KIA Forte Soul Rio Fuel Tank Pump Gasoline Pump Assembly

Description

Installation Steps

 1: Preparation & Safety Precautions

1. Gather Tools: Torque wrench, socket set (8mm, 12mm), pry tools, fuel line disconnect tool, electrical tape, new O-rings, and fuel-resistant sealant.
2. Safety First:
   • Disconnect the battery negative electrode to prevent electrical sparks.
   • Release residual fuel pressure by running the engine until it stalls (refer to your vehicle’s service manual).
3. Vehicle Setup: Park on a flat surface and use jack stands to elevate the rear if accessing the fuel tank from beneath.

 2: Fuel Pump Removal

For Forte/Soul/Rio (Sedan/Hatchback):

1. Access the Fuel Pump:
   • Remove the rear seat cushion (2x 12mm bolts in Forte/Rio; Soul may have clips).
   • Pry up the fuel pump service cover (secured with tar-like adhesive or screws).
2. Disconnect Components:
   • Detach electrical connectors (fuel pump, sender, pressure sensor).
   • Release fuel feed tube and vapor tube using quick-connector tools.
3. Remove the Fuel Pump:
   • Unscrew the 8mm mounting bolts securing the pump plate cover.
   • Lift the pump assembly straight out, ensuring the rubber gasket stays intact.

For Fuel Tank Replacement (Optional):

1. Drain Fuel: Siphon remaining fuel into an approved container.
2. Remove Tank:
   • Disconnect filler neck and fuel lines.
   • Loosen tank band nuts (39.2–54.0 N·m for Forte; torque varies by model).
   • Lower the tank carefully using a jack.

 3: Fuel Pump Installation

1. Inspect Components:
   • Verify the new pump matches the factory part number (e.g., Forte uses 31110-1M500; confirm with dealer).
   • Clean the tank opening and replace the rubber gasket.
2. Align and Secure:
   • Insert the pump into the tank, aligning the groove with the tank’s guide.
   • Hand-tighten the plate cover bolts, then torque to specifications:
     • Forte/Soul (LEV2): 2.0–3.0 N·m (1.4–2.2 lb-ft).
     • Rio: 1.96–2.94 N·m (1.44–2.17 lb-ft).
3. Reconnect Lines:
   • Attach fuel feed/vapor tubes and electrical connectors.
   • Use new O-rings and sealant on high-pressure lines (if applicable).

 4: Fuel Tank Reinstallation (If Removed)

1. Position the Tank: Lift it into place and secure with bands (torque as per model).
2. Reconnect Lines: Attach filler neck, fuel lines, and evap hoses.
3. Test for Leaks: Prime the fuel system (turn ignition on/off 3x) and check for leaks before starting the engine.

 5: Testing & Final Checks

1. Pressure Test: Use a fuel pressure gauge to verify proper pressure (refer to service manual).
2. Fuel Level Calibration: Ensure the float arm moves freely and the gauge reads accurately.
3. Functionality Test: Start the engine and check for smooth operation, no noises, or warning lights.