Remove and replace the fuel pump module assembly located under the rear seat of the 2015 Kia Forte, including depressurizing the fuel system and properly torquing all connections.

Warnings

Tools required

Parts

• Fuel pump module assembly × 1 — Use OEM specification
• Fuel pump module O-ring seal × 1 — 31112-A7000 or equivalent
• Fuel line O-rings × 2 — Use OEM specification

Preparation

1. Park vehicle on level ground in a well-ventilated area away from ignition sources
2. Ensure fuel tank is no more than half full to minimize spillage; if necessary, siphon excess fuel using approved equipment
3. Place fire extinguisher within immediate reach
4. Disconnect negative battery cable and wait 3 minutes for system capacitor discharge
5. Remove rear seat cushion by pulling up firmly on front edge to release retaining clips
6. Clean the area around the fuel pump access cover to prevent debris from entering the tank

Procedure

1. 1

   Depressurize fuel system
   Start the engine and allow it to run until it stalls from fuel starvation (typically 1-3 minutes). Attempt to restart 2-3 times to ensure all residual pressure is released. Wait at least 5 minutes before proceeding. If engine does not start, remove fuel pump relay (located in engine compartment fuse box, position 23) and crank engine for 5 seconds to purge pressure.
   ⚠️This step is CRITICAL. Skipping or improperly performing this step can result in high-pressure fuel spray when lines are disconnected.
2. 2

   Remove fuel pump access cover
   Locate the rectangular metal access cover under the rear seat. Remove the four screws securing the cover using a 10mm socket. Carefully lift and remove the access cover to expose the fuel pump module assembly. Use shop towels to clean any debris from the exposed area.
   Torque spec

   Access Cover Screws4 Nm (3 lb-ft)
3. 3

   Disconnect electrical connector
   Press the locking tab on the fuel pump module electrical connector and carefully pull straight up to disconnect. Inspect connector terminals for corrosion or damage. Do not proceed if connector or wiring shows signs of damage.
   ⚠The connector locking tab is plastic and can break if excessive force is used. Apply gentle, steady pressure while pressing the release tab.
4. 4

   Disconnect fuel supply and return lines
   Place shop towels around the fuel line connections to absorb residual fuel. Press the quick-disconnect tabs on both the supply line (larger diameter) and return line (smaller diameter) and pull lines straight off the pump module fittings. Have fuel-safe container ready to catch any fuel spillage. Cap or plug open lines immediately to prevent contamination.
   ⚠️Even with depressurized system, expect residual fuel spillage. Keep ignition sources away and have absorbent materials ready.
5. 5

   Remove fuel pump lock ring
   Install the fuel pump lock ring tool onto the lock ring tabs. Turn counterclockwise to loosen the lock ring. If lock ring is difficult to turn, tap the tool handle gently with a rubber mallet - do NOT use excessive force or metal hammers. Once loosened, remove lock ring completely and set aside.
   ⚠Never use a chisel, punch, or improvised tools on the lock ring. Damage to the lock ring or tank flange will cause fuel leaks and require tank replacement.
   Torque spec

   Fuel Pump Lock Ring64 Nm (48 lb-ft)
6. 6

   Remove fuel pump module assembly
   Carefully lift the fuel pump module assembly straight up and out of the fuel tank. Tilt the assembly slightly to the side as it clears the opening to prevent damage to the fuel level sender float arm. Expect approximately 1-2 cups of fuel to drain from the module. Place module in fuel-safe container and allow to drain completely. Remove and discard the old O-ring seal from the tank flange.
   ⚠The fuel level sender arm extends below the module and can bend or break if not carefully maneuvered during removal.
7. 7

   Inspect fuel tank opening
   Use a flashlight to inspect inside the fuel tank opening for debris, rust, or contamination. Inspect the tank flange O-ring sealing surface for damage, scratches, or deformation. Clean the sealing surface with a lint-free cloth. If any damage is visible, the tank must be inspected further or replaced.
   ℹ️Do not allow any debris to fall into the fuel tank during inspection or installation.
8. 8

