relay Connector, Component Side
FPPWR-A - Pin 3	FPPWR-B - Pin 5

Is the resistance less than 5 ohms?

Yes	No
GO to KA36.	INSTALL a new IFS relay.

KA36 CHECK THE FUNCTIONALITY OF FP RLY

Connect a 5 amp fused jumper wire between the following:

Point A FP Relay Connector, Component Side	Point B
FP	Ground

Connect a 5 amp fused jumper wire between the following:

Point A FP Relay Connector, Component Side	Point B Vehicle battery
VPWR	Positive terminal

Measure the resistance between:

( + )FP Relay Connector, Component Side	( - )FP Relay Connector, Component Side
B+	FPPWR

Is the resistance less than 5 ohms?

Yes	No
REPAIR open circuit. BETWEEN: FPM splice and IFS RLY	INSTALL a new FP relay.

KA37 CONTINUOUS MEMORY DTC P0232: IS A CONTINUOUS DTC P0230 PRESENT?

CHECK Continuous Memory DTCs:

Is DTC P0230 present?

Yes	No
GO to KA40.	GO to KA38.

KA38 CHECK THE FUEL PUMP SECONDARY CIRCUITS FOR FAULT

NOTE: Be aware that P0232 could be set if the inertia fuel shutoff (IFS) switch is tripped then reset, or if power is supplied to the FP PWR circuit when the PCM expected the fuel pump to be off (fuel pump prime procedure will produce this).".

Key ON Engine OFF.
Access the PCM -FPM PID.
Observe the FPM PID for an indication of a fault while completing the following: The FPM PID will turn ON when a fault is indicated.

Shake, wiggle, and bend the FPPWR circuit between the FP RLY and the FP.
Shake, wiggle, and bend the FP GND.
Shake, wiggle, and bend the FPM circuit between the PCM and the splice to the FPPWR circuit.
Lightly tap on the FP & IFS & FP RLY to simulate road shock.
For 5.4L SC F -Series: disconnect the low speed fuel pump relay and note the FPM PID.

Is a fault indicated?

Yes	No
KEY OFF. For 5.4L SC F -Series: If the FPM PID is consistently on with the low speed fuel pump relay disconnected, VERIFY condition of fuel pump ground circuit resistor. If OK, REPAIR the open circuit between the low speed fuel pump relay, through the resistor to the splice. Otherwise, GO to All others, Action to Take. All Others ISOLATE the fault Repair as necessary.	KEY OFF. Unable to duplicate or identify the fault at this time. GO to PINPOINT TEST Z step 1 .

KA39 CONTINUOUS MEMORY DTC P0231: CHECK THE HARNESS

NOTE: Some applications have the FPM splice to the FP PWR circuit between the IFS switch and the FP. On those applications, be aware that P0231 could be set if the IFS switch is tripped then reset.

PCM connector disconnected.
Connect a 5 amp fused jumper wire between the following:

Point A PCM Connector, Harness Side	Point B
FP	Ground

Key ON Engine OFF.
Measure the voltage between:

( + )PCM Connector, Harness Side	( - )
FPM	Ground

The FP will turn on and voltage will be greater than 10 V.
CHECK for an indication of a fault while completing the following. The voltage changes suddenly when a fault is detected.
- Shake, wiggle, and bend the B+ supply to the FPR.
- Shake, wiggle, and bend the FP PWR circuit between the FPR and the FPM splice.
- Lightly tap on the FPR & IFS to simulate road shock.
For 5.4L SC F -Series:
- Shake, wiggle, and bend the circuits connected to the IFSR.
- Lightly tap on the IFS & IFSR to simulate road shock.
Key OFF.
Visually inspect the FPR and its loom connector for damage and corrosion, repair or clean as necessary.

Is a fault indicated?

Yes	No
ISOLATE the fault Repair as necessary.	Unable to duplicate or identify the fault at this time. GO to PINPOINT TEST Z step 1 .

KA40 CONTINUOUS MEMORY DTC P0230: CHECK THE FP PRIMARY CIRCUITS

Key ON Engine OFF.
Wait for 5 seconds.
Access the PCM -FPF PID.
Observe the FPF PID for an indication of a fault while completing the following:
The PID indicates a fault (or YES), when a fault is detected.
Shake, wiggle, and bend the FP circuit between the PCM and the FPR.
Shake, wiggle, and bend the VPWR circuit between the electronic engine control power relay and the FPR.
Lightly tap on the FPR to simulate road shock.
Key OFF.
Visually inspect the PCM connector and wires as far back as the main loom for damage. Repair or clean as appropriate.
Visually inspect the FPR connector and wires as far back as the main loom for damage. Repair or clean as appropriate.

