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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 2803 (Engine Controls - (Hybrid) - Pinpoint Tests JF - TD) >> PINPOINT TEST KB: Fuel Pump Driver Module (FPDM) >> Test Procedure

Test Procedure

WARNING: This page is about a different car, the 2007 Mercury Mariner and 2007 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
  1. KB1 DIAGNOSTIC TROUBLE CODES (DTCS) P1233, P1235, AND P1237: CHECK FOR SELF-TEST DTCS 
    • Are any of the following DTCs present during PCM or transaxle control module (TCM) self-test: P1233, P1235, or P1237? 
    Yes No
    For DTC P1233, GO to  KB2.
    For DTC P1235, GO to  KB17.
    For DTC P1237, GO to  KB25.    		 RETURN to the SYMPTOM CHARTS article, Symptom Charts for further direction.
  2. KB2 DTC P1233: IS DTC P1233 PRESENT IN THE KOEO SELF-TEST? 
    • Is DTC P1233 present in the KOEO or KOER self-test? 
    Yes No
    GO to  KB4. The PCM is now receiving a signal from the FPDM. One possible cause of DTC P1233 is that the IFS switch was tripped, then reset.
    GO to  KB3.
  3. KB3 DOES THE ENGINE START? 
    • Does the engine start? 
    Yes No
    GO to  KB13. DISREGARD the DTC at this time. RETURN to Section 3 and continue as directed. After repairing the no start, to diagnose intermittent causes of P1233,
    GO to  KB13.
  4. KB4 KOEO DTC P1233: DOES THE ENGINE START? 
    • Does the engine start? 
    Yes No
    To check the FPM circuit,
    GO to  KB9.    		 VERIFY the IFS switch is set (button pressed).
    GO to  KB5.
  5. KB5 CHECK THE VOLTAGE AND GROUND CIRCUITS TO THE FPDM 
    • FPDM connector disconnected.
    • Key ON, engine OFF.
    • Measure the voltage between:
      ( + ) FPDM Connector, Harness Side ( - ) FPDM Connector, Harness Side
      VPWR - Pin 5 GND - Pin 3
    • Is the voltage greater than 10.5 V? 
    Yes No
    INSTALL a new FPDM. REFER to FUEL CHARGING AND CONTROLS - HYBRID .
    CLEAR the DTCs. REPEAT the self-test.    		 GO to  KB6.
  6. KB6 CHECK VOLTAGE TO FPDM 
    • Key ON, engine OFF.
    • Measure the voltage between:
      ( + ) FPDM Connector, Harness Side ( - )
      VPWR - Pin 5 Ground
    • Is the voltage greater than 10.5 V? 
    Yes No
    REPAIR the open ground circuit to the FPDM.
    CLEAR the DTCs. REPEAT the self-test.    		 GO to  KB7.
  7. KB7 CHECK THE VOLTAGE TO FRONT IFS SWITCH 
    • Key in OFF position.
    • IFS Switch connector disconnected.
    • Key ON, engine OFF.
    • Measure the voltage between:
      ( + ) IFS Switch Connector, Harness Side ( - )
      VPWR - Pin 2 Ground
    • Is the voltage greater than 10.5 V? 
    Yes No
    GO to  KB8. There is a VPWR circuit concern. 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 a short to ground before installing a new fuse/fuse link.
    CLEAR the DTCs. REPEAT the self-test.
  8. KB8 CHECK THE RESISTANCE OF FRONT IFS SWITCH 
    • Key in OFF position.
    • Measure the resistance between:
      ( + ) IFS Switch Connector, Component Side ( - ) IFS Switch Connector, Component Side
      VPWR - Pin 2 FPDMPWR-A - Pin 1
    • Is the resistance less than 5 ohms? 
    Yes No
    REPAIR the open FPDM PWR circuit.
    CLEAR the DTCs. REPEAT the self-test.    		 INSTALL a new IFS switch. REFER to FUEL TANK AND LINES - HYBRID .
    CLEAR the DTCs. REPEAT the self-test.
  9. KB9 CHECK THE FPM CIRCUIT FOR AN OPEN IN THE HARNESS 
    • FPDM connector disconnected.
