This procedure covers the complete removal and replacement of the fuel tank on a 2015 Kia Forte with 1.8L I4 engine, including fuel system depressurization, tank support, and all fuel line connections.

Warnings

Tools required

Parts

• Fuel tank (if replacing) × 1 — Use OEM specification
• Fuel tank strap set × 1 — 31420-A7000 or equivalent
• Fuel line O-rings × 4 — Use OEM specification
• Fuel filler neck hose clamp × 1 — Use OEM specification
• Fuel pump gasket/seal (if servicing pump) × 1 — Use OEM specification

Preparation

1. Park vehicle on level, solid ground in a well-ventilated area away from ignition sources
2. Ensure fuel tank is as empty as possible (less than 1/4 tank recommended)
3. Disconnect negative battery cable and isolate it away from the terminal
4. Allow vehicle to sit for at least 30 minutes after disconnecting battery to allow fuel system pressure to dissipate
5. Raise vehicle and support securely on jack stands at all four corners at manufacturer-specified lift points
6. Remove rear wheels for improved access to tank straps and components
7. Place fire extinguisher within immediate reach of work area
8. Have multiple drain pans ready to catch residual fuel

Procedure

1. 1

   Depressurize fuel system and remove fuel pump access cover
   From inside the vehicle, remove the rear seat cushion by pulling up firmly at the front edge. Locate the fuel pump access cover on the floor pan. Remove the four screws securing the cover and lift it away. Disconnect the fuel pump electrical connector by pressing the release tab. This ensures the fuel system is fully depressurized.
   ⚠Even with battery disconnected, residual pressure may remain in fuel lines. Have shop rags ready to catch any fuel spray when disconnecting lines.
   Torque spec

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

   Disconnect fuel filler neck and vapor lines
   Working from underneath the vehicle at the left rear area, locate the fuel filler neck connection to the tank. Loosen the hose clamp securing the filler neck to the tank using a flat blade screwdriver or socket. Slide the clamp away from the connection point. Disconnect the filler neck hose from the tank - residual fuel will drain, so position a drain pan underneath. Locate and disconnect the vapor line(s) from the top of the tank by pressing the quick-connect release tabs.
   Torque spec

   Filler Neck Clamp4 Nm (3 lb-ft)
3. 3

   Disconnect fuel supply and return lines
   Locate the fuel supply and return lines at the front of the fuel tank. These are quick-connect style fittings. Using the appropriate fuel line disconnect tool, press the release mechanism and pull the lines straight away from the tank connections. Have a drain pan positioned below as residual fuel will leak out. Cap or plug the lines to prevent contamination.
   ⚠Fuel line disconnect tools are specific to fitting size. Using incorrect tools can damage fittings and cause dangerous fuel leaks.
   Torque spec

   Fuel Line Fittings25 Nm (18 lb-ft)
4. 4

   Disconnect EVAP and vent lines
   Locate the EVAP canister lines and vent lines connected to the top and front of the fuel tank. These are typically smaller diameter quick-connect fittings. Press the release tabs and pull the lines straight away from their connections. Note the routing and orientation of each line for reassembly.
   Torque spec

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

   Support fuel tank with transmission jack
   Position a transmission jack or fuel tank support stand directly under the center of the fuel tank. Raise the jack until it just makes contact with the tank and provides light support. Place a piece of wood between the jack and tank to distribute load and prevent damage. The tank should be supported but not lifted - the straps should still be bearing the weight.
   ⚠️The tank must be properly supported before removing strap bolts. If support is inadequate, the tank will fall causing crushing injury and fuel spill.
6. 6

   Remove fuel tank strap bolts
   Locate the two fuel tank strap bolts at the front mounting points on each strap (total of 4 bolts for 2 straps). Using a 14mm socket and ratchet, remove all four strap bolts. The straps are hinged at the rear, so they will swing down once the front bolts are removed. Carefully lower the straps away from the tank.
   ⚠As bolts are removed, tank weight will transfer to the jack. Lower the jack slowly and watch for any lines or wires still connected.
   Torque spec

   Tank Strap Bolts35 Nm (26 lb-ft)
7. 7

   Lower tank and disconnect remaining connections
   Slowly lower the transmission jack while guiding the fuel tank down. Lower approximately 6-8 inches and stop. Check for any remaining electrical connectors, ground straps, or lines still attached to the top of the tank. If present, disconnect them before lowering further. The fuel pump wiring harness should already be disconnected from Step 1.
   ⚠Do not force the tank down. If resistance is felt, stop and check for forgotten connections that could be damaged.
8. 8

