Fuel Filler Neck

This procedure covers the removal and replacement of the fuel filler neck assembly on a 2015 Kia Forte with 1.8L I4 engine, including disconnection of hoses and clamps.

Warnings

Tools required

Parts

• Fuel filler neck assembly × 1 — Use OEM specification
• Filler neck gasket/seal × 1 — Use OEM specification
• Hose clamps (if damaged) × 2 — Use OEM specification

Preparation

1. Park vehicle on a level surface and apply parking brake.
2. Place wheel chocks at front wheels.
3. Relieve any residual fuel system pressure if applicable.
4. Raise the rear of the vehicle and support securely on jack stands.
5. Remove left rear wheel for better access to filler neck area.
6. Remove inner fender liner or splash shield to access filler neck components.

Procedure

1. 1

   Access fuel door and filler cap area
   Open the fuel door. Remove the fuel filler cap and set aside. From inside the trunk, locate and remove any trim panels or carpet that cover the filler neck access area on the driver's side quarter panel.
2. 2

   Disconnect filler neck hoses from tank
   Working from underneath the vehicle near the fuel tank, locate the fuel filler neck connection point at the fuel tank. Use hose clamp pliers to compress and slide the hose clamp away from the connection point. Carefully twist and pull the filler neck hose from the fuel tank inlet. Be prepared for residual fuel spillage.
   ⚠Fuel will drain from the hose connection. Position drain pan underneath.
3. 3

   Disconnect vent hose
   Locate the vapor vent hose connected to the filler neck assembly. Use hose clamp pliers to release the clamp, then disconnect the vent hose from the filler neck. Move the hose aside to prevent fuel vapor spillage.
4. 4

   Remove filler neck mounting hardware
   Locate the filler neck mounting bolts that secure the filler neck to the body/quarter panel. Typically there are 2-3 bolts accessible from the wheel well area and potentially one from inside the trunk area. Remove all filler neck mounting bolts using a 10mm socket.
   Torque spec

   Filler Neck Bolts10 Nm (7 lb-ft)
5. 5

   Remove filler neck assembly
   Carefully guide the fuel filler neck assembly out through the quarter panel opening, maneuvering it past any brackets or body structures. The neck may need to be angled or rotated to clear the body. Remove the assembly from the vehicle and inspect the gasket/seal at the fuel door opening.
6. 6

   Inspect and clean mounting surfaces
   Inspect the fuel tank inlet and body mounting points for corrosion, damage, or debris. Clean all mounting surfaces with shop towels. Check that the new filler neck gasket/seal is properly positioned on the replacement assembly. Verify all hose connections on the new filler neck are clean and free of debris.
7. 7

   Install new filler neck assembly
   Guide the new fuel filler neck assembly into position through the quarter panel opening, ensuring the gasket/seal aligns properly with the fuel door opening. Align all mounting bolt holes with the body mounting points.
8. 8

   Install and torque mounting bolts
   Install all filler neck mounting bolts finger-tight first to ensure proper alignment. Once all bolts are started, torque each mounting bolt to specification using a torque wrench in a cross-pattern sequence to ensure even seating.
   Torque spec

   Filler Neck Bolts10 Nm (7 lb-ft)
9. 9

   Reconnect vent hose
   Reconnect the vapor vent hose to the filler neck nipple. Ensure the hose is fully seated, then position the hose clamp over the connection point and secure. Verify the clamp is properly tightened but not overtightened to avoid damaging the hose.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
10. 10

    Reconnect filler neck to fuel tank
    Working from underneath the vehicle, guide the filler neck hose onto the fuel tank inlet. Ensure the hose is fully seated over the tank inlet pipe (typically at least 1.5 inches of overlap). Position the hose clamp over the connection point and tighten to specification.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)
11. 11

    Reinstall access panels and components
    Reinstall the inner fender liner or splash shield. Reinstall the left rear wheel and torque lug nuts to specification per vehicle manual. Lower the vehicle from jack stands. Reinstall any trunk trim panels or carpet that were removed for access.

Reassembly

1. Ensure all hose clamps are properly tightened and positioned.
2. Verify the filler neck gasket/seal is properly seated at the fuel door opening.
3. Double-check that all mounting bolts are torqued to specification.
4. Ensure no tools or parts were left in the trunk or wheel well area.

Verification

• Install the fuel filler cap and ensure it clicks and seals properly.
• Add 2-3 gallons of fuel and monitor for any leaks at the filler neck connections, hose clamps, and tank inlet.
• Start the engine and allow it to idle while checking for fuel odors or visible leaks around the filler neck area.
• Verify the fuel door closes properly and the filler neck aligns correctly with the fuel door opening.
• Check that there are no check engine lights or EVAP system codes after completing the repair.

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