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Home >> Ford >> 2003 >> Excursion 6.0 P, RWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (ENGINE CONTROLS - SELF-DIAGNOSTICS - 7.3L (995, 996 F650/750, 99F E Series & 99F F450/550) DIESEL) >> System Tests >> Test FK: Fuel Pump Monitor Control (ECONOLINE, Excursion & F250-550) >> Testing

Test FK: Fuel Pump Monitor Control (ECONOLINE, Excursion & F250-550): Testing

WARNING: This page is about a different variant/trim than selected.
FAULT CODE SETTING CONDITION

Fault Code
(All except F650-750)		 KOEO KOER Continuous Memory
P0230 Test FK  , Step  1)   Test FK  , Step  16)
P0231 (1) Test FK  , Step  5)   Test FK  , Step  18)
P0232 Test FK  , Step  11)   Test FK  , Step  20)
(1) MIL illuminates when fault is detected in second drive cycle (California, OBD-II calibration).
    NOTE: For additional testing information, see DIAGNOSTIC AIDS .

  1. 1) KOEO DTC P0230: Check Fuel Pump Relay PWR Fuse
    DTC P0230 indicates PCM has detected a fuel pump relay driver circuit failure. Possible causes are:
    • Blown Fuse
    • Faulty Fuel Pump Relay
    • Open FPC Circuit
    • Faulty PCM

    On Excursion and F250-550, go directly to next step. On Econoline, remove and inspect fuse No. 8 (30-amp) from central junction box. Central junction box is located behind lower left side of instrument panel. If fuse is okay, reinstall fuse and go to next step. If fuse is blown, replace fuse. Clear DTCs and retest.

  2. 2) Check Power To Fuel Pump Relay Coil

    On Econoline, remove fuel pump relay from battery junction box. Battery junction box is located on left front of engine compartment. On Excursion and F250-550, remove fuel pump relay from central junction box. Central junction box is located behind lower left side of instrument panel. On all models, turn ignition on. Using DVOM, measure voltage between chassis ground and fuel pump relay cavity No. 85 (Econoline), or cavity No. 1 (Excursion and F250-550) in battery junction box. See Figure or Figure . If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 volts or less, check for open in Red/Light Green wire between fuse No. 8 and fuel pump relay (Econoline), or check for open circuit in central junction box between PCM PWR relay and fuel pump relay (Excursion and F250-550). Repair circuit or replace central junction box as necessary. See WIRING DIAGRAMS . Clear DTCs and retest.
    3. NOTE: When ignition is turned on, PCM will ground fuel pump relay for only 20 seconds when engine is not running.

  3. 3) Check Relay Trigger Circuit
    Ensure fuel pump relay is removed. Using DVOM, measure resistance between chassis ground and fuel pump relay cavity No. 86 (Econoline), or cavity No. 2 (Excursion and F250-550). See Figure or Figure . Turn ignition on. If resistance is less than 100 ohms within 20 seconds of turning ignition on, replace fuel pump relay. Clear DTCs and retest. If resistance is 100 ohms or more at all times, go to next step.

  4. 4) Check For Open FPC Circuit

    Turn ignition off. Disconnect PCM connector and inspect for damaged pins, corrosion and loose wires. PCM is located in left rear of engine compartment, near brake master cylinder. Repair connector as necessary. Install Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance of FPC circuit (Light Blue/Orange wire) between test pin No. 94 at breakout box and fuel pump relay cavity No. 86 (Econoline), or cavity No. 2 (Excursion and F250-550). See Figure or Figure . If resistance is less than 5 ohms, replace PCM. Clear DTCs and retest. If resistance is 5 ohms or more, repair open in Light Blue/Orange wire between PCM and fuel pump relay. Clear DTCs and retest.
    5. NOTE: For additional testing information, see DIAGNOSTIC AIDS .
    NOTE: When ignition is turned on, PCM will ground fuel pump relay for only 20 seconds when engine is not running.

  5. 5) KOEO DTC P0231: Check FPM Circuit To IFS Switch
    If DTC P0230 is also present, go to step  1). DTC P0231 indicates fuel pump relay driver failed on and was not detected on FPM circuit when fuel pump was commanded on by PCM. Possible causes are:
    • Faulty Inertia Fuel Shutoff (IFS) Switch
    • Blown Fuel Pump Fuse
    • Open Fuel Pump Control (FPC) Or Fuel Pump Monitor (FPM) Circuit
    • Faulty Fuel Pump Relay

    Disconnect IFS switch connector. IFS switch is located behind right kick panel. Turn ignition on. Using DVOM, measure voltage between chassis ground and Dark Green/Yellow wire at IFS switch harness connector. See Figure or Figure . If voltage is more than 10.5 volts within 20 seconds of turning ignition on, go to next step. If voltage is 10.5 volts or less at all times, go to step  8).

  6. 6) Check IFS Switch

    Reconnect IFS switch connector. Using DVOM, measure voltage between chassis ground and Pink/Black wire at IFS switch harness connector. If battery voltage is present, go to next step. If battery voltage is not present, reset or replace inertia switch.