Is a fault indicated?

Yes	No
ISOLATE the fault Repair as necessary.	Unable to duplicate or identify the fault at this time.

KA41 KOEO DTC P1232: CHECK THE VPWR CIRCUIT FOR AN OPEN IN THE HARNESS

LSFP Relay connector disconnected.
Key ON Engine OFF.
Measure the voltage between:

( + )LSFP Relay Connector, Harness Side	( - )
VPWR - Pin 2	Ground

Is the voltage less than 10.5 V?

Yes	No
KEY OFF. GO to KA42.	REPAIR open circuit.

KA42 CHECK THE LOW SPEED FUEL PUMP RELAY

Measure resistance between pin 85 and all the other pins of the Low Speed Fuel Pump Relay. One measurement must be between 40 and 100 ohms, with the other measurements being greater than 10,000 ohms.

Are all Resistance checks OK?

Yes	No
GO to KA43.	INSTALL a new LSFP relay.

KA43 CHECK THE LOW FUEL PUMP CIRCUIT FOR A SHORT TO POWER IN THE HARNESS

PCM connector disconnected.
Key ON Engine OFF.
Measure the voltage between:

( + )LSFP Relay Connector, Harness Side	( - )
LFP - Pin 1	Ground

Is the voltage less than 1 V?

Yes	No
KEY OFF. GO to KA44.	REPAIR short circuit.

KA44 CHECK THE LFP CIRCUIT FOR A SHORT TO GROUND IN THE HARNESS

Measure the resistance between:

( + )LSFP Relay Connector, Harness Side	( - )
LFP - Pin 1	Ground

Is the resistance greater than 10K ohms?

Yes	No
GO to KA45.	REPAIR short circuit.

KA45 CHECK THE LFP CIRCUIT FOR AN OPEN IN THE HARNESS

Measure the resistance between:

( + )LSFP Relay Connector, Harness Side	( - )PCM Connector, Harness Side
LFP - Pin 1	LFP

Is the resistance less than 5 ohms?

Yes	No
INSTALL a new PCM. REFER to FLASH ELECTRICALLY ERASEABLE PROGRAMMABLE READ ONLY MEMORY - FLASH EEPROM .	REPAIR open circuit.

KA46 CHECK THE FUEL PUMP GROUND RESISTOR CIRCUIT FOR AN OPEN IN THE HARNESS

LSFP Relay connector disconnected.
Key ON Engine OFF.
Access the PCM -FPM PID.

Is the PID state OFF?

Yes	No
KEY OFF. No fault is present Disregard DTC P0232 at this time RETURN to QT: STEP 1: PCM QUICK TEST and CONTINUE diagnosis as directed.	REPAIR open circuit.

KA47 CONTINUOUS MEMORY DTC P1232: CHECK THE LOW SPEED FUEL PUMP PRIMARY CIRCUITS

Key ON Engine OFF.
Wait for 5 seconds.
Access the PCM -LFPF PID.
Observe the LFPF PID for an indication of a fault while completing the following:
NOTE:
- The LFPF PID indicates a fault (or YES), when a fault is detected.
- Shake, wiggle, and bend the VPWR circuit between electronic engine control power relay and the LSFPR.
- Shake, wiggle, and bend the LFP circuit between the PCM and the LSFPR.
- Lightly tap on the LSFPR to simulate road shock.
Key OFF.
Visually inspect the PCM and its loom connector for damage and corrosion, repair or clean as necessary.
Visually inspect the LSFPR connector and wires as far back as the main loom for damage. Repair or clean as appropriate.

Is a fault indicated?

Yes	No
ISOLATE the fault Repair as necessary.	Unable to duplicate or identify the fault at this time. GO to PINPOINT TEST Z step 1 .

KA48 CHECK THE FUEL PUMP GROUND RESISTOR

LSFP Relay connector disconnected.
Measure the resistance between:

( + )LSFP Relay Connector, Harness Side	( - )
FPGND	Ground

Is the resistance less than 7 ohms?

Yes	No
GO to KA49.	REPAIR open circuit.

KA49 CHECK FOR AN OPEN CIRCUIT BETWEEN LSFPR & FP

Repeat the test for each fuel pump.
FP connector disconnected.
Measure the resistance between:

( + )LSFP Relay Connector, Harness Side	( - )FP Connector, Harness Side
FPGND	FPGND

Is the resistance less than 5 ohms?

Yes	No
GO to KA50.	REPAIR open circuit.

KA50 CHECK THE INTERNAL RESISTANCE OF FP

Repeat the test for each fuel pump.
Measure the resistance between:

( + )FP Connector, Component Side	( - )FP Connector, Component Side
FPPWR-B	FPGND

Is the resistance less than 10 ohms?

Yes	No
GO to KA51.	INSTALL a new FP.

KA51 CHECK FOR AN OPEN CIRCUIT BETWEEN FPM SPLICE AND FUEL PUMPS

Repeat the test for each fuel pump.
IFS Relay connector disconnected.
Measure the resistance between:

( + )IFS Relay Connector, Harness Side	( - )FP Connector, Harness Side
FPPWR-B - Pin 5	FPPWR-B

Is the resistance less than 5 ohms?

Yes	No
No fault is present Disregard DTC P0232 at this time RETURN to QT: STEP 1: PCM QUICK TEST and CONTINUE diagnosis as directed.	REPAIR open circuit.

KA52 HARD START/LACKS POWER: CHECK THE GROUND CIRCUIT USED FOR THE HIGH SPEED FUEL PUMP OPERATION BETWEEN THE LSFP AND GND

LSFP Relay connector disconnected.
Measure the resistance between:

( + )LSFP Relay Connector, Harness Side	( - )
GND - Pin 4	Ground

Is the resistance less than 5 ohms?

Yes	No
GO to KA53.	REPAIR open circuit.

KA53 CHECK FOR AN OPEN CIRCUIT BETWEEN LSFPR AND SPLICE TO GROUND CIRCUIT THAT GOES THROUGH THE RESISTOR

Measure the resistance between:

( + )LSFP Relay Connector, Harness Side	( - )
From Fuel Pump (GND) - Pin 3	Ground

Is the resistance less than 7 ohms?

Yes	No
GO to KA54.	REPAIR open circuit.

KA54 CHECK FOR LOW SPEED FUEL PUMP CONTACTS ALWAYS CLOSED

Measure the resistance between:

( + )LSFP Relay Connector, Harness Side	( - )LSFP Relay Connector, Harness Side
FPGND	GND - Pin 4

Is the resistance less than 5 ohms?

Yes	No
High speed fuel pump circuits OK. RETURN to QT: STEP 1: PCM QUICK TEST and CONTINUE diagnosis as directed.	INSTALL a new LSFP relay.

KA55 KOEO AND KOER DTC P0230: CHECK FOR FP CIRCUIT CYCLING AT THE PDJB

NOTE: Related to applications with the FP relay integral to the PDJB circuit board.

Disconnect the PDJB connector that contains the FP circuit.
Connect non-powered test lamp between:

( + )PDJB Connector, Harness Side	( - )Vehicle battery
FP	Negative terminal

For F-Series and Excursion: (add the following jumper to complete the circuit).
Connect a 5 amp fused jumper wire between the following:

Point A PDJB Connector, Harness Side	Point B
GND	Ground

Key ON Engine OFF.
Scan Tool Connected
Enter Output Test Mode. Refer to OUTPUT TEST MODE .
Command outputs ON
Command outputs OFF

Does the test lamp turn on and off when the output(s) is commanded on and off?

Yes	No
GO to KA56.	KEY OFF. GO to KA57.

KA56 CHECK THE VPWR VOLTAGE THROUGH FP RLY AT PDJB

Key ON Engine OFF.
Measure the voltage between:

( + )PDJB Connector, Harness Side	( - )Vehicle battery
FP	Negative terminal

Is the voltage greater than 10 V?

Yes	No
Unable to duplicate or identify the fault at this time. RETURN to QT: STEP 1: PCM QUICK TEST and CONTINUE diagnosis as directed.	INSTALL a new PDJB.

