Fix P025A: Mechanic’s solutions that WORKED

The code P025A: Fuel Pump Control Module Enable Circuit points out a fault in the circuit responsible for enabling the fuel pump control module. This module plays a crucial role in managing the fuel supply to the engine. Issues with this circuit can stem from faulty modules, wiring problems, or overheating components.

P025A quick overview

Meaning	P025A: Fuel Pump Control Module Enable Circuit
Is it serious?	This code is serious as it relates to the fuel system’s operation, which can lead to stalling, no-start conditions, or poor engine performance.
Possible causes	– Faulty fuel pump control module – Damaged or corroded wiring and connectors – Overheating of related electronic components like the PCM – Faulty or intermittent power supply to the fuel pump control module
How to diagnose?	Inspect Wiring and Connectors: Check for damage, corrosion, or loose connections in the fuel pump control module circuit. Check Fuse and Relay: Ensure the fuel pump relay and associated fuses are functioning correctly. Cool Down Components: If overheating is suspected, cool down components like the PCM to see if the issue temporarily resolves. Verify Grounds: Recheck all ground connections, especially after major repairs or component replacements. Scan for Other Codes: Use a diagnostic scanner to check for additional codes that may indicate related issues.

How to fix P025A – learn from mechanics

I looked into P025A service cases at iatn.com website where in the private forums the mechanics seek advice from other mechanics. I looked up a bunch of cases to help you decide how to fix your issue and see what would a real mechanic do to solve it.

Case #1: Ram

Vehicle Information:
2017 Ram 1500 Big Horn 5.7L

Issue + Repair History:

• SES light on with codes P0678, P1206, and P025A.
• Replaced fuel pump assembly; codes returned after a short drive.
• Replaced fuel pump control module; issues persisted.
• Fuel pressure varied from 38psi to 75psi KOER.

Suggestions to Fix Issue:

• Check wiring and connectors for corrosion or loose terminals.
• Follow detailed diagnostic procedures for circuit checks between FPCM and PCM.
• Consider potential PCM replacement if the issue persists.
• Inspect the harness for damage, especially near the frame where rubbing could occur.

Final Fix:

• Located and repaired a wiring harness issue where the driver’s front inner fender liner rubbed through the wire harness on the frame rail.
• Cleared codes and confirmed repair was successful.

Case #2: GMC

Vehicle Information:
2009 GMC Sierra 1500 WT 4.8L

Issue + Repair History:

• Vehicle cut out twice while driving but never completely quit.
• Did not restart in the morning, then spontaneously started.
• Code P025A present.

Suggestions to Fix Issue:

• Check for intermittent connections at the fuel pump control module.
• Clean connections and apply dielectric grease.
• Inspect the fuel pump control module for water ingress and corrosion.
• Verify the location of the fuel pump control module on the frame.

Final Fix:

• Found the fuel pump control module filled with water and corroded.
• Replaced the module, which required programming with a tech 2 scanner.

Case #3: Ford

Vehicle Information:
2010 Ford F-150 STX 4.6L

Issue + Repair History:

• Experienced intermittent no-start, occurring about once every 2 weeks.
• Customer replaced the fuel pump driver module with a new one from Ford.
• Later experienced no-start with codes P025A, U0109, and P0201-P0208.

Suggestions to Fix Issue:

• Check for power and ground at the fuel pump driver.
• Inspect fuse 27 in the BJB for damage or melting.
• Consider the possibility of a failing PCM.

Final Fix:

• Found fuse 27 connection was bad in the fuse box above the radiator.
• Referred to TSB 15-0137 and applied the updated repair kit for the issue.

Case #4: Chevrolet

Vehicle Information:
2008 Chevrolet Suburban 1500 LTZ 5.3L

Issue + Repair History:

• Vehicle towed in as a no-start, later started but cut out and jerked under load.
• Codes P0230, P025A, P069E present with erratic fuel pressure drops under load.
• Replaced the fuel pump control module, problem persisted.
• Found power supply to fuel pump module was not steady under load.

Suggestions to Fix Issue:

• Check the fuel pump ground and relay.
• Inspect the CKP sensor for intermittent faults.
• Ensure ignition voltage on relay and check for open or shorted control ground circuit.
• Test circuit from PCM to pin 13, including pin fit at both ends.
• Consider replacing ECM or FPCM if power is dropping out.
• Inspect harness and terminals for damage or run a new wire if necessary.

Final Fix:

• Found the wire harness had come out of retainers and was rubbing against the front drive shaft yoke, causing a short to ground.
• Repaired the damaged wiring and resecured the harness away from moving parts.

Case #5: Buick

Vehicle Information:
2012 Buick LaCrosse 2.4L

Issue + Repair History:

• Installed a new engine due to lack of oil changes.
• Vehicle stalled 30 minutes into the test drive, then restarted after cooling down.
• Codes P0627 and P025A appeared indicating issues with the fuel pump control module.
• Replaced fuel pump control module with a used one, but the issue persisted.

Suggestions to Fix Issue:

• Check underhood relay or fuse panel for issues.
• Consider a problem with the PCM overheating; try cooling it to see if the vehicle restarts.
• Verify fuel pressure after stall and recheck all grounds, especially after the motor swap.
• Ensure all connections, especially at the ECM and FPCM, are clean, well-seated, and free of dirt and debris.

Final Fix:

• Found the X108 connector was not fully closed, causing the problems.
• Thoroughly walked through the diagnostic process and fixed the connection issue, resolving the stalling and no-start problems.

Advice	Brief Description of Diagnostic Step
Check Connections	Inspect and ensure all related connectors are fully seated and free of dirt or corrosion, especially at the FPCM and ECM.
Inspect Wiring	Look for damaged, frayed, or bare wires, especially in areas prone to rubbing or heat exposure.
Verify Grounds	Recheck all ground connections, particularly after major repairs or component replacements.
Consider Module Replacement	If diagnostics point to a failure, consider replacing the fuel pump control module, but ensure it’s programmed correctly.
Cool Down Suspected Components	If overheating is suspected (like the PCM), try cooling it down to see if it temporarily resolves the issue.
Follow Pinpoint Tests	Conduct detailed tests outlined in service manuals for the fuel control and related circuits.

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