Yeah, apparently, it's not a serviceable component. Which is a really bad design. Service info states its 0.5hr to replace it but I can't see how that is possible. I would check with the dealership and see if that's really the case. If the entire Battery Junction box (BJB) needs to be replaced for one relay, I'd try taking it apart and check for a broken or cracked solder joint inside the BJB. When it comes to situations or modules like this, I'll always take them apart and try to fix myself. But if you look also at the control for the FP Relay, it's a Ground side (N-Channel) Mosfet chip inside the BCM. A Mosfet is basically a high-power transistor. I would check this circuit before replacing the BJB.
The yellow/violet colored wire (pin 24) from the BJB connector C1035A is the wire that should be grounded for the relay to turn on. If there is any voltage drop (high resistance) on this wire through the BCM, that is limiting current flow, that might be the problem. And not the FP relay.
I would find connector C1035A, it's probably located on the bottom of the BJB, there is one other connector that looks the same, but its missing pins 21-24. So, you'll have to ID the connector by its wiring colors and pin locations.
With the connector still plugged in, Back probe pin 24 and with a multimeter on DC volts, measure from pin 24 and battery negative while the fault is occurring.
When the BCM is supposed to be Grounding the FP Relay you should read close to 0 volts, If the BCM is not able to fully ground the relay, you'll read some voltage drop on that wire to battery negative.
Since Fuse 75 is hot at all times you will read battery voltage on pin 24 until you turn the key On. Voltage will be coming through the FP Relay until the BCM pulls that control circuit to ground. Then it will read 0 volts.
I just don't want to see you replace the BJB and the fault still occur. Technically you could ground that pin 24 wire and the FP should kick right on, because that's all the BCM does with that Mosfet, it just makes a path to ground through it. But check for voltage drop first, see if there is any when the relay is not turning on the pump.
I added the aftermarket diagram last just to simplify the circuit, if you have any questions before the test, just let me know.
Set the multimeter on a lower DC voltage setting or auto if it has it. It may only be a couple volts of voltage drop, but may be enough to limit current flow, relays don't take much current to turn on, but I've seen mosfets burn out many times.
One other thing, since Fuse 75 feeds both sides of the FP relay, you aren't hearing the FP Relay click, it can't be because there's no power to it, you're probably hearing the PCM power relay click. If you look on that OEM diagram, with Fuse 75 out, there's no power to that FP relay at all. So, something else is going on.
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Wednesday, December 13th, 2023 AT 6:57 PM