   Remove fuel tank from vehicle
   Continue lowering the transmission jack until the tank can be maneuvered out from under the vehicle. Guide the tank toward the rear and side of the vehicle to clear any obstructions. Once clear, lower the jack completely and move the tank to a safe, well-ventilated work area. If servicing the fuel pump or sender, remove it now according to manufacturer procedures.
   ⚠️Even an 'empty' fuel tank contains flammable vapors. Store the tank outdoors or in a well-ventilated area away from any ignition sources.
9. 9

   Inspect and clean tank mounting area
   With the tank removed, inspect the tank straps for corrosion, damage, or stretching. Inspect the tank mounting surface on the vehicle underbody for corrosion or damage. Clean the mounting area with a parts brush. Inspect all heat shields and brackets, replacing if damaged. If installing a new tank, transfer the fuel pump assembly and any sensors from the old tank using new gaskets and seals.
   Torque spec

   Bracket Bolts19 Nm (14 lb-ft)
10. 10

    Position new/serviced tank and raise into place
    Place the fuel tank (new or serviced) onto the transmission jack with the wood pad in place. Ensure the fuel pump access opening is oriented toward the front of the vehicle and the filler neck connection is toward the left rear. Carefully raise the tank into position under the vehicle, guiding it to align with the mounting strap locations. Raise until the tank is in its mounting position but do not fully seat it yet.
    ⚠Ensure all lines and wiring harnesses are routed above and clear of the tank before final positioning to prevent pinching.
11. 11

    Install fuel tank straps and bolts
    Swing the fuel tank straps up into position over the tank. Align the strap bolt holes with the mounting points on the vehicle frame. Install all four strap bolts and thread them in by hand. Once all bolts are started, tighten them in a cross pattern (front left, front right, then alternate) to the specified torque of 35.0 Nm (26 lb-ft). Do not overtighten as this can damage the tank.
    Torque spec

    Tank Strap Bolts35 Nm (26 lb-ft)
12. 12

    Reconnect fuel and vapor lines with new O-rings
    Install new O-rings on all fuel line fittings - do not reuse old O-rings. Lightly lubricate the new O-rings with clean gasoline. Connect the fuel supply and return lines to the tank fittings by pushing straight in until you hear and feel a positive click. Tug on each line to verify it is locked in place. Connect all EVAP and vent lines in the same manner, ensuring each clicks into place. Torque any threaded fuel line fittings to 25.0 Nm (18 lb-ft) and other line fittings to 26.0 Nm (19 lb-ft).
    ⚠️Failure to use new O-rings or properly seat fuel line connections will result in fuel leaks and fire hazard. Verify each connection by tugging on the line.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)
13. 13

    Reconnect filler neck and secure clamp
    Slide the fuel filler neck hose onto the tank filler neck connection. Ensure it is fully seated. Position the hose clamp over the connection point and tighten to 4.0 Nm (3 lb-ft). Do not overtighten as this can cut or damage the rubber hose.
    Torque spec

    Filler Neck Clamp4 Nm (3 lb-ft)
14. 14

    Reconnect electrical connections
    If any electrical connectors or ground straps were disconnected from the top of the tank during removal, reconnect them now ensuring positive connection with audible clicks. From inside the vehicle, reconnect the fuel pump electrical connector at the access panel. Ensure the connector is fully seated and locked.
15. 15

    Reinstall access cover and rear seat
    Install the fuel pump access cover in the floor pan and secure with the four screws, torquing to 10.0 Nm (8 lb-ft). Reinstall the rear seat cushion by aligning the rear hooks and pressing down firmly at the front until it latches. Install the rear wheels if removed and torque lug nuts to manufacturer specification.
    Torque spec

    Cover Screws10 Nm (8 lb-ft)

Reassembly

1. Double-check all fuel line connections by tugging firmly on each line to verify they are locked in place
2. Verify all electrical connectors are fully seated with positive connection
3. Ensure tank straps are properly positioned and torqued evenly
4. Verify no tools or parts were left in the tank area or under the vehicle
5. Remove jack stands and lower vehicle to ground only after all work is verified complete

Verification

• Reconnect the negative battery cable and ensure it is tight
• Turn the ignition to ON position (do not start engine) and listen for the fuel pump to activate for 2-3 seconds to pressurize the system
• Cycle the ignition ON and OFF three times to fully pressurize the fuel system
• Carefully inspect all fuel line connections, filler neck, and tank seams for any signs of fuel leakage using a flashlight
• Start the engine and allow it to idle while monitoring for fuel leaks - check all connections again
• With engine running, have an assistant add 2-3 gallons of fuel while you inspect the filler neck connection and tank area for leaks
• Check for proper fuel gauge operation on the instrument cluster
• Take a short test drive and recheck all connections for leaks after the vehicle has been driven and fuel has been sloshed in the tank
• If any fuel odor is detected or leaks are found, immediately shut off the engine, disconnect the battery, and repair the leak before operating the vehicle

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