Kia Sportage 1998-02

Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Open the rear access door.
  8.  
  9. Release the catch for the back seat and tilt the seat out of the way.
  10.  
  11. Move the carpet behind the seat that covers the fuel pump access panel.
  12.  
  13. Disconnect the fuel pump electrical connectors.
  14.  
  15. Remove the screw securing the ground wire.
  16.  
  17. Remove the four screws securing the fuel pump access panel and position it out of the way.
  18.  
  19. Remove the hose clamps connecting the fuel hoses to the fuel pump.
  20.  
  21. Disconnect the fuel hoses from the fuel pump.
  22.  
  23. Disconnect the fuel tank pressure sensor electrical connector.
  24.  
  25. Remove the eight retaining screws securing the sender assembly to the tank.
    WARNING
    The fuel assembly is easily damaged. Use care when removing the assembly from the tank.

  26.  
  27. While twisting and tilting, gradually lift the fuel sender assembly and remove from the tank.
  28.  
  29. Wrap the fuel pump assembly in a rag before removing the assembly from the vehicle.
  30.  
  31. Cover or seal the fuel tank until installing the fuel pump assembly.
  32.  
  33. Remove the retaining hardware that holds the sender to the fuel pump assembly.
  34.  

To install:

  1. Install the retaining hardware that holds the sender to the fuel pump assembly.
  2.  
  3. Remove the temporary covering or seal that was used to protect the tank.
  4.  
  5. Install the fuel pump into the access port on top of the fuel tank.
  6.  
  7. Carefully, twist the fuel pump as necessary to properly position it in the fuel tank.
  8.  
  9. Install the eight retaining screws securing the sender assembly to the tank.
  10.  
  11. Connect the two fuel hoses to the pump and secure with clamps.
  12.  
  13. Connect the fuel tank pressure sensor electrical connector.
  14.  
  15. Insert the ground wire and fuel pump electrical connector through the access hole and install the access cover.
  16.  
  17. Connect the fuel pump electrical connector.
  18.  
  19. Secure any loose wiring with adhesive tape and reattach the carpeting.
  20.  
  21. Release the catch for the rear seat and put the rear seat in the normal position.
  22.  
  23. Close the rear access door.
  24.  
  25. Reconnect the negative battery cable.

    Click image to see an enlarged view

    Fig. Fuel tank access cover location



    Click image to see an enlarged view

    Fig. Exploded view of the fuel sender assembly

  26.  

 
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