Fuel Tank Strap

This procedure replaces the fuel tank retention straps on a 2015 Kia Forte 1.8L, requiring fuel tank lowering and fuel system depressurization.

Warnings

Tools required

Parts

• Fuel tank strap (left) × 1 — Use OEM specification
• Fuel tank strap (right) × 1 — Use OEM specification
• Fuel line O-rings × 1 — Use OEM specification
• Fuel filler neck hose clamps × 2 — Use OEM specification

Preparation

1. Park vehicle on level concrete surface outdoors or in well-ventilated area away from all ignition sources
2. Turn off engine and remove key from ignition. Allow engine and exhaust system to cool completely (minimum 2 hours)
3. Disconnect negative battery cable and isolate from battery terminal
4. Chock front wheels securely
5. Remove fuel filler cap to relieve tank pressure
6. Verify fuel level is below 1/4 tank. If above 1/4, siphon fuel into approved containers until below 1/4 tank
7. Raise rear of vehicle with floor jack and support securely on jack stands at manufacturer lift points. Vehicle must be level side-to-side
8. Remove rear wheels for improved access (optional but recommended)
9. Place drain pan under fuel tank area to catch any fuel spillage
10. Have transmission jack ready and positioned near fuel tank

Procedure

1. 1

   Relieve fuel system pressure
   Locate the fuel pump fuse (fuse #23, 15A) in the engine compartment fuse box. Remove the fuel pump fuse. Reconnect the negative battery cable temporarily. Attempt to start the engine; it should start briefly then stall as fuel pressure is consumed. Crank the engine for 5 additional seconds to ensure pressure is relieved. Disconnect negative battery cable again. This depressurizes the fuel lines before disconnection.
   ⚠️The engine will stall during this step - this is normal and necessary. Do not attempt to add starting fluid or investigate why it stalled.
2. 2

   Access fuel tank connections
   From under the vehicle, locate the fuel tank. Identify the fuel feed line, return line (if equipped), evaporative emission lines, fuel pump electrical connector, and fuel filler neck connection on the tank. Spray all connection points with penetrating oil if corrosion is present. Clean around connection points with wire brush to prevent debris from entering fuel system.
   ⚠Do not use metal brushes directly on fuel line threads or fittings. Use plastic or brass brushes only to avoid damaging sealing surfaces.
3. 3

   Disconnect electrical connector
   Locate the fuel pump/sender electrical connector on top of the fuel tank. Press the locking tab and disconnect the electrical connector. Move the wiring harness aside and secure it away from the tank to prevent damage during lowering.
4. 4

   Disconnect fuel lines
   Using the appropriate fuel line disconnect tool, disconnect the fuel feed line from the tank. A small amount of fuel will drain - catch it with the drain pan. Disconnect the fuel return line if equipped. Disconnect EVAP vapor line. Cap all open fuel lines immediately with suitable plugs or tape to prevent contamination and fuel spillage. Verify all lines are completely disconnected and moved clear of the tank.
   ⚠️Fuel will spray when lines are disconnected even after depressurization. Keep face away from connection point and have rags ready to catch fuel.
   Torque spec

   Fuel Line Fittings25 Nm (18 lb-ft)
5. 5

   Disconnect fuel filler neck
   Locate the fuel filler neck connection at the rear of the tank. Loosen the hose clamp securing the filler neck to the tank using a flathead screwdriver or appropriate socket. Loosen the hose clamp on the vapor/vent line connected to the filler neck. Carefully twist and pull the filler neck hose from the tank inlet - some fuel may spill from this connection.
   ⚠Filler neck hose may be stuck due to age and fuel exposure. Do not use excessive force or sharp tools that could puncture the hose or tank.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
6. 6

   Support fuel tank
   Position transmission jack or fuel tank support jack under the center of the fuel tank. Raise jack until it just contacts the tank bottom with light pressure. Secure tank to jack with a strap or chain to prevent it from shifting during lowering. Ensure jack is stable and positioned to support the full weight of the tank.
   ⚠️The tank must be securely attached to the jack. If the tank slides off the jack during lowering, crushing injury will occur.
7. 7

   Remove heat shield if equipped
   If the fuel tank has a protective heat shield, remove the mounting bolts securing the shield to the underbody or tank straps. Set heat shield aside. Note the orientation and position of any spacers or insulators for reinstallation.
   Torque spec

   Mounting Bolts26 Nm (19 lb-ft)
8. 8

   Remove fuel tank strap fasteners
   Locate the two fuel tank strap mounting bolts at the rear of each strap where they attach to the vehicle frame. There are four bolts total - two per strap. Using a 14mm socket, remove all four strap mounting bolts while supporting the straps with your other hand. The tank will now be supported only by the jack. Keep the bolts separated and labeled as left and right if threads differ.
   ⚠️As you remove the final bolts, the full weight of the tank transfers to the jack. Ensure jack is stable before removing last bolt.
   Torque spec

   Mounting Bolts26 Nm (19 lb-ft)
9. 9

   Lower tank and remove straps
   Very slowly lower the transmission jack 6-8 inches, just enough to access the fuel tank straps. The straps will become slack. Carefully unhook or slide the old fuel tank straps from the tank mounting points. Inspect the strap mounting points on the tank for damage or corrosion. Clean mounting surfaces with wire brush if needed. Remove old straps completely from vehicle.
   ⚠Do not lower the tank more than necessary. Lowering too far may damage electrical connectors or remaining lines that were not visible during initial inspection.
10. 10

