Test Procedure

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: For DTC P1233, GO to KB2.
  For DTC P1235, GO to KB17.
  
  For DTC P1237, GO to KB25.
- No: RETURN to SYMPTOM CHARTS for further direction.
KB2: DTC P1233: IS DTC P1233 PRESENT IN THE KOEO SELF-TEST?
- Is DTC P1233 present in the KOEO or KOER self-test?
- Yes: GO to KB4.
- No: 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.
KB3: DOES THE ENGINE START?
- Does the engine start?
- Yes: GO to KB13.
- No: 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.
KB4: KOEO DTC P1233: DOES THE ENGINE START?
- Does the engine start?
- Yes: To check the FPM circuit, GO to KB9.
- No: VERIFY the IFS switch is set (button pressed).
  GO to KB5.

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: INSTALL a new FPDM. REFER to the FUEL CHARGING AND CONTROLS -- HYBRID .
CLEAR the DTCs. REPEAT the self-test.
No: GO to KB6.

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: REPAIR the open ground circuit to the FPDM.
CLEAR the DTCs. REPEAT the self-test.
No: GO to KB7.

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: GO to KB8.
No: 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.

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: REPAIR the open FPDM PWR circuit.
CLEAR the DTCs. REPEAT the self-test.
No: INSTALL a new IFS switch. REFER to the FUEL TANK REMOVAL/INSTALLATION -- HYBRID and FUEL LINES REMOVAL/INSTALLATION -- HYBRID .
CLEAR the DTCs. REPEAT the self-test.

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: GO to KB10.
No: REPAIR the open circuit. CLEAR the DTCs. REPEAT the self-test.

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: GO to KB11.
No: REPAIR the short circuit. CLEAR the DTCs. REPEAT the self-test.

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: GO to KB12.
No: REPAIR the short circuit. CLEAR the DTCs. REPEAT the self-test.

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: GO to KB37.
No: INSTALL a new FPDM. REFER to the FUEL CHARGING AND CONTROLS -- HYBRID .
CLEAR the DTCs. REPEAT the self-test.

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: ISOLATE the concern and REPAIR as necessary.
CLEAR the DTCs. REPEAT the self-test.
No: GO to KB14.

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: ISOLATE the concern and REPAIR as necessary.
CLEAR the DTCs. REPEAT the self-test.
No: GO to KB15.

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: ISOLATE the concern and REPAIR as necessary.
CLEAR the DTCs. REPEAT the self-test.
No: GO to KB16.

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: ISOLATE the concern and REPAIR as necessary.
CLEAR the DTCs. REPEAT the self-test.
No: Unable to duplicate or identify the concern at this time.
GO to PINPOINT TEST Z .

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: GO to KB18.
- No: CHECK for an intermittent concern, GO to KB22.

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: GO to KB19.
No: REPAIR the open circuit. CLEAR the DTCs. REPEAT the self-test.

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: GO to KB20.
No: REPAIR the short circuit. CLEAR the DTCs. REPEAT the self-test.

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: GO to KB21.
No: REPAIR the short circuit. CLEAR the DTCs. REPEAT the self-test.

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: GO to KB37.
No: INSTALL a new FPDM. REFER to the FUEL CHARGING AND CONTROLS -- HYBRID .
CLEAR the DTCs. REPEAT the self-test.

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: ISOLATE the concern and REPAIR as necessary.
CLEAR the DTCs. REPEAT the self-test.
No: GO to KB23.

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: ISOLATE the concern and REPAIR as necessary.
CLEAR the DTCs. REPEAT the self-test.
No: GO to KB24.

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: ISOLATE the concern and REPAIR as necessary.
CLEAR the DTCs. REPEAT the self-test.
No: Unable to duplicate or identify the concern at this time.
GO to PINPOINT TEST Z .

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: GO to KB26.
- No: CHECK for an intermittent concern, GO to KB35.
KB26: DOES THE ENGINE START?
- Does the engine start?
- Yes: GO to KB33.
- No: GO to KB27.

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: GO to KB28.
No: GO to KB31.

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: GO to KB29.
No: REPAIR the short circuit. CLEAR the DTCs. REPEAT the self-test.

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: GO to KB30.
No: REPAIR the short circuit. CLEAR the DTCs. REPEAT the self-test.

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 to OUTPUT 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: INSTALL a new FP. REFER to the FUEL TANK REMOVAL/INSTALLATION -- HYBRID and FUEL LINES REMOVAL/INSTALLATION -- HYBRID .
CLEAR the DTCs. REPEAT the self-test.
No: 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 the FUEL CHARGING AND CONTROLS -- HYBRID .

CLEAR the DTCs. REPEAT the self-test.

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: GO to KB32.
No: REPAIR the open circuit. CLEAR the DTCs. REPEAT the self-test.

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: Unable to duplicate or identify the concern at this time.
VERIFY the results of the previous test steps.
No: INSTALL a new FP. REFER to the FUEL TANK REMOVAL/INSTALLATION -- HYBRID and FUEL LINES REMOVAL/INSTALLATION -- HYBRID .
CLEAR the DTCs. REPEAT the self-test.

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: GO to KB34.
No: REPAIR the short circuit. CLEAR the DTCs. REPEAT the self-test.

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: INSTALL a new FPDM. REFER to the FUEL CHARGING AND CONTROLS -- HYBRID .
CLEAR the DTCs. REPEAT the self-test.
No: REPAIR the short circuit. CLEAR the DTCs. REPEAT the self-test.

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: ISOLATE the concern and REPAIR as necessary.
CLEAR the DTCs. REPEAT the self-test.
No: GO to KB36.

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: ISOLATE the concern and REPAIR as necessary.
CLEAR the DTCs. REPEAT the self-test.
No: Unable to duplicate or identify the concern at this time.
GO to PINPOINT TEST Z .

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: INSTALL a new PCM. REFER to FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) .
- No: The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector.