How to Install a Fuel Pump on a 2002 Kia Rioby Russell Wood
The 2002 Kia Rio is an economical vehicle that gets good gas mileage. One of the components of the fuel system that helps with getting that great mileage is the fuel pump mounted in the gas tank. This pump is critical to the fuel-injection system, and when it starts to put out inconsistent pressure or when it fails completely, the vehicle will start to have idling problems or may not be able to run at all. Fixing the problem means replacing the fuel pump, which can be done in about an hour.
Open up the rear doors and reach in between the seam between the top of the back seat and the bottom. Unbolt the lower seat cushion from the chassis using the 3/8-inch ratchet and socket. Pull the bottom cushion away from the chassis and set it outside the vehicle.
Open the gas door and remove the gas cap. Unbolt the silver fuel pump cover from the chassis using the 3/8-inch ratchet and socket. Unplug the electrical connection to the fuel pump with your hands. Put the key in the ignition and attempt to start the car. If it starts, allow it to run until the engine dies. Then remove the key from the ignition.
Disconnect the fuel line connections to the fuel pump, using a pair of pliers. Then pull the fuel pump and bracket assembly out of the gas tank. Pull the stock seal off the gas tank with your hands. Set a replacement seal onto the tank, then install the replacement fuel pump in the tank. Reconnect the fuel lines to the fuel pump, using the pliers.
Connect the electrical connection to the fuel pump, using your hands. Then bolt the silver cover to the chassis with the 3/8-inch ratchet and socket. Reinstall the rear seat cushion, using the ratchet.
Things You'll Need
- Open-end wrench set
- 3/8-inch ratchet and socket set
- Replacement fuel pump
- Replacement seal ring
- Never smoke or have an open flame nearby while you're working on the fuel system of a vehicle. If you do, you risk causing a fire and damaging yourself and the vehicle.
Russell Wood is a writer and photographer who attended Arizona State University. He has been building custom cars and trucks since 1994, including several cover vehicles. In 2000 Wood started a career as a writer, and since then he has dedicated his business to writing and photographing cars and trucks, as well as helping people learn more about how vehicles work.