    Inspect and prepare tank
    With tank partially lowered, inspect the tank body for damage, corrosion, or leaks. Check the fuel pump mounting area and all fittings for corrosion or cracks. If any damage is found, tank must be replaced - do not reinstall a damaged fuel tank. Clean the strap contact areas on the tank with wire brush. Apply light coat of anti-seize or rust preventive to strap contact points if desired.
    ⚠Do not use petroleum-based products on tank exterior. Use only fuel-safe anti-corrosion products if treating metal surfaces.
11. 11

    Install new fuel tank straps
    Position the new fuel tank straps over the tank in their mounting positions. Ensure straps are oriented correctly with the mounting bolt holes toward the rear and the curved sections supporting the tank bottom. The straps should mirror each other left-to-right. Hook or position straps into the tank mounting points. Verify straps are fully seated and not twisted.
12. 12

    Raise tank into position
    Slowly raise the transmission jack to bring the fuel tank and new straps up toward the vehicle underbody. Align the strap mounting holes with the frame mounting points. Ensure all lines, hoses, and the electrical connector are routed properly and not pinched. Continue raising until strap bolt holes align perfectly with frame mounting holes. Have an assistant help align if working alone.
    ⚠Check routing of all fuel lines, EVAP lines, and wiring during raising. Lines can become pinched between tank and underbody causing failure after installation.
13. 13

    Install strap mounting bolts
    Thread all four fuel tank strap mounting bolts by hand first to ensure proper thread engagement. Once all bolts are hand-started, tighten them in a cross pattern (right front, left rear, left front, right rear) using a torque wrench to 26.0 Nm (19 lb-ft). Verify straps are evenly tensioned and tank is held securely against the underbody without excessive play.
    ⚠Do not overtighten strap bolts. Excessive torque can deform the tank or crack mounting points. Use calibrated torque wrench only.
    Torque spec

    Mounting Bolts26 Nm (19 lb-ft)
14. 14

    Reinstall heat shield
    If heat shield was removed, position it back in place ensuring proper alignment with any spacers or insulators. Install heat shield mounting bolts and torque to 26.0 Nm (19 lb-ft). Ensure heat shield does not contact the tank directly and maintains proper clearance from exhaust components.
    Torque spec

    Mounting Bolts26 Nm (19 lb-ft)
15. 15

    Reconnect fuel filler neck
    Slide the fuel filler neck hose onto the tank inlet. Ensure hose is fully seated onto the tank neck before tightening. Install new hose clamps if old clamps are corroded. Position clamp beyond the bead on the tank neck and tighten to 3.0 Nm (2 lb-ft). Reconnect vapor/vent line and secure with clamp to 3.0 Nm (2 lb-ft). Verify filler neck has no kinks.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)
16. 16

    Reconnect fuel lines
    Install new O-rings on all fuel line fittings - do not reuse old O-rings. Lightly lubricate new O-rings with clean gasoline. Connect the fuel feed line to the tank fitting and tighten to 26.0 Nm (19 lb-ft). Connect return line if equipped and torque to 26.0 Nm (19 lb-ft). Connect EVAP vapor line. Verify all quick-connect fittings are fully seated with an audible click if applicable.
    ⚠️Improper fuel line connection is a major fire hazard. Pull on each line after connection to verify it is fully locked. A loose fitting will leak under pressure.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)
17. 17

    Reconnect electrical connector
    Reconnect the fuel pump/sender electrical connector to the top of the tank. Ensure connector locks with an audible click. Tug gently on connector to verify it is fully seated. Route wiring harness away from any sharp edges or hot exhaust components.
18. 18

    Remove jack and inspect installation
    Carefully lower and remove the transmission jack from under the fuel tank. Perform a visual inspection of the entire installation. Verify all lines are connected, straps are properly tensioned, no tools or rags are left on tank, and no lines are kinked or pinched. Check that tank sits evenly in the straps with no sagging on either side.

Reassembly

1. Reinstall rear wheels if removed and torque lug nuts to manufacturer specification (100-110 lb-ft)
2. Lower vehicle from jack stands carefully
3. Reconnect negative battery cable
4. Reinstall fuel pump fuse in engine compartment fuse box
5. Add fuel to bring tank to 1/4-1/2 full before starting engine for first time

Verification

• Turn ignition to ON position (do not start) for 5 seconds, then OFF. Repeat 3 times to allow fuel pump to prime system and build pressure
• Inspect under vehicle at all fuel line connections, filler neck, and tank seams for any fuel leaks during priming cycles
• Start engine and let idle for 5 minutes while monitoring for leaks underneath the vehicle
• Perform visual inspection of all connections under vehicle with engine running - look for drips, seepage, or fuel odor
• Rev engine to 2500 RPM briefly and recheck all connections for leaks under increased fuel flow
• Turn off engine and perform final inspection of tank straps - verify tank has not shifted or sagged
• Test drive vehicle and listen for any unusual noises from fuel tank area such as banging or slapping that would indicate loose straps
• After test drive, perform final leak inspection under vehicle with fuel system hot and at operating pressure
• Monitor fuel gauge operation to verify fuel level sender is functioning correctly after reconnection

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