   Prepare new fuel pump module
   Remove new fuel pump module from packaging. Install the new O-ring seal onto the fuel pump module flange, ensuring it seats properly in the groove. Lightly lubricate the O-ring with clean gasoline to ease installation. Install new O-rings onto the fuel line fittings on the pump module. Verify the fuel level sender float arm moves freely and is not damaged.
   ⚠Use only gasoline or approved fuel-safe lubricant on O-rings. Do not use petroleum jelly, silicone, or other lubricants that may degrade fuel system components.
9. 9

   Install fuel pump module
   Align the fuel pump module with the tank opening, ensuring the alignment marks or tabs match the tank flange orientation. Carefully lower the module into the tank, tilting slightly to guide the fuel level sender float arm through the opening without contact. Press down firmly to seat the module flange and O-ring against the tank flange. Verify the module is fully seated before proceeding.
   ⚠Incorrect orientation will prevent proper fuel level readings and may cause fuel system malfunction.
10. 10

    Install and torque lock ring
    Place the fuel pump lock ring onto the module flange threads. Using the lock ring tool, turn clockwise to tighten. Torque to 64.0 Nm (48 lb-ft) using a torque wrench on the tool handle. Verify the lock ring is fully seated and the O-ring has not shifted during installation.
    ⚠️CRITICAL TORQUE SPEC: Under-torquing will cause fuel leaks. Over-torquing can damage the tank flange or lock ring threads. Use a calibrated torque wrench.
    Torque spec

    Fuel Pump Lock Ring64 Nm (48 lb-ft)
11. 11

    Reconnect fuel lines
    Remove caps or plugs from fuel lines. Push the fuel supply line (larger) and return line (smaller) onto the corresponding pump module fittings until a distinct click is heard, indicating the quick-disconnect has locked. Pull gently on each line to verify secure connection. Torque any threaded fuel line fittings to 25.0 Nm (18 lb-ft).
    ⚠️CRITICAL: Improperly connected fuel lines will cause fuel leaks under pressure, creating severe fire hazard.
    Torque spec

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

    Reconnect electrical connector
    Align the electrical connector with the fuel pump module terminal and push firmly until the locking tab clicks into place. Tug gently on the connector to verify it is locked. Ensure no wires are pinched or stressed.
13. 13

    Reinstall access cover
    Position the metal access cover over the fuel pump module opening. Install the four screws and torque to 4.0 Nm (3.0 lb-ft) in a cross-pattern to ensure even seating. Verify the cover is flush with the floor pan.
    Torque spec

    Access Cover Screws4 Nm (3 lb-ft)
14. 14

    Reinstall rear seat and reconnect battery
    Reinstall the rear seat cushion by aligning the retaining clips and pressing down firmly until clips engage. Reconnect the negative battery cable and tighten the terminal nut securely.

Reassembly

1. Double-check all fuel line connections are fully seated and locked before starting engine
2. Verify access cover screws are torqued properly and cover is secure
3. Ensure no tools or parts remain under the rear seat area

Verification

• Turn ignition to ON position (do not start) and listen for fuel pump priming (2-3 second hum). Cycle ignition off and on three times to build fuel pressure
• Inspect access cover area and fuel line connections for any signs of fuel leakage during priming
• Start engine and verify it runs smoothly without hesitation or stalling
• With engine running, inspect all fuel connections again for leaks using a flashlight
• Monitor fuel gauge to confirm it reads accurately (may take several minutes to update)
• Test drive vehicle and verify normal operation with no fuel delivery issues or fuel odor
• After test drive, perform final leak inspection of all fuel connections and access cover area
• If any fuel odor or leakage is detected, immediately shut off engine and repair before operating vehicle

More procedures for this vehicle