LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2022 >> Transit Connect Titanium, Gas/Ethanol >> Repair and Diagnosis >> External Pages >> Different car >> Section 596 (Handles, Locks, Latches And Entry Systems) >> Diagnosis And Testing >> Locks, Latches and Entry Systems >> Pinpoint Tests >> Pinpoint Test Ah: The Fuel Filler Door Release Is Inoperative (Hybrid Vehicles)

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

WARNING: This page is about a different car, the 2021 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.
  1. Refer to ELECTRONIC ENGINE CONTROLS - 3.5L for schematic and connector information. Refer to HEADLAMPS/AUTOLAMPS for schematic and connector information.

    Normal Operation and Fault Conditions 

    REFER to: Handles, Locks, Latches and Entry Systems - System Operation and Component Description .

    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
    • Headlamp switch
    • 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.

  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  AH8
    No  GO to  AH3

  5. AH3 BYPASS THE FUEL FILLER DOOR RELEASE SWITCH

    • Ignition OFF.

    • Disconnect Headlamp Switch C205.

    • Ignition ON.

    • Connect:
      Positive Lead Measurement / Action Negative Lead
      C205-2
      GFD562064Courtesy of FORD MOTOR COMPANY
      		 C205-4

    • 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  INSTALL a new headlamp switch. REFER to: Headlamp Switch .
    No  GO to  AH4

  6. AH4 CHECK THE FUEL FILLER RELEASE SWITCH GROUND CIRCUIT FOR AN OPEN

    • Connect:
      Positive Lead Measurement / Action Negative Lead
      C205-2
      GFD562064Courtesy 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  AH5

  7. AH5 CHECK THE FUEL FILLER RELEASE SWITCH INPUT CIRCUIT FOR A SHORT TO GROUND

    • Ignition OFF.

    • Disconnect PCM C175B.

    • Measure:
      Positive Lead Measurement / Action Negative Lead
      C205-2
      GFD561510Courtesy of FORD MOTOR COMPANY
      		 Ground

    Is the resistance greater than 10, 000 ohms? 

    Yes  GO to  AH6
    No  REPAIR the circuit.

  8. AH6 CHECK THE FUEL FILLER RELEASE SWITCH RETURN CIRCUIT FOR A SHORT TO VOLTAGE

    • Ignition ON.

    • Measure:
      Positive Lead Measurement / Action Negative Lead
      C205-4
      GFD561510Courtesy of FORD MOTOR COMPANY
      		 Ground

    Is any voltage present? 

    Yes  REPAIR the circuit.
    No  GO to  AH7

  9. AH7 CHECK THE FUEL FILLER RELEASE SWITCH INPUT AND RETURN CIRCUITS FOR AN OPEN

    • Ignition OFF.

    • Measure:
      Positive Lead Measurement / Action Negative Lead
      C205-2
      GFD561510Courtesy of FORD MOTOR COMPANY
      		 C175B-3
      C205-4
      GFD561510Courtesy of FORD MOTOR COMPANY
      		 C175B-31

    Are the resistances less than 3 ohms? 

    Yes  GO to  AH13
    No  REPAIR the circuit in question.

  10. AH8 CHECK THE FUEL FILLER DOOR RELEASE USING THE PCM (POWERTRAIN CONTROL MODULE) FUEL FILL DOOR UNLOCK CONTROL OUTPUT IS COMMANDED TO ENABLE STATE (FUELDR_UNLOCK) PID (PARAMETER IDENTIFICATION)

    • Access the PCM and control the FUELDR_UNLOCK (none) PID

    • Command the PCM FUELDR_UNLOCK PID On.

    Does the fuel filler door latch release? 

    Yes  GO to  AH12
    No  GO to  AH9

  11. AH9 CHECK THE FUEL FILLER DOOR SOLENOID VOLTAGE SUPPLY CIRCUIT FOR AN OPEN

    NOTE: The following step uses a test lamp to simulate normal circuit loads. Use only a Rotunda Test Lamp (SGT27000) or 250-300mA incandescent bulb test lamp. To avoid connector terminal damage, use the Rotunda Flex Probe kit for the test lamp probe connection to the vehicle. Do not use the test lamp probe directly on any connector.

    • Ignition OFF.

    • Disconnect Fuel Filler Door Latch C4089.

    • Ignition ON.

    • Connect:
      Positive Lead Measurement / Action Negative Lead
      C4089-1
      GFD562065Courtesy of FORD MOTOR COMPANY
      		 Ground

    Does the test lamp illuminate? 

    Yes  DISCONNECT the test lamp. GO to  AH10
    No  REPAIR the circuit.

  12. AH10 CHECK THE FUEL FILLER DOOR RELEASE RELAY OUTPUT USING THE PCM (POWERTRAIN CONTROL MODULE) FUEL FILL DOOR UNLOCK CONTROL OUTPUT IS COMMANDED TO ENABLE STATE (FUELDR_UNLOCK) PID (PARAMETER IDENTIFICATION)

    NOTE: The following step uses a test lamp to simulate normal circuit loads. Use only a Rotunda Test Lamp (SGT27000) or 250-300mA incandescent bulb test lamp. To avoid connector terminal damage, use the Rotunda Flex Probe kit for the test lamp probe connection to the vehicle. Do not use the test lamp probe directly on any connector.

    • Connect:
      Positive Lead Measurement / Action Negative Lead
      C4089-1
      GFD562065Courtesy of FORD MOTOR COMPANY
      		 C4089-4

    • NOTE: The PCM only activates the relay momentarily. It is important to monitor the test lamp while commanding the fuel filler door latch to release.

      Using a diagnostic scan tool, command the PCM FUELDR_UNLOCK PIDOn.

    Does the test lamp momentarily illuminate? 

    Yes  INSTALL a new fuel filler door latch.
    No  GO to  AH9

  13. AH11 CHECK THE FUEL FILLER DOOR SOLENOID GROUND CIRCUIT FOR AN OPEN

    • Ignition OFF.

    • Disconnect PCM C175B.

    • Measure:
      Positive Lead Measurement / Action Negative Lead
      C4089-4
      GFD561510Courtesy of FORD MOTOR COMPANY
      		 C175B-14

    Is the resistance less than 3 ohms? 

    Yes  GO to  AH13
    No  REPAIR the circuit.

  14. AH12 CHECK THE PCM (POWERTRAIN CONTROL MODULE) THE FUEL FILL DOOR POSITION SENSOR/SWITCH CIRCUIT INPUT (FUELDR_POS_SW) PID (PARAMETER IDENTIFICATION)

    • Close the fuel filler door.

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

    • Monitor the PCM FUELDR_POS_SW PID.

    • Press the fuel filler door latch release button on the headlamp switch.

    Does the PID indicate Closed with the fuel filler door closed and Open after the fuel filler door latch is released? 

    Yes  The system is operating correctly. Inform the vehicle owner of the normal operation of the fuel filler door latch release operation.
    No  GO to Pinpoint Test AJ 

  15. AH13 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 TESTING
    Internet Explorer version 11 or greater is required to perform this Pinpoint Test. 
    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.
scientia non olet · About LEMON Manuals