KA57 CHECK THE FP CIRCUIT FOR A SHORT TO POWER IN THE HARNESS

PCM connector disconnected.
Key ON Engine OFF.
Measure the voltage between:

( + )PDJB Connector, Harness Side	( - )
FP	Ground

Is the voltage less than 1 V?

Yes	No
KEY OFF. GO to KA58.	REPAIR short circuit.

KA58 CHECK THE FUEL PUMP CIRCUIT FOR A SHORT TO GROUND IN THE HARNESS

Measure the resistance between:

( + )PDJB Connector, Harness Side	( - )
FP	Ground

Is the resistance greater than 10K ohms?

Yes	No
GO to KA59.	REPAIR short circuit.

KA59 CHECK THE FUEL PUMP CIRCUIT FOR AN OPEN IN THE HARNESS

Measure the resistance between:

( + )PDJB Connector, Harness Side	( - )PCM Connector, Harness Side
FP	FP

Is the resistance less than 5 ohms?

Yes	No
GO to KA60.	REPAIR open circuit.

KA60 WAS KOEO DTC P0231, P0232 ALSO PRESENT?

Was KOEO DTC P0231, P0232 also present?

Yes	No
GO to KA61.	INSTALL a new PCM. REFER to FLASH ELECTRICALLY ERASEABLE PROGRAMMABLE READ ONLY MEMORY - FLASH EEPROM .

KA61 CHECK THE FUEL PUMP PRIMARY CIRCUIT INSIDE THE PCM

NOTE: The following step(s) monitor the FPF PID to indicate if a fault is detected in the FP circuit in the PCM.

PCM connector connected.
PDJB connector connected.
Key ON Engine OFF.
Access the PCM -FPF PID.

Is the PID state FAULT?

Yes	No
KEY OFF. INSTALL a new PCM. Refer to FLASH ELECTRICALLY ERASEABLE PROGRAMMABLE READ ONLY MEMORY - FLASH EEPROM .	GO to KA62.

KA62 CHECK THE FUEL PUMP PRIMARY CIRCUIT INSIDE THE PCM WHILE CRANKING THE ENGINE

Observe the FPF PID for an indication of a fault while completing the following:

Crank the engine.

Does the PID display indicate a fault during crank?

Yes	No
KEY OFF. INSTALL a new PCM. Refer to FLASH ELECTRICALLY ERASEABLE PROGRAMMABLE READ ONLY MEMORY - FLASH EEPROM .	KEY OFF. GO to KA63.

KA63 WAS KOEO DTC P0231 ALSO PRESENT?

Was KOEO DTC P0231 also present?

Yes	No
GO to KA80.	DTC P0232 is present GO to KA64.

KA64 KOEO AND KOER DTC P0232: DOES THE ENGINE START?

NOTE: Related to applications with the FP relay integral to the PDJB circuit board.

Does the engine start?

Yes	No
GO to KA65.	GO to KA73.

KA65 VERIFY THAT FP IS OFF

Key ON Engine OFF.
Wait for 5 seconds.
The fuel pump is located above the fuel tank. Listen for the sound of the fuel pump operating which can be heard from outside the vehicle.

Is FP OFF with the key on?

Yes	No
KEY OFF. GO to KA69.	KEY OFF. GO to KA66.

KA66 CHECK THE FPPWR CIRCUIT FOR A SHORT TO POWER IN THE HARNESS

PDJB connector disconnected.
Key ON Engine OFF.

Is FP OFF with the key on?

Yes	No
GO to KA67.	REPAIR short circuit to PWR.

KA67 CHECK FOR FPR CONTACTS ALWAYS CLOSED

PDJB connector connected.
Disconnect the PDJB connector that contains the FPPWR circuit.
Key ON Engine OFF.
Wait for 5 seconds.

Is FP OFF with the key on?

Yes	No
GO to KA68.	INSTALL a new PDJB.

KA68 CHECK THE FPM CIRCUIT FOR A SHORT TO POWER IN THE HARNESS

PDJB connector connected.
PCM connector disconnected.
Key ON Engine OFF.

Is FP OFF with the key on?

Yes	No
INSTALL a new PCM.	REPAIR short circuit to PWR.

KA69 CHECK THE FUEL PUMP SECONDARY CIRCUITS FOR OPEN IN THE PDJB

Disconnect the PDJB connector that contains the FPPWR circuit.
Disconnect the PDJB connector that contains the FPM circuit.
Measure the resistance between:

( + )PDJB Connector, Component Side	( - )PDJB Connector, Component Side
FPM	FPPWR-A

Is the resistance less than 5 ohms?

