Fuel Pump Driver Module (FPDM) 2014 Ford Explorer 3.5L

Engine has no codes. Scan tool shows cam and crank correlation are good. Fuel pressure from pump is at 60 psi when turned on via scan tool. Fuel rail pressure does not bleed off after crank. Has spark. MAF, RPM and coolant temp readings are good during crank. Has fuel smell when cranking. If I pull the fuel pump fuse the engine will start using the residual gas in the cylinders and while it is running on the residual gas if I put the fuel pump fuse in before it dies the engine will stay running. When I shut it off and try to restart it cranks but no start.
I replaced the injectors and spark-plugs. I also bypassed the purge solenoid and plugged all vacuum ports on the intake. There are no vacuum leaks and since the purge solenoid is bypassed the engine is not getting canister vapors. The FPDM was replaced about a year ago due to a no-fuel issue. The injectors and coils are pulsing during crank and the compression averages around 116 psi.

If you could suggest another area to test or look at that would helpful

• Engine No Start Diagnostics

A Gasoline Engine Requires 4 things to run:

1. Spark – Ignition system spark at the spark plugs
2. Fuel – Fuel pressure and fuel injector pulse
3. Compression – What is a compression test
4. Timing – All of the above at the right time

Your job is to determine which one of these the engine is not getting and correct it. In your case I am curious if you tried spraying starter fluid through the air filter to see if it will start and run as long as you continue to spraying starting fluid in. Given the vehicle has a previous history of a failing FPDM that may be a good place to look. Either way it sounds like you may have a flooding issue. To check for that, I would crank the engine a bunch trying to start it(knowing it isn’t going to) and then pull the spark plugs to see if they are wet. Not wet, no fuel. Spray starting fluid in while cranking( and foot partially on gas pedal) and see if it runs on that. Definite fuel related issue. I suspect a failed FPDM again. I looked up a replacement for you as it is under $100. Easy enough to do it yourself.

FPDM on Ford Explorer

The FPDM on a 2014 Ford Explorer is a crucial component that regulates the voltage supply to the electric fuel pump. It is responsible for modulating the fuel pump’s power to optimize fuel delivery, reduce electrical load, and improve cold-start behavior. The FPDM is integrated into the fuel pump module inside the tank or located nearby in the rear of the vehicle. If the FPDM malfunctions, it can lead to symptoms such as a lack of fuel pump priming on ignition, repeated hard starts, no-start conditions, irregular fuel pressure, engine stalling, and poor fuel efficiency. It is essential to diagnose these symptoms and perform tests to confirm a fault with the FPDM.

Check Your WARRANTY on the one you had replaced.

FPDM Removal

NOTE: Removal steps in this procedure may contain installation details.

1. Remove the RH C-pillar trim panel.
   
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2. • 6 Nm (53 lb-in).

Installation

1. To install, reverse the removal procedure.