  7. 7) Check For Open FPM Circuit

    Disconnect PCM connector and inspect for damaged pins, corrosion and loose wires. PCM is located in left rear of engine compartment, near brake master cylinder. Repair connector as necessary. Install Rotunda Breakout Box (014-00950), leaving PCM disconnected. Disconnect IFS switch connector. Using DVOM, measure resistance of FPM circuit (Pink/Black wire) between IFS switch harness connector and test pin No. 40 at breakout box. If resistance is less than 5 ohms, replace PCM. Clear DTCs and retest. If resistance is 5 ohms or more, repair open in Pink/Black wire between PCM and IFS switch. Clear DTCs and retest.

  8. 8) Check Fuel Pump Fuse

    Turn ignition off. On Econoline, remove and inspect fuse No. 17 (30-amp) from battery junction box. Battery junction box is located on left front of engine compartment. On Excursion and F250-550, remove fuse No. 40 (20-amp) from central junction box. Central junction box is located behind lower left side of instrument panel. On all models, if fuse is okay, reinstall fuse and go to next step. If fuse is blown, replace fuse. Clear DTCs and retest.

  9. 9) Check For Power To Fuel Pump Relay

    Remove fuel pump relay from battery junction box (Econoline) or central junction box (Excursion and F250-550). Turn ignition on. Using DVOM, measure voltage between chassis ground and fuel pump relay cavity No. 30 (Econoline), or cavity No. 3 (Excursion and F250-550). See Figure or Figure . If voltage is more than 10.5 volts, go to next step. If voltage is 10.5 volts or less, check for open in Yellow wire between fuse No. 17 and fuel pump relay (Econoline), or check for open circuit in central junction box between fuse No. 40 and fuel pump relay (Excursion and F250-550). Repair circuit or replace central junction box as necessary. See WIRING DIAGRAMS . Clear DTCs and retest.

  10. 10) Check IFS Switch Power Circuit

    Turn ignition off. Disconnect IFS switch connector. IFS switch is located behind right kick panel. Using DVOM, measure resistance of Dark Green/Yellow wire between IFS switch harness connector and fuel pump relay cavity No. 87 (Econoline), or cavity No. 5 (Excursion and F250-550). If resistance is less than 5 ohms, replace fuel pump relay. Clear DTCs and retest. If resistance is 5 ohms or more, locate and repair open in Dark Green/Yellow wire between IFS switch and fuel pump relay. Clear DTCs and retest.
    11. NOTE: For additional testing information, see DIAGNOSTIC AIDS .
    NOTE: Ignore DTC P0230 at this time.

  11. 11) KOEO DTC P0232: Repeat KOEO Self-Test
    DTC P0232 indicates fuel pump relay driver failed off and voltage was detected on FPM circuit when fuel pump was commanded off. Possible causes are:
    • Short To Voltage In IFS Switch Power Circuit
    • Short To Voltage In FPM Or Fuel Pump Power Circuit
    • Short To Ground In FPC Circuit
    • Faulty Fuel Pump Relay
    • Faulty PCM

    On Excursion and F250-550, go to next step. On Econoline, remove fuse No. 8 (30-amp) from central junction box. Central junction box is located behind lower left side of instrument panel. Turn ignition on. Perform KOEO ON-DEMAND SELF-TEST . If DTC P0232 is present, reinstall fuse and go to next step. If DTC P0232 is not present, go to step  15).

  12. 12) Check Fuel Pump Relay For Internal Short

    On Econoline, remove fuel pump relay from battery junction box. Battery junction box is located on left front of engine compartment. On Excursion and F250-550, remove fuel pump relay from central junction box. Central junction box is located behind lower left side of instrument panel. On all models, perform KOEO ON-DEMAND SELF-TEST  under QUICK TEST. If DTC P0232 is present, go to next step. If DTC P0232 is not present, replace fuel pump relay. Clear DTCs and retest.

  13. 13) Check For Short To Voltage In IFS PWR Circuit

    Disconnect IFS switch connector. IFS switch is located behind right kick panel. Repeat KOEO ON-DEMAND SELF-TEST. If DTC P0232 is present, go to next step. If DTC P0232 is not present, repair short to voltage in Dark Green/Yellow wire between IFS switch and fuel pump relay. Clear DTCs and retest.

  14. 14) Check For Short To Voltage In FPM Circuit Or Fuel Pump PWR Feed Circuit

    Turn ignition off. Disconnect PCM connector and inspect for damaged pins, corrosion and loose wires. PCM is located in left rear of engine compartment, near brake master cylinder. Repair connector as necessary. Install Rotunda Breakout Box (014-00950), leaving PCM disconnected. Turn ignition on. Using DVOM, measure voltage between chassis ground and test pin No. 40 at breakout box. If voltage is more than 10.5 volts, repair short to voltage in fuel pump PWR feed or fuel pump monitor circuit. See WIRING DIAGRAMS . Clear DTCs and retest. If voltage is 10.5 volts or less, replace PCM (Econoline), or go to next step (Excursion and F250-550). Clear DTCs and retest.