Yes	No
GO to KA70.	REPAIR open circuit. INSTALL a new PDJB.

KA70 CHECK THE FPM CIRCUIT FOR AN OPEN IN THE HARNESS

PCM connector disconnected.
Measure the resistance between:

( + )PCM Connector, Harness Side	( - )PDJB Connector, Harness Side
FPM	FPM

Is the resistance less than 5 ohms?

Yes	No
GO to KA71.	REPAIR open circuit.

KA71 WAS KOEO DTC P0231 PRESENT?

Was KOEO DTC P0231 present?

Yes	No
INSTALL a new PCM. REFER to FLASH ELECTRICALLY ERASEABLE PROGRAMMABLE READ ONLY MEMORY - FLASH EEPROM .	DTC P0232 is present GO to KA72.

KA72 CHECK THE FPM PID

PCM connector connected.
PDJB connector disconnected.
Access the PCM -FPM PID.

Is the PID state OFF?

Yes	No
KEY OFF. The FPM circuit is OK in the harness and PCM. Disregard DTC P0232 at this time. RETURN to QT: STEP 1: PCM QUICK TEST and CONTINUE diagnosis as directed.	INSTALL a new PCM. REFER to FLASH ELECTRICALLY ERASEABLE PROGRAMMABLE READ ONLY MEMORY - FLASH EEPROM .

KA73 CHECK IF IFS TRIPPED

Is IFS tripped?

Yes	No
Reset Switch	GO to KA74.

KA74 CHECK THE IFS SWITCH

Inertia Switch connector disconnected.
Measure the resistance between:

( + )IFS Connector, Component Side	( - )IFS Connector, Component Side
FPPWR-A - Pin 2	FPPWR-B - Pin 1

Is the resistance less than 5 ohms?

Yes	No
GO to KA75.	INSTALL a new IFS.

KA75 CHECK THE FUEL PUMP SECONDARY CIRCUITS FOR OPEN IN THE PDJB

Disconnect the PDJB connector that contains the FPPWR circuit.
Disconnect the PDJB connector that contains the FPM circuit.
Measure the resistance between:

( + )PDJB Connector, Component Side	( - )PDJB Connector, Component Side
FPM	FPPWR-A

Is the resistance less than 5 ohms?

Yes	No
GO to KA76.	REPAIR open circuit INSTALL a new PDJB.

KA76 CHECK THE FPPWR CIRCUIT FOR AN OPEN IN THE HARNESS

Measure the resistance between:

( + )IFS Connector, Harness Side	( - )PDJB Connector, Harness Side
FPPWR-A - Pin 2	FPPWR-A

Is the resistance less than 5 ohms?

Yes	No
GO to KA77.	REPAIR open circuit.

KA77 CHECK THE FUEL PUMP GROUND CIRCUIT FOR AN OPEN IN THE HARNESS

FP connector disconnected.
Measure the resistance between:

( + )FP Connector, Harness Side	( - )
FPGND	Ground

Is the resistance less than 5 ohms?

Yes	No
GO to KA78.	REPAIR open circuit.

KA78 CHECK THE FPPWR CIRCUIT FOR AN OPEN IN THE HARNESS

Measure the resistance between:

( + )IFS Connector, Harness Side	( - )FP Connector, Harness Side
FPPWR-A - Pin 2	FPPWR

Is the resistance less than 5 ohms?

Yes	No
GO to KA79.	REPAIR open circuit.

KA79 CHECK THE INTERNAL RESISTANCE OF FP

Measure the resistance between:

( + )FP Connector, Harness Side	( - )FP Connector, Harness Side
FPPWR	FPGND

Is the resistance less than 10 ohms?

Yes	No
All FP circuit checks are OK Verify the test step results If all test steps are OK, Reconnect all the disconnected components. Disregard DTC P0232 at this time RETURN to QT: STEP 1: PCM QUICK TEST and CONTINUE diagnosis as directed.	INSTALL a new FP.

KA80 KOEO AND KOER DTC P0231: WAS KOEO DTC P0230 ALSO PRESENT?

NOTE: Related to applications with the FP relay integral to the PDJB circuit board.

