how to fix a stuck fuel gauge in Toyota RAV4 Fifth Generation (2019-present)

Solution

1. Preparation

• Gather tools and parts needed for the repair.
• Tools Required:
  • OBD-II scanner
  • Multimeter
  • Socket set
  • Screwdrivers
  • Torque wrench
• Safety Warnings:
  • Disconnect the battery before working on electrical systems.
  • Allow the fuel system to depressurize by removing the fuel pump relay and starting the engine until it stalls.

2. Inspect and Repair Wiring

1. Locate the fuel level sending unit connection under the vehicle.
2. Visually inspect the wiring for any signs of damage or corrosion.
3. If any damage is found, repair or replace the affected wiring or connectors.
4. Reconnect the harness and ensure a secure fit.

3. Replace Fuel Level Sending Unit (if necessary)

1. If the sending unit is faulty, proceed with removal:
   • Drain fuel to a safe level to avoid spillage.
   • Remove the rear seat or access panel to reach the fuel tank.
   • Disconnect the electrical connector from the fuel level sending unit.
   • Unscrew the retaining ring and carefully lift the sending unit out of the tank.
2. Install the new fuel level sending unit:
   • Lubricate the O-ring with clean engine oil.
   • Position the new sending unit into the tank and secure it with the retaining ring.
   • Reconnect the electrical connector.

4. Reassemble and Test

1. Reinstall the access panel or rear seat.
2. Reconnect the battery.
3. Start the vehicle and monitor the fuel gauge for proper operation.
4. If necessary, clear any error codes from the OBD-II scanner.