    • PCM connector disconnected.
    • Measure the resistance between:
      ( + ) FPDM Connector, Harness Side ( - ) PCM Connector, Harness Side
      FPM - Pin 1 FPM - Pin B46
    • Is the resistance less than 5 ohms? 
    Yes No
    GO to  KB10. REPAIR the open circuit. CLEAR the DTCs. REPEAT the self-test.
  10. KB10 CHECK THE FPM CIRCUIT FOR A SHORT TO VOLTAGE IN THE HARNESS 
    • Key ON, engine OFF.
    • Measure the voltage between:
      ( + ) FPDM Connector, Harness Side ( - )
      FPM - Pin 1 Ground
    • Is the voltage less than 1 V? 
    Yes No
    GO to  KB11. REPAIR the short circuit. CLEAR the DTCs. REPEAT the self-test.
  11. KB11 CHECK THE FPM CIRCUIT FOR A SHORT TO GROUND IN THE HARNESS 
    • Key in OFF position.
    • Measure the resistance between:
      ( + ) FPDM Connector, Harness Side ( - )
      FPM - Pin 1 Ground
    • Is the resistance greater than 10K ohms? 
    Yes No
    GO to  KB12. REPAIR the short circuit. CLEAR the DTCs. REPEAT the self-test.
  12. KB12 CHECK FOR FPM OUTPUT FROM THE PCM 
    NOTE: It is OK for the voltage to cycle below this range and then return within range.
    • FPDM connector connected.
    • Key ON, engine OFF.
    • Measure the voltage between:
      ( + ) PCM Connector, Harness Side ( - )
      FPM - Pin B46 Ground
    • Is the voltage between 0.02 - 1 V? 
    Yes No
    GO to  KB37. INSTALL a new FPDM. REFER to FUEL CHARGING AND CONTROLS - HYBRID .
    CLEAR the DTCs. REPEAT the self-test.
  13. KB13 CHECK THE FPDM PWR AND GND CIRCUITS FOR AN INTERMITTENT CONCERN 
    NOTE: Be aware that DTC P1233 could be set if the IFS switch is tripped then reset.
    • Key in OFF position.
    • FPDM connector disconnected.
    • Connect a non-powered test lamp between:
      ( + ) FPDM Connector, Harness Side ( - ) FPDM Connector, Harness Side
      FPDM PWR GND - Pin 3
    • Key ON, engine OFF.
    • Observe the test lamp for an indication of a concern while carrying out the following. Note that the lamp turns OFF when a concern is detected.
    • Wiggle, shake, and bend small sections of the wiring harness while working from the component to the module.
    • Is a concern present? 
    Yes No
    ISOLATE the concern and REPAIR as necessary.
    CLEAR the DTCs. REPEAT the self-test.    		 GO to  KB14.
  14. KB14 CHECK FOR AN INTERMITTENT OPEN IN THE FPM CIRCUIT 
    • Key in OFF position.
    • PCM connector disconnected.
    • Measure the resistance between:
      ( + ) FPDM Connector, Harness Side ( - ) PCM Connector, Harness Side
      FPM - Pin 1 FPM - Pin B46
    • Observe the DMM for an indication of a concern while completing the following. The resistance changes suddenly when a concern is present.
    • Wiggle, shake, and bend small sections of the wiring harness while working from the component to the module.
    • Is a concern present? 
    Yes No
    ISOLATE the concern and REPAIR as necessary.
    CLEAR the DTCs. REPEAT the self-test.    		 GO to  KB15.
  15. KB15 CHECK FOR AN INTERMITTENT SHORT TO VOLTAGE IN THE FPM CIRCUIT 
    • Key ON, engine OFF.
    • Measure the voltage between:
      ( + ) FPDM Connector, Harness Side ( - ) Vehicle Battery
      FPM - Pin 1 Negative terminal
    • Observe the DMM for an indication of a concern while completing the following. The voltage changes suddenly when a concern is present.
    • Wiggle, shake, and bend small sections of the wiring harness while working from the component to the module.
