Fuel Starts W/ Fluid. Torque App Shows No Fuel Pressure at Rail. Help Please

For the 1999-2004 model year the fuel rail pressures sensor (FRPS) is a "no start" sensor. That is without a valid FRPS input, it should be expected the car will not start.

Any time a DTC calls out a "Circuit Malfunction" it means there's something sooooooo wrong with the circuit that the PCM is unable to perform any meaningful diagnosis. Think: short, open, ground fault.

The 5 volt reference circuit is critical to the operation of sensors that use 5 volts. It's quite possible that a problem at a different sensor can "bring down" the entire 5 volt reference for all/most 5 volt sensors. So don't limit your visual inspection and trouble shooting to just the FRPS.

Tell us EXACTLY how you are testing for key on voltage at the trunk mounted IFS switch. How did you confirm that the ground is good?

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Devmart said:

I plugged grounded test prong into cable harness that plugs into inertia switch and do not receive any reading.

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The Trunk mounted IFS is a simple on/off two prong switch. As such it does not have a built in ground. So the testing should be from one terminal of the IFS switch and a body ground. Have you actually identified the trunk mounted IFS switch?

Devmart said:

Also when jumper cable was unplugged fuel gauge moved to totally empty and did not move on key turn. After re plugging fuel gauge moved from totally empty to over 1/4 fuel on turn key.

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I don't understand why you are messing with the connector going to the fuel pump itself. And yes I think it's likely that the P1233 DTC is from unplugging the connector to the fuel pump. This breaks the communication path from the FPDM to the fuel pump itself. This causes the FPDM to report a problem to the PCM. Also note that the fuel pump is not powered with 12 volts directly. So attempting to directly measure power to the fuel pump with a VOM is not the way to go. Test for basic +12 volts at the IFS switch.

IMO you are either over thinking this or simply jumping around too much. Go back to basics. What are the key on voltage reading at the fuel rail pressure sensor (FRPS) located in the engine bay fuel rail BN/WH and GY/RD wires?

This should be the 5 volt reference. What to do next depends upon IF the 5 volt reference is present or not.

Have you done a through visual inspection of the wiring harness for water or rodent damage?

Devmart said:

.03 volts at pink and black wire- Right side of Harness ifs harness

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^^^SMOKING gun alert!!>>> 0.03 volts at the trunk mounted IFS switch PK/BK wire PROVES that the IFS switch is not passing power.

I suspect that if you were to provide a temporary jumper wire across the IFS switch, this will improve the situation. For example, the sound of the fuel pump running at initial key on.

Bottom line. As a simple switch there must be voltage on both sides in order for the current to pass through the switch.

Note, there could be other problems with your car. But getting power to the fuel pump puts you one step closer.

We need to fall back and double check the work. I'm thinking there are some "missing" details regarding HOW some of the tests have been done.

For example. When testing the trunk IFS switch did you do the tests/measurements with the switch connected or disconnected? The requested tests need to be done with the IFS fully connected and in circuit.

Also suggest double checking your work as it would be fairly rare for the IFS switch itself to have failed.

Double check there is still key on voltage at the trunk mounted IFS. IE, that a fuse hasn't been blown from the recent work done.

Regarding the voltage tests at the FRPS, all tests need to be done using the GY/RD wire as the ground reference (not the car's frame ground).

Does your ODB2 scanner have the ability to monitor PID's? IE can you see if the fuel pressure PID changes while jumping the center signal return line to the 5 volt supply? Repeat to the signal ground. Jumping should cause the FRPS to immediately jump to max and then Min values.