Kia Sorento Fuel Pump Removal: 2016 Guide

Nov 17, 2025 by Alex Braham 42 views

Hey guys! So, you're tackling a fuel pump replacement on your 2016 Kia Sorento, huh? It might seem daunting, but with the right guidance, you can totally nail this. Let's break down the process of safely and effectively removing the fuel pump from your Kia Sorento. Remember, safety first, so always disconnect the battery and work in a well-ventilated area.

Preparing for the Fuel Pump Removal

Before diving in, preparation is key. Start by gathering all the necessary tools. You’ll need a socket set, wrenches, screwdrivers (both flathead and Phillips), a fuel line disconnect tool, a hammer, and some penetrating oil. It's also wise to have a container to catch any spilled fuel, as well as some shop rags to clean up any messes. Safety glasses and gloves are a must to protect yourself from fuel and any debris. Make sure you have a new fuel pump ready to install once you remove the old one. This will minimize downtime and ensure you're not stuck halfway through the job.

Next, you’ll want to relieve the fuel pressure in the system. This is a crucial step to prevent fuel from spraying everywhere when you disconnect the fuel lines. Locate the fuel pump fuse or relay in the fuse box, typically under the hood or inside the cabin. Consult your owner's manual for the exact location. Start the engine and then pull the fuse or relay. Let the engine run until it stalls, which indicates that the fuel pressure has been relieved. After the engine stalls, try starting it again a couple of times to ensure all the residual fuel pressure is gone. This step is super important for safety!

With the fuel pressure relieved, you can now access the fuel pump. In the 2016 Kia Sorento, the fuel pump is usually located under the rear seat. You'll need to remove the rear seat cushion to gain access. This typically involves unclipping or unbolting the seat cushion. Refer to your vehicle's repair manual for the specific procedure. Once the seat cushion is removed, you should see an access panel. Remove this panel to reveal the fuel pump assembly. This is where the actual work begins, so take a deep breath and get ready to get your hands dirty.

Step-by-Step Fuel Pump Removal Process

Alright, let’s get into the nitty-gritty of removing that fuel pump. Follow these steps closely:

Disconnect the Electrical Connections: The first thing you'll see are the electrical connectors attached to the fuel pump module. Carefully disconnect these connectors. Be gentle; you don't want to break any of the plastic clips. Use a small screwdriver if needed to help release the connectors, but avoid forcing anything. Make sure to note how the connectors are oriented so you can reconnect them correctly later. Taking a photo with your phone can be super helpful.
Disconnect the Fuel Lines: Next up are the fuel lines. This is where that fuel line disconnect tool comes in handy. There are different types of fuel line connectors, so make sure you have the correct tool for your Sorento. Slide the tool into the connector to release the locking mechanism and then gently pull the fuel line off. Have your container ready to catch any fuel that spills out. Be patient and work slowly to avoid damaging the fuel lines or connectors. If the lines are stuck, try spraying a little penetrating oil to help loosen them up.
Remove the Fuel Pump Retaining Ring: The fuel pump assembly is held in place by a retaining ring. This ring can be made of plastic or metal and usually requires a special tool to remove it. However, you can often remove it using a hammer and a flathead screwdriver. Place the screwdriver against one of the notches on the ring and gently tap it with the hammer to rotate the ring counterclockwise. Work your way around the ring, tapping it a little at a time until it's loose enough to remove by hand. Be careful not to damage the fuel tank or the retaining ring itself.
Remove the Fuel Pump Assembly: With the retaining ring removed, you can now lift the fuel pump assembly out of the tank. Do this slowly and carefully, making sure not to snag any of the fuel lines or electrical wires. As you lift the assembly, be aware that there will still be some fuel inside the pump module. Tilt the assembly to drain as much fuel as possible back into the tank before completely removing it. Once the assembly is out, inspect the fuel tank opening for any debris or contamination. Clean it if necessary before installing the new fuel pump.

Tips and Tricks for a Smooth Removal

Take Photos: Before disconnecting anything, take photos of the fuel pump assembly. This will serve as a valuable reference when you're reinstalling the new pump, ensuring you reconnect everything correctly.
Use Penetrating Oil: If you're having trouble disconnecting the fuel lines, don't force them. Spray some penetrating oil on the connectors and let it sit for a few minutes. This will help loosen any corrosion or buildup and make the lines easier to remove.
Work in a Well-Ventilated Area: Fuel fumes are dangerous, so make sure you're working in a well-ventilated area. Open a garage door or work outside to minimize your exposure to the fumes.
Be Patient: Removing a fuel pump can be a time-consuming process, so don't rush it. Take your time and work carefully to avoid making mistakes. If you get stuck, consult your vehicle's repair manual or watch a few more videos online.

Installing the New Fuel Pump

Once you've successfully removed the old fuel pump, you're ready to install the new one. The installation process is essentially the reverse of the removal process. Here are a few key things to keep in mind:

Transfer Components: Carefully transfer any necessary components from the old fuel pump assembly to the new one. This may include the fuel level sending unit, the fuel filter, and any rubber seals or gaskets. Make sure everything is clean and in good condition before transferring it over.
Install New Seals and Gaskets: Whenever you replace a fuel pump, it's a good idea to install new seals and gaskets. This will help prevent leaks and ensure a proper seal between the fuel pump assembly and the fuel tank.
Reconnect Everything: Carefully reconnect all the fuel lines and electrical connectors. Make sure everything is securely fastened and properly oriented. Refer to the photos you took earlier to ensure you're reconnecting everything correctly.
Install the Retaining Ring: Place the fuel pump assembly back into the tank and install the retaining ring. Make sure the ring is properly seated and tightened to the correct torque specification. This is crucial to prevent fuel leaks.

Final Checks and Start-Up

Before you button everything up, double-check all your connections and make sure everything is secure. Reinstall the access panel, the rear seat cushion, and any other components you removed during the process. Once everything is back in place, reconnect the battery and get ready to start the engine.

Turn the ignition key to the "on" position but don't start the engine. This will allow the fuel pump to prime the fuel system. Listen for the fuel pump to run for a few seconds and then shut off. Repeat this process a few times to ensure the fuel system is properly primed. Then, start the engine and let it run for a few minutes to check for any leaks or other issues. If everything sounds and looks good, you've successfully replaced your fuel pump!

Safety First!

I can't stress this enough: safety should always be your top priority when working on your car's fuel system. Fuel is highly flammable and can be dangerous if not handled properly. Always disconnect the battery before starting any work on the fuel system. Work in a well-ventilated area to avoid inhaling fuel fumes. Wear safety glasses and gloves to protect yourself from fuel and any debris. And never smoke or use open flames near the fuel system.

When to Call a Professional

While replacing a fuel pump is a manageable task for many DIYers, there are times when it's best to call a professional mechanic. If you're not comfortable working on your car's fuel system, or if you run into any unexpected problems during the process, don't hesitate to seek help from a qualified technician. They have the expertise and tools to diagnose and repair any issues safely and efficiently.

Conclusion

So, there you have it – a comprehensive guide to removing the fuel pump from your 2016 Kia Sorento! Remember to take your time, follow the steps carefully, and prioritize safety above all else. With a little patience and the right tools, you can save yourself some money and gain a sense of accomplishment by tackling this repair yourself. Good luck, and happy wrenching!