    • Is a concern present? 
    Yes No
    ISOLATE the concern and REPAIR as necessary.
    CLEAR the DTCs. REPEAT the self-test.    		 GO to  KB16.
  16. KB16 CHECK FOR AN INTERMITTENT SHORT TO GROUND IN THE FPM CIRCUIT 
    • Key in OFF position.
    • Measure the resistance between:
      ( + ) FPDM Connector, Harness Side ( - )
      FPM - Pin 1 Ground
    • Observe the DMM for an indication of a concern while completing the following. The resistance changes suddenly when a concern is present.
    • Wiggle, shake, and bend small sections of the wiring harness while working from the component to the module.
    • Is a concern present? 
    Yes No
    ISOLATE the concern and REPAIR as necessary.
    CLEAR the DTCs. REPEAT the self-test.    		 Unable to duplicate or identify the concern at this time.
    refer to PINPOINT TEST Z .
  17. KB17 KOEO AND KOER DTC P1235: IS DTC P1235 PRESENT IN THE KOEO OR KOER SELF-TEST? 
    • Is DTC P1235 present in the KOEO or KOER self-test? 
    Yes No
    GO to  KB18. CHECK for an intermittent concern,
    GO to  KB22.
  18. KB18 CHECK THE FP CIRCUIT FOR AN OPEN IN THE HARNESS 
    • FPDM connector disconnected.
    • PCM connector disconnected.
    • Measure the resistance between:
      ( + ) PCM Connector, Harness Side ( - ) FPDM Connector, Harness Side
      FP - Pin B12 FP - Pin 6
    • Is the resistance less than 5 ohms? 
    Yes No
    GO to  KB19. REPAIR the open circuit. CLEAR the DTCs. REPEAT the self-test.
  19. KB19 CHECK THE FP CIRCUIT FOR A SHORT TO VOLTAGE IN THE HARNESS 
    • Key ON, engine OFF.
    • Measure the voltage between:
      ( + ) FPDM Connector, Harness Side ( - )
      FP - Pin 6 Ground
    • Is the voltage less than 1 V? 
    Yes No
    GO to  KB20. REPAIR the short circuit. CLEAR the DTCs. REPEAT the self-test.
  20. KB20 CHECK THE FP CIRCUIT FOR A SHORT TO GROUND IN THE HARNESS 
    • Key in OFF position.
    • Measure the resistance between:
      ( + ) FPDM Connector, Harness Side ( - )
      FP - Pin 6 Ground
    • Is the resistance greater than 10K ohms? 
    Yes No
    GO to  KB21. REPAIR the short circuit. CLEAR the DTCs. REPEAT the self-test.
  21. KB21 CHECK THE FP CIRCUIT IN THE FPDM 
    • FPDM connector connected.
    • Key ON, engine OFF.
    • Measure the voltage between:
      ( + ) PCM Connector, Harness Side ( - )
      FP - Pin B12 Ground
    • Is the voltage greater than 10.5 V? 
    Yes No
    GO to  KB37. INSTALL a new FPDM. REFER to FUEL CHARGING AND CONTROLS - HYBRID .
    CLEAR the DTCs. REPEAT the self-test.
  22. KB22 CHECK FOR AN INTERMITTENT OPEN IN THE FP CIRCUIT 
    • Key in OFF position.
    • FPDM connector disconnected.
    • PCM connector disconnected.
    • Measure the resistance between:
      ( + ) FPDM Connector, Harness Side ( - ) PCM Connector, Harness Side
      FP - Pin 6 FP - Pin B12
    • Observe the DMM for an indication of a concern while completing the following. The resistance changes suddenly when a concern is present.
    • Wiggle, shake, and bend small sections of the wiring harness while working from the component to the module.
    • Is a concern present? 
    Yes No
    ISOLATE the concern and REPAIR as necessary.
    CLEAR the DTCs. REPEAT the self-test.    		 GO to  KB23.
  23. KB23 CHECK FOR AN INTERMITTENT SHORT TO VOLTAGE IN THE FP CIRCUIT 
    • Key ON, engine OFF.
