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How to replace fuel tank on 2005 kia sportage?

The procedure is as below:---

Removal & Installation


  1. Before servicing the vehicle, refer to the Precautions section.
  2. Properly relieve the fuel system pressure.
  3. Disconnect the negative battery cable.
  4. Following proper procedures, drain the fuel tank.
  5. Remove the rear seat cushion frame hinge bolts, and then lift the cushion.
  6. Disconnect the fuel pump components as follows:
    1. Remove the service cover under the carpet.
    2. Disconnect the fuel pump wiring connector.
    3. Remove the fuel feed hose and suction hose.

  7. Disconnect the fuel gauge sender components as follows:
    1. Remove the service cover under the carpet.
    2. Disconnect the fuel sender wiring connector.
    3. Disconnect the suction hose.

  8. Raise and properly support the vehicle.
  9. Disconnect the fuel filler hose (A), fuel leveling hose (B) and ventilation hose (C).
  10. Remove the front and main muffler assembly.
  11. On 4WD Models, remove the rear driveshaft.
  12. Remove the four parking brake cable mounting bolts(A).
  13. Position a suitable jack at the center of the tank and remove the two fuel tank bands securing the tank to the chassis. Allow the tank to rest on the jack.
  14. Carefully lower the tank assembly from the vehicle.
  15. Remove the fuel pump module from the tank.
  16. Remove the fuel gauge sender assembly from the tank.
    WARNING
    Make certain to seal all fuel tank openings until the tank is reinstalled in the vehicle.


To install:

  1. Ins the fuel gauge sender assembly.
  2. Install the fuel pump module.
  3. Position the fuel tank on a suitable jack at the center of the tank and carefully raise the fuel tank assembly under the vehicle until the assembly is positioned at the point of installation.
  4. Secure the tank to the chassis with two fuel tank bands and tighten the mounting nuts to 29-40 ft. lbs. (39-54 Nm).
  5. Install the four parking brake mounting bolts(A).
  6. On 4WD Models, install the rear driveshaft.
  7. Install the front and main muffler assembly.
  8. Connect the fuel filler hose (A), fuel leveling hose (B) and ventilation hose (C).
  9. Lower the vehicle.
  10. Connect the fuel gauge sender electrical connector and suction hose.
  11. Connect the fuel pump electrical connector.
  12. Connect the fuel pump fuel feed hose and suction hose.
  13. Replace the fuel pump and fuel gauge sender service covers.
  14. Install the rear seat cushion and secure with the frame hinge bolts.
  15. Connect the negative battery cable.
  16. Pressurize the fuel system and check for leaks.

    Click image to see an enlarged view

    Fig. Fuel hose identification



    Click image to see an enlarged view

    Fig. Disconnect the parking brake cables at the points shown



    Click image to see an enlarged view

    Fig. Fuel tank band locations



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