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Pinpoint Test Ah: The Fuel Filler Door Release Is Inoperative (Hybrid Vehicles)

  1. Refer to Headlamps/Autolamps for schematic and connector information.

    Normal Operation and Fault Conditions 

    REFER to: Handles, Locks, Latches and Entry Systems - Component Location .

    DTC Fault Trigger Conditions 

    DTC Description Fault Trigger Condition
    PCM P04C2:00 Fuel Fill Door Unlock Control Circuit High: No Sub Type Information Sets when the PCM detects a short to voltage or an open from the fuel filler door release relay control circuit.
    PCM P04C9:00 Fuel Fill Door Open Request Sensor/Switch Performance/Stuck Off: No Sub Type Information Sets when the PCM receives no request to open the fuel filler door and the vehicle experienced a refueling event.
    PCM P04CA:00 Fuel Fill Door Open Request Sensor/Switch Circuit Low: No Sub Type Information Sets when the PCM detects a request to open the fuel filler door during the self-test.
    PCM P04CB:00 Fuel Fill Door Open Request Sensor/Switch Circuit High: No Sub Type Information Sets when the PCM detects an open from the fuel filler door input.
    PCM P04CD:00 Fuel Fill Door Open Request Sensor/Switch Stuck On: No Sub Type Information Sets when the PCM detects a constant request from the fuel filler door release switch (short to ground from the fuel filler door release switch input circuit).

    Possible Sources 

    • Wiring, terminals or connectors
    • Fuel filler door lock
    • Fuel filler door latch
    • PCM

    Visual Inspection and Pre-checks 

    • Inspect the fuel filler door latch for damage.

  2. NOTE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

  3. AH1 CHECK FOR A MECHANICAL FAILURE

    • Ignition OFF.

    • Use the manual fuel filler door release cable to release the fuel filler door latch.

    Does the fuel filler door latch release? 

    Yes  CLOSE the fuel filler door. GO to  AH2
    No  INSTALL a new fuel filler door housing. REFER to: Fuel Filler Door Assembly

  4. AH2 CHECK THE PCM (POWERTRAIN CONTROL MODULE) THE CUSTOMER IS REQUESTING OR HAS RECENTLY REQUESTED TO OPEN OR UNLOCK THE FUEL FILL DOOR (FUELDR_REQ) PID (PARAMETER IDENTIFICATION)

    • Ignition ON.

    • Access the PCM and monitor the FUELDR_REQ (none) PID

    • Monitor the PCM FUELDR_REQ PID while pressing and releasing the fuel filler door release button.

    Does the PID correspond with the fuel filler door release button press? 

    Yes  GO to  AH7
    No  GO to  AH3

  5. AH3 CHECK THE FUEL FILLER RELEASE SWITCH GROUND CIRCUIT FOR AN OPEN

    • Disconnect C205.

    • Connect:
      Positive Lead Measurement / Action Negative Lead
      C205-1
      GFD591632Courtesy of FORD MOTOR COMPANY
      		 Ground

    • NOTE: It may take up to 30 seconds for the fuel filler door to release after the jumper wire is removed.

      Remove the fused jumper wire.

    Does the fuel filler door latch release? 

    Yes  REPAIR the circuit.
    No  GO to  AH4

  6. AH4 CHECK THE FUEL FILLER RELEASE SWITCH INPUT CIRCUIT FOR A SHORT TO GROUND

    • Ignition OFF.

    • Disconnect PCM C1381B.

    • Measure:
      Positive Lead Measurement / Action Negative Lead
      C205-4
      GFD591770Courtesy of FORD MOTOR COMPANY
      		 Ground

    Is the resistance greater than 10, 000 ohms? 

    Yes  GO to  AH5
    No  REPAIR the circuit.

  7. AH5 CHECK THE FUEL FILLER RELEASE SWITCH RETURN CIRCUIT FOR A SHORT TO VOLTAGE

    • Ignition ON.

    • Measure:
      Positive Lead Measurement / Action Negative Lead
      C205-2
      GFD591770Courtesy of FORD MOTOR COMPANY
      		 Ground

    Is any voltage present? 

    Yes  REPAIR the circuit.
    No  GO to  AH6

  8. AH6 CHECK THE FUEL FILLER RELEASE SWITCH INPUT AND RETURN CIRCUITS FOR AN OPEN

    • Ignition OFF.

    • Measure:
      Positive Lead Measurement / Action Negative Lead
      C205-4
      GFD591770Courtesy of FORD MOTOR COMPANY
      		 C1381B-6
      C205-2
      GFD591770Courtesy of FORD MOTOR COMPANY
      		 C1381B-10

    Are the resistances less than 3 ohms? 

    Yes  GO to  AH7
    No  REPAIR the circuit in question.

  9. AH7 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION

    • Disconnect and inspect all the PCM connectors.

    • Repair:

      • corrosion (install new connectors or terminals - clean module pins)
      • damaged or bent pins - install new terminals pins
      • pushed-out pins - install new pins as necessary

    • Reconnect the PCM connectors and make sure they seat and latch correctly.

    • Operate the system and determine if the concern is still present.

    Is the concern still present? 

    Yes  CHECK OASIS for any applicable service articles: TSB, GSB, SSM or FSA. If a service article exists for this concern, DISCONTINUE this test and FOLLOW the service article instructions. If no service articles address this concern, Refer to PCM Guided Routine .
    No  The system is operating correctly at this time. The concern may have been caused by module connections. ADDRESS the root cause of any connector or pin issues.
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