2016 Ford Explorer Fuel Pump Fuse: Location, Diagram, and Troubleshooting Guide

The 2016 Ford Explorer fuel pump fuse is a 30-amp fuse located in the Power Distribution Box (under-hood fuse box) on the driver's side of the engine compartment. It is specifically labeled as fuse number 63.

If your 2016 Explorer cranks but won't start, or if you don't hear the fuel pump prime when you turn the key to the "ON" position, a blown fuel pump fuse is one of the first things you should check. This guide will walk you through exactly where to find it, how to test it, and what to do if it keeps blowing.

Where Is the Fuel Pump Fuse Located?

The 2016 Ford Explorer (fifth generation, U502 body style) has its main fuse box, called the Power Distribution Box, under the hood. This is not the same as the smaller fuse panel inside the passenger compartment.

Step-by-step location:

  1. Open the hood and make sure the engine is off and cool.
  2. Look on the driver's side of the engine compartment, near the battery and the windshield.
  3. You will see a large black plastic box. Remove the cover by pressing the release tabs.
  4. On the underside of the cover, there is a diagram showing the location and function of each fuse and relay. If the diagram is missing or faded, look for the following information.

Fuse Identification:

According to the official fuse box diagram for the 2016 Ford Explorer, the fuel pump is protected by fuse 63, which is a 30-amp fuse. It is a medium-profile (MCase) fuse, which is larger than a standard mini fuse. It is typically colored green (the standard color for a 30-amp fuse).

Important: The 2016 Explorer's fuel pump fuse is not located in the interior fuse panel under the dashboard. It is exclusively in the engine compartment Power Distribution Box.

How to Check the Fuel Pump Fuse

Before you assume the fuel pump itself is bad, test the fuse. This is a simple, five-minute job.

1. Visual Inspection:

  • Use the fuse puller tool (usually found inside the fuse box or in the vehicle's tool kit) to remove fuse 63.
  • Hold the fuse up to a light. Look through the transparent plastic body at the metal strip inside.
  • If the metal strip is broken or melted, the fuse is blown.
  • If the metal strip looks intact, the fuse is likely good, but you should still test it with a multimeter to be sure.

2. Multimeter Test (More Reliable):

  • Set your multimeter to measure continuity (the "beep" setting) or resistance (Ohms).
  • Touch one probe to each of the two small metal prongs on top of the fuse.
  • If you hear a beep or the reading is near zero ohms, the fuse is good.
  • If you get no beep or an "OL" (open loop) reading, the fuse is blown.

What Does Fuse 63 Control?

Fuse 63 is dedicated to the fuel pump. When this fuse blows, the fuel pump receives no power. This means:

  • No fuel pressure is delivered to the engine.
  • The engine will crank (the starter works) but will not start.
  • You will not hear the usual 2-second humming sound from the rear of the vehicle when you first turn the ignition key to the "ON" position.

Why Did the Fuel Pump Fuse Blow?

A fuse is a safety device. It blows to protect the wiring and components from an electrical overload. If you replace the fuse and it blows again immediately, or shortly after, there is a deeper problem. Common causes for a 2016 Explorer fuel pump fuse to blow include:

1. A Failing Fuel Pump Motor
This is the most common cause. As the fuel pump ages, its internal electric motor can wear out. When the windings inside the motor short out, they draw excessive current, which blows the fuse. If the fuse blows repeatedly, especially when the engine is hot or under load, the fuel pump itself is the likely culprit.

2. Damaged or Chafed Wiring
The wiring harness that runs from the fuse box to the fuel pump (located inside the fuel tank) is long and runs along the vehicle's frame. Over time, the insulation can rub against sharp metal edges, especially near the rear axle or fuel tank straps. This can cause a short to ground, blowing the fuse.

3. A Faulty Fuel Pump Relay
While less common, a relay that is stuck closed can keep the fuel pump running constantly, even when the engine is off, potentially overloading the circuit. However, relay failure more often results in the pump not working at all, without blowing the fuse.

4. Corrosion or Water Damage
If the fuse box itself has been exposed to moisture (from a leaky windshield or hood seal), corrosion can develop on the fuse terminals or the fuse box circuit board, causing a short.

How to Diagnose Further (If the Fuse Keeps Blowing)

If replacing the fuse doesn't solve the problem, follow these steps in order:

Step 1: Check the Fuel Pump Relay
Locate the fuel pump relay in the same Power Distribution Box. It is usually labeled "Fuel Pump Relay." You can test it by swapping it with a relay of the same rating (like the horn or A/C clutch relay). If the fuse blows with the old relay but not with the swapped relay, the relay is bad.

Step 2: Check for Wiring Issues
Inspect the wiring harness under the vehicle, particularly near the fuel tank. Look for any signs of rubbing, chafing, or exposed copper wire. Pay close attention to areas where the harness passes over sharp metal brackets.

Step 3: Test the Fuel Pump Itself
This is the most reliable test. Using a multimeter, you can check the resistance of the fuel pump motor at the fuel pump connector (located on top of the fuel tank). A healthy pump typically shows a resistance reading between 0.5 and 3.0 ohms. A reading of zero (short circuit) or infinite (open circuit) indicates a bad pump. However, because the pump is inside the tank, many owners choose to replace the pump assembly as the next step.

When to Replace the Fuel Pump

If you have confirmed that:

  • The fuse is not the issue.
  • The relay is working.
  • The wiring looks good.
  • The fuse blows each time you try to start the vehicle.

...then the fuel pump itself is almost certainly the problem. Replacing the fuel pump module on a 2016 Ford Explorer is an advanced DIY job. It requires dropping the fuel tank, which is heavy and can be dangerous. Most owners choose to have this done by a professional mechanic.

Recommended Fuel Pump Replacement: KEMSO Racing

When it's time to replace your fuel pump, you want a part that is reliable, durable, and built to last. That's why we recommend KEMSO brand fuel pumps.

Why choose KEMSO?

  • High Performance: KEMSO fuel pumps are engineered to meet or exceed OEM specifications, ensuring your Explorer runs smoothly and efficiently.
  • OEM Replacement: They are designed as a direct, bolt-in replacement for your factory fuel pump module. No modifications or special tools are needed.
  • Lifetime Warranty: We stand behind the quality of our products. Every KEMSO fuel pump comes with a lifetime warranty, giving you peace of mind on the road.

Visit the KEMSO Racing website to find the perfect fuel pump for your 2016 Ford Explorer: https://www.kemsoracing.com/

Summary

  • Location: Engine compartment Power Distribution Box, fuse 63.
  • Rating: 30-amp (green medium-profile fuse).
  • Symptom: Engine cranks but won't start; no fuel pump priming sound.
  • Common Cause of Blown Fuse: Failing fuel pump motor or chafed wiring.

Always start your diagnosis by checking the fuse. It's the easiest and cheapest fix. If the fuse is good but the pump still isn't working, move on to the relay and wiring. And if the pump itself is bad, trust KEMSO for a high-quality, long-lasting replacement.

For more information and to purchase a replacement fuel pump, visit https://www.kemsoracing.com/ .


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