    • Measure the voltage between:
      ( + ) FPDM Connector, Harness Side ( - ) Vehicle Battery
      FP - Pin 6 Negative terminal
    • Observe the DMM for an indication of a concern while completing the following. The voltage changes suddenly when a concern is present.
    • Wiggle, shake, and bend small sections of the wiring harness while working from the component to the module.
    • Is a concern present? 
    Yes No
    ISOLATE the concern and REPAIR as necessary.
    CLEAR the DTCs. REPEAT the self-test.    		 GO to  KB24.
  24. KB24 CHECK FOR AN INTERMITTENT SHORT TO GROUND IN THE FP CIRCUIT 
    • Key in OFF position.
    • Measure the resistance between:
      ( + ) FPDM Connector, Harness Side ( - )
      FP - Pin 6 Ground
    • Observe the DMM for an indication of a concern while completing the following. The resistance changes suddenly when a concern is present.
    • Wiggle, shake, and bend small sections of the wiring harness while working from the component to the module.
    • Is a concern present? 
    Yes No
    ISOLATE the concern and REPAIR as necessary.
    CLEAR the DTCs. REPEAT the self-test.    		 Unable to duplicate or identify the concern at this time.
    refer to PINPOINT TEST Z .
  25. KB25 DTC P1237: IS DTC P1237 PRESENT IN THE KOEO OR KOER SELF-TEST? 
    • Is DTC P1237 present in the KOEO or KOER self-test? 
    Yes No
    GO to  KB26. CHECK for an intermittent concern,
    GO to  KB35.
  26. KB26 DOES THE ENGINE START? 
    • Does the engine start? 
    Yes No
    GO to  KB33. GO to  KB27.
  27. KB27 CHECK FPPWR, FPRTN, AND INTERNAL FUEL PUMP CIRCUIT RESISTANCE 
    • FPDM connector disconnected.
    • Measure the resistance between:
      ( + ) FPDM Connector, Harness Side ( - ) FPDM Connector, Harness Side
      FPPWR - Pin 4 FPRTN - Pin 2
    • Is the resistance less than 10 ohms? 
    Yes No
    GO to  KB28. GO to  KB31.
  28. KB28 CHECK THE FPRTN CIRCUIT FOR A SHORT TO VOLTAGE IN THE HARNESS 
    • Key ON, engine OFF.
    • Measure the voltage between:
      ( + ) FPDM Connector, Harness Side ( - )
      FPRTN - Pin 2 Ground
    • Is the voltage less than 1 V? 
    Yes No
    GO to  KB29. REPAIR the short circuit. CLEAR the DTCs. REPEAT the self-test.
  29. KB29 CHECK THE FPPWR CIRCUIT FOR A SHORT TO GROUND IN THE HARNESS 
    • Key in OFF position.
    • Measure the resistance between:
      ( + ) FPDM Connector, Harness Side ( - )
      FPPWR - Pin 4 Ground
    • Is the resistance greater than 10K ohms? 
    Yes No
    GO to  KB30. REPAIR the short circuit. CLEAR the DTCs. REPEAT the self-test.
  30. KB30 CHECK FOR VOLTAGE TO THE FP 
    NOTE: During output test mode, the fuel pump stays commanded on for only about 5 seconds.
    • FP connector disconnected.
    • FPDM connector connected.
    • Key ON, engine OFF.
    • Enter output test mode. Refer toOUTPUT TEST MODE (OTM) .
    • Command the outputs ON.
    • Measure the voltage between:
      ( + ) FP Connector, Harness Side ( - ) FP Connector, Harness Side
      FPPWR FPRTN
    • Is the voltage greater than 10 V? 
    Yes No
    INSTALL a new FP. REFER to FUEL TANK AND LINES - HYBRID .
    CLEAR the DTCs. REPEAT the self-test.    		 VERIFY the vehicle battery was at a proper charge during the test.
    VERIFY the pump ON command did not time out before the voltage check was made.
    If OK, INSTALL a new FPDM. REFER to FUEL CHARGING AND CONTROLS - HYBRID .
    CLEAR the DTCs. REPEAT the self-test.