  15. 15) Check FPC Circuit For Short To Ground

    Turn ignition off. Remove fuel pump relay if not already removed. Disconnect PCM connector and inspect for damaged pins, corrosion and loose wires. PCM is located in left rear of engine compartment, near brake master cylinder. Repair connector as necessary. Install Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between chassis ground and test pin No. 94 at breakout box. If resistance is less than 10 k/ohms, repair short to ground in Light Blue/Orange wire between PCM and fuel pump relay. Clear DTCs and retest. If resistance is 10 k/ohms or more, replace PCM. Clear DTCs and retest.
    16. NOTE: For additional testing information, see DIAGNOSTIC AIDS .

  16. 16) Continuous Memory DTC P0230: Repeat KOEO Self-Test
    DTC P0230 indicates PCM has detected a fuel pump relay driver circuit failure. Possible causes are:
    • Blown Fuse
    • Faulty Fuel Pump Relay
    • Open Or Intermittent FPC Circuit Fault

    Perform KOEO ON-DEMAND SELF-TEST  under QUICK TEST. If DTC P0230 is present, go to step  1). If DTC P0230 is not present, go to next step.

  17. 17) Check For Intermittent Fault

    Clear DTCs. Wiggle and bend small sections of wiring harness starting at fuel pump relay and working toward PCM. On Econoline, fuel pump relay is located in battery junction box. Battery junction box is located on left side of engine compartment. On Excursion and F250-550, fuel pump relay is located in central junction box. Central junction box is located behind lower left side of instrument panel. On all models, PCM is located in left rear of engine compartment, near brake master cylinder. Retrieve DTCs. If Continuous Memory DTC P0230 is present, locate and repair fault in wiring harness. Clear DTCs and retest. If Continuous Memory DTC P0230 is not present, no fault is indicated at this time. Testing is complete. Clear DTCs and retest.
    18. NOTE: For additional testing information, see DIAGNOSTIC AIDS .
    NOTE: When ignition is turned on, PCM will ground fuel pump relay for only 20 seconds when engine is not running.

  18. 18) Continuous Memory DTC P0231: Repeat KOEO Self-Test
    DTC P0231 indicates fuel pump relay driver failed on and was not detected on FPM circuit when fuel pump was commanded on by PCM. Possible causes are:
    • Open Inertia Fuel Shutoff (IFS) Switch
    • Blown Fuel Pump PWR Fuse
    • Open FPC Or FPM Circuit
    • Faulty Fuel Pump Relay

    If Continuous Memory DTC P0230 is also present, go to step  16). Ensure IFS switch had not been reset without clearing DTCs. Perform KOEO ON-DEMAND SELF-TEST  under QUICK TEST. If KOEO DTC P0231 is present, go to step  5). If KOEO P0231 is not present, go to next step.

  19. 19) Check For Intermittent

    Clear DTCs. Wiggle and bend small sections of wiring harness starting at fuel pump relay and working toward PCM. On Econoline, fuel pump relay is located in battery junction box. Battery junction box is located on left side of engine compartment. On Excursion and F250-550, fuel pump relay is located in central junction box. Central junction box is located behind lower left side of instrument panel. On all models, PCM is located in left rear of engine compartment, near brake master cylinder. Retrieve DTCs. If Continuous Memory DTC P0231 is present, locate and repair fault in wiring harness. Clear DTCs and retest. If Continuous Memory DTC P0231 is not present, no fault is indicated at this time. Testing is complete. Clear DTCs and retest.
    20. NOTE: For additional testing information, see DIAGNOSTIC AIDS .

  20. 20) Continuous Memory DTC P0232: Repeat KOEO Self-Test
    DTC P0232 indicates fuel pump relay driver failed off and voltage was detected on FPM circuit when fuel pump was commanded off. Possible causes are:
    • Short To Voltage In Fuel Pump PWR Circuits
    • Shorted Fuel Pump Relay

    Perform KOEO ON-DEMAND SELF-TEST  under QUICK TEST. If KOEO DTC P0232 is present, go to step  11). If KOEO DTC P0232 is not present, go to next step.

  21. 21) Check For Intermittent

    Clear DTCs. Wiggle and bend small sections of wiring harness starting at fuel pump relay and working toward PCM. On Econoline, fuel pump relay is located in battery junction box. Battery junction box is located on left side of engine compartment. On Excursion and F250-550, fuel pump relay is located in central junction box. Central junction box is located behind lower left side of instrument panel. On all models, PCM is located in left rear of engine compartment, near brake master cylinder. Retrieve DTCs. If Continuous Memory DTC P0232 is present, locate and repair fault in wiring harness. Clear DTCs and retest. If Continuous Memory DTC P0232 is not present, no fault is indicated at this time. Testing is complete. Clear DTCs and retest.
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