This procedure covers the removal and replacement of the fuel level sensor assembly, which is integrated into the fuel pump module inside the fuel tank of the 2015 Kia Forte 1.8L.

Warnings

Tools required

Parts

• Fuel level sensor assembly or complete fuel pump module × 1 — Use OEM specification
• Fuel pump module gasket/seal × 1 — Use OEM specification
• Fuel line O-rings × 2 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Disconnect negative battery cable and wait at least 3 minutes before proceeding
3. Relieve fuel system pressure by removing fuel pump relay (located in underhood fuse box, position M27) and attempting to start the engine until it stalls, then crank for 5 additional seconds
4. Ensure fuel tank is less than half full; drain if necessary using approved fuel transfer equipment
5. Remove rear seat cushion by releasing two front clips and lifting upward and forward
6. Remove rear seat back by unbolting lower mounting bolts and releasing upper clips

Procedure

1. 1

   Access fuel pump service cover
   Locate the rectangular service cover in the floor pan beneath the rear seat. Remove the screws securing the cover using a 10mm socket. Carefully lift the cover to expose the fuel pump module assembly. Clean any dirt or debris from around the fuel pump mounting area to prevent contamination.
   Torque spec

   Cover Screws10 Nm (8 lb-ft)
2. 2

   Disconnect electrical connector
   Press the locking tab on the fuel pump module electrical connector and carefully pull it straight off the module. Ensure the connector is positioned away from the work area to prevent damage.
   ⚠Do not pull on wires; press the locking tab and pull only on the connector body.
3. 3

   Disconnect fuel supply line
   Using the appropriate fuel line disconnect tool, release the quick-connect fitting on the fuel supply line. Press the disconnect tool onto the fitting, then pull the line away from the pump module. Place a shop towel beneath the connection to catch residual fuel spillage. Cap or plug the fuel line to prevent contamination.
   ⚠️Expect fuel spillage. Keep shop towels ready and ensure proper ventilation.
4. 4

   Disconnect fuel return line
   If equipped, disconnect the fuel return line using the same technique as the supply line. Note the orientation and routing of all fuel lines for proper reinstallation. Have shop towels ready to catch any remaining fuel.
   ⚠Some fuel will drain from disconnected lines. Use fuel-safe container to catch spillage.
5. 5

   Remove fuel pump locking ring
   Using the fuel pump locking ring tool or large adjustable spanner, rotate the locking ring counterclockwise to unlock it. The ring has multiple tabs; tap the tabs with a brass punch and hammer if necessary to break it loose. Once unlocked, remove the locking ring completely and set aside with its gasket.
   ⚠Do not use steel punches or hammers that could create sparks near fuel vapors. Use brass or plastic tools only.
6. 6

   Remove fuel pump module assembly
   Carefully lift the fuel pump module straight up and out of the fuel tank. Tilt the assembly slightly to maneuver the fuel level float arm through the opening. Be cautious as fuel will drain from the module. Allow excess fuel to drain back into tank before fully removing. Place the module in a fuel-safe container.
   ⚠Module is heavy when full of fuel and contains fragile components. Handle carefully to avoid damaging the fuel level float arm.
7. 7

   Replace fuel level sensor
   If replacing only the fuel level sensor (not the entire module), disconnect the sensor electrical connector from the pump module. Remove the sensor mounting bracket bolts using a 10mm socket. Carefully slide the sensor and float arm assembly out of the module, taking care not to bend the float arm. Install the new sensor in reverse order, ensuring the float arm moves freely through its full range of motion.
   ⚠Float arm is delicate. Do not bend or force the arm during removal or installation.
   Torque spec

   Bracket Bolts19 Nm (14 lb-ft)
8. 8

   Prepare tank opening and new module
   Inspect the fuel tank opening for debris or damage. Clean the sealing surface with a clean shop towel. Remove and discard the old fuel pump module gasket from the tank. Install the new gasket onto the fuel tank opening, ensuring proper alignment. Install new O-rings onto all fuel line fittings, lightly lubricating with clean gasoline.
   ℹ️Never reuse the old gasket or O-rings. Always install new sealing components to prevent fuel leaks.
9. 9

   Install fuel pump module
   Carefully lower the fuel pump module (or original module with new sensor) into the fuel tank opening. Align the module orientation mark with the corresponding mark on the tank. Guide the fuel level float arm through the opening without bending it. Press the module down firmly to seat it on the gasket.
   ⚠Ensure proper rotational alignment of module before seating. Incorrect alignment will prevent locking ring installation.
10. 10

    Install locking ring
    Place the locking ring over the fuel pump module and align the tabs. Rotate the ring clockwise using the locking ring tool until it clicks into the locked position. Ensure the ring is fully seated and locked in all positions around the circumference.
    ℹ️Ring should lock with audible clicks. Verify it cannot be rotated further clockwise when fully locked.
11. 11

    Reconnect fuel lines
    Connect the fuel supply line to the pump module fitting, pushing firmly until it clicks into place. Tug gently to verify secure connection. If equipped, reconnect the fuel return line in the same manner. Verify both connections are secure and properly seated.
    ℹ️Quick-connect fittings should click audibly when properly seated. Always verify with gentle pull test.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)
12. 12

    Reconnect electrical connector
    Plug the electrical connector onto the fuel pump module until it clicks into the locked position. Verify the locking tab is fully engaged.
13. 13

    Reinstall service cover
    Position the service cover over the fuel pump access opening. Install and torque the cover screws in a cross pattern to specification.
    Torque spec

    Cover Screws10 Nm (8 lb-ft)

Reassembly

1. Reinstall rear seat back by engaging upper clips first, then installing and tightening lower mounting bolts
2. Reinstall rear seat cushion by aligning rear tabs and pressing down firmly at front until clips engage
3. Reinstall fuel pump relay in underhood fuse box position M27
4. Reconnect negative battery cable and tighten securely

Verification

• Turn ignition to ON position (do not start) and listen for fuel pump operation for 2-3 seconds. Repeat this 3-4 times to pressurize the fuel system
• Inspect all fuel line connections and pump module gasket area for any signs of fuel leakage
• Start the engine and allow it to idle. Check again for fuel leaks at all connections
• Verify fuel gauge reading on instrument cluster corresponds to actual fuel level in tank. May need to add known quantity of fuel to verify accuracy
• Drive vehicle and monitor fuel gauge operation through various fuel levels to ensure sensor is functioning correctly throughout its range
• Clear any diagnostic trouble codes related to fuel level sensor using scan tool if present

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