  31. KB31 ISOLATE THE OPEN IN THE FP CIRCUIT 
    • FP connector disconnected.
    • Measure the resistance between:
      ( + ) FPDM Connector, Harness Side ( - ) FP Connector, Harness Side
      FPPWR - Pin 4 FPPWR
      FPRTN - Pin 2 FPRTN
    • Are the resistances less than 5 ohms? 
    Yes No
    GO to  KB32. REPAIR the open circuit. CLEAR the DTCs. REPEAT the self-test.
  32. KB32 CHECK THE FUEL PUMP 
    • Measure the resistance between:
      ( + ) FP Connector, Harness Side ( - ) FP Connector, Harness Side
      FPPWR FPRTN
    • Is the resistance less than 10 ohms? 
    Yes No
    Unable to duplicate or identify the concern at this time.
    VERIFY the results of the previous test steps.    		 INSTALL a new FP. REFER to FUEL TANK AND LINES - HYBRID .
    CLEAR the DTCs. REPEAT the self-test.
  33. KB33 CHECK THE FPPWR CIRCUIT FOR A SHORT TO VOLTAGE IN THE HARNESS 
    • FPDM connector disconnected.
    • Key ON, engine OFF.
    • Measure the voltage between:
      ( + ) FPDM Connector, Harness Side ( - )
      FPPWR - Pin 4 Ground
    • Is the voltage less than 1 V? 
    Yes No
    GO to  KB34. REPAIR the short circuit. CLEAR the DTCs. REPEAT the self-test.
  34. KB34 CHECK THE FPRTN CIRCUIT(S) FOR A SHORT TO GROUND IN THE HARNESS 
    • Key in OFF position.
    • Measure the resistance between:
      ( + ) FPDM Connector, Harness Side ( - )
      FPRTN - Pin 2 Ground
    • Is the resistance greater than 10K ohms? 
    Yes No
    INSTALL a new FPDM. REFER to FUEL CHARGING AND CONTROLS - HYBRID .
    CLEAR the DTCs. REPEAT the self-test.    		 REPAIR the short circuit. CLEAR the DTCs. REPEAT the self-test.
  35. KB35 CHECK FOR AN INTERMITTENT OPEN OR SHORT IN THE FPPWR AND FPRTN CIRCUITS 
    • Key in OFF position.
    • FPDM connector disconnected.
    • Measure the resistance between:
      ( + ) FPDM Connector, Harness Side ( - ) FPDM Connector, Harness Side
      FPPWR - Pin 4 FPRTN - Pin 2
    • Observe the DMM for an indication of a concern while completing the following. The resistance changes suddenly when a concern is present.
    • Wiggle, shake, and bend small sections of the wiring harness while working from the component to the module.
    • Is a concern present? 
    Yes No
    ISOLATE the concern and REPAIR as necessary.
    CLEAR the DTCs. REPEAT the self-test.    		 GO to  KB36.
  36. KB36 CHECK FOR AN INTERMITTENT SHORT TO VOLTAGE IN THE FPRTN CIRCUIT 
    • Key ON, engine OFF.
    • Measure the voltage between:
      ( + ) FPDM Connector, Harness Side ( - ) Vehicle Battery
      FPRTN - Pin 2 Negative terminal
    • Observe the DMM for an indication of a concern while completing the following. The voltage changes suddenly when a concern is present.
    • Wiggle, shake, and bend small sections of the wiring harness while working from the component to the module.
    • Is a concern present? 
    Yes No
    ISOLATE the concern and REPAIR as necessary.
    CLEAR the DTCs. REPEAT the self-test.    		 Unable to duplicate or identify the concern at this time.
    refer to PINPOINT TEST Z .
  37. KB37 CHECK FOR CORRECT PCM OPERATION 
    • Disconnect all the PCM connectors.
    • Visually inspect for:
      • pushed out pins
      • corrosion
    • Connect all the PCM connectors and make sure they seat correctly.
    • Carry out the PCM self-test and verify the concern is still present.
    • Is the concern still present? 
    Yes No
    INSTALL a new PCM. REFER toFLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) . The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector.
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