CHECK PCM KOEO DTCs:

Is DTC P0230 present?

Yes	No
GO to KA70.	GO to KA81.

KA81 KOEO DTC P0231: DOES THE ENGINE START?

Does the engine start?

Yes	No
GO to KA70.	GO to KA82.

KA82 CHECK THE FUEL PUMP FUSE

CHECK the FP fuse. Is it OK?

Yes	No
GO to KA83.	Before replacing fuse : Check for damage to wiring Check for a damaged or seized motor.

KA83 CHECK THE FUEL PUMP SECONDARY CIRCUITS FOR OPEN IN THE PDJB

Disconnect the PDJB connector that contains the FPPWR circuit.
Key ON Engine OFF.
Scan Tool Connected
Enter Output Test Mode. Refer to OUTPUT TEST MODE .
Command outputs ON
Measure the voltage between:

( + )PDJB Connector, Harness Side	( - )
FPPWR-A	Ground

Is the voltage greater than 10.5 V?

Yes	No
All Fuel Pump circuit checks are OK Verify the test step results If all test steps are OK, Reconnect all the disconnected components. Disregard DTC P0232 at this time RETURN to QT: STEP 1: PCM QUICK TEST and CONTINUE diagnosis as directed.	INSTALL a new PDJB.

KA84 CONTINUOUS MEMORY DTC P0230: CHECK THE FP PRIMARY CIRCUITS

NOTE: Related to applications with the FP relay integral to the PDJB circuit board.

Key ON Engine OFF.
Wait for 5 seconds.
Access the PCM -FPF PID.
Observe the FPF PID for an indication of a fault while completing the following:
The PID indicates a fault (or YES), when a fault is detected.
Shake, wiggle, and bend the FP circuit between the PCM and the PDJB.
Lightly tap on the PDJB to simulate road shock.
Key OFF.
Visually inspect the PCM and its loom connector for damage and corrosion, repair or clean as necessary.
Visually inspect the PDJB and its loom connector for damage and corrosion, repair or clean as necessary.

Is a fault indicated?

Yes	No
ISOLATE the fault Repair as necessary.	Unable to duplicate or identify the fault at this time. GO to PINPOINT TEST Z step 1 .

KA85 CONTINUOUS MEMORY DTC P0231: CHECK THE FUEL PUMP SECONDARY CIRCUITS FOR FAULT

Disconnect the PDJB connector that contains the FPPWR circuit.
Key ON Engine OFF.
Scan Tool Connected
Enter Output Test Mode. Refer to OUTPUT TEST MODE .
Command outputs ON

Measure the voltage between:

( + )PDJB Connector, Harness Side	( - )
FPPWR-A	Ground

Observe the Voltage for an indication of a fault while completing the following: Voltage drops suddenly when a fault is detected. Be aware that Output Test Mode turns off the FP after a calibrated time. If this happens, command the outputs on again to continue testing.
- Lightly tap on the FP FUSE to simulate road shock.
- Lightly tap on the PDJB to simulate road shock.

Is a fault indicated?

Yes	No
ISOLATE the fault and REPAIR as necessary.	Unable to duplicate or identify the fault at this time. GO to PINPOINT TEST Z step 1 .

KA86 KOEO DTC P0232: CHECK THE FUEL PUMP SECONDARY CIRCUITS FOR FAULT

CHECK Self-Test DTCs:

Is DTC P0230 present?

Yes	No
GO to KA84.	GO to KA87.

KA87 KOEO DTC P0232: CHECK THE FUEL PUMP SECONDARY CIRCUITS FOR FAULT

Key ON Engine OFF.
Access the PCM -FPM PID.
Observe the PID for an indication of a fault while completing the following:
The FPM PID will turn ON when a fault is indicated.
Shake, wiggle, and bend the FPPWR circuit between the FPPWR pin at the PDJB and the FP.
Shake, wiggle, and bend the FP GND.
Shake, wiggle, and bend the FPM circuit between the PDJB and the PCM.
Lightly tap on the FP to simulate road shock.
Lightly tap on the IFS to simulate road shock.
Lightly tap on the PDJB to simulate road shock.

Is the PID state FAULT?

Yes	No
KEY OFF. ISOLATE the fault and REPAIR as necessary.	KEY OFF. Unable to duplicate or identify the fault at this time. GO to PINPOINT TEST Z step 1 .