Replacing The Fuel Pump In A Kia Picanto: Step-By-Step Guide

The Kia Picanto is a popular car, but like all vehicles, it has its problems. One issue that has been reported by owners is a failure of the fuel pump, which can lead to the car not starting. This is a job that can be done at home with the right tools and know-how, and there are plenty of online guides and videos available to help. The fuel pump is located under the rear seat, and the whole process should take around 30 minutes. It is important to disconnect the battery before starting any work.

Removing the fuel filter

To remove the fuel filter from your Kia Picanto, follow these steps:

Firstly, locate the fuel filter unit. It is underneath the rear seat. Start by pushing the rear seat forward to reveal a large, black plastic cap covering the whole fuel unit. This cap can be removed by hand, but it may be stuck down with strong adhesive, so be prepared to use some force.

Next, remove the electrical cables, the rubber pipe, and the black fuel line from the fuel unit. To remove the black fuel line, push in the buttons on either side of the connector. Be prepared for a small spray of fuel, so have a towel nearby.

Now, you should see a black outer ring holding the fuel unit in place. This black ring has marks around its rim and can be removed by placing two screwdrivers at opposite sides and then hammering in opposite directions to get the black ring turning. An extra pair of hands may be required for this step.

Once all cables and the black ring have been removed, pull the fuel unit out of the petrol tank. When the fuel unit is almost all the way out, angle it to remove it completely, as the level float is attached to the bottom of the unit.

Now, you can carry the fuel unit to a clean workspace. Cover the fuel tank with the black plastic cap to prevent any dirt from getting inside.

Remove the top of the fuel unit by releasing the three clips on the outside of the unit. Make sure to retain the spring inside. Remove the large rubber seal, all electrical cables, and the two plastic caps. You will need to reuse these parts, so keep them safe.

There are two very small notches on the side of the fuel unit holding the fuel filter in place. It may take some force to remove the filter, but with some effort, it should come out.

Now, you can remove the fuel pump from the fuel filter. To do this, unclip the white end cap from the bottom of the fuel pump by removing the four catches/notches.

Finally, there is an extra material filter attached to the bottom of the fuel pump. Remember which way this was connected to the fuel filter, as one side is flat and the other is circular.

The fuel filter is now removed. The installation of a new fuel filter is the reverse of the process described above.

Disconnecting the battery

Locate the battery: The battery in your Kia Picanto is located in the engine compartment, typically towards the front of the vehicle. It is a rectangular unit with two terminals, one positive (+) and one negative (-).

Gather the necessary tools: Before you begin, ensure you have the necessary tools for the job. You will need a basic set of tools, including a wrench or socket set to loosen and tighten the battery terminals. It is also recommended to wear protective gear, such as gloves and eye protection.

Turn off the ignition: Before proceeding, make sure that the ignition is turned off. This is crucial to prevent any electrical shorts or accidental activation of components while working on the car.

Loosen the negative terminal: Using your wrench or socket, loosen the nut or bolt securing the negative (--) battery cable. You may need to wiggle the cable free gently, being careful not to strain the cable.

Disconnect the negative cable: Once the nut or bolt is loosened, carefully remove the negative cable from the battery terminal. You may need to wiggle it gently to detach it completely. Be cautious not to let the cable touch any metal surfaces or the positive terminal.

Secure the cable: After disconnecting the negative cable, ensure that it is secured safely away from the battery. You can use a cable tie or tape to hold it in place, preventing accidental contact with the battery.

Work safely: With the battery disconnected, you can now proceed with changing the fuel pump or performing other maintenance tasks. Remember to exercise caution when working with fuel and always refer to a reliable repair guide or seek professional assistance if needed.

Remembering to disconnect the battery before performing any maintenance on your Kia Picanto is crucial for your safety and the protection of your vehicle's electrical system. Always take the time to locate and remove the negative battery cable before proceeding with any repairs or service.

Removing the rear seat

To remove the rear seat of a Kia Picanto, follow these steps:

Firstly, turn the ignition switch off and disconnect the negative battery cable. This is an important safety precaution to prevent any accidents. Then, you will need to push the rear seat forward. This action will reveal a large, black plastic cap covering the fuel unit. This cap can be removed by hand, but it may require some force due to the strong adhesive.

Next, you will need to remove the electrical cables connected to the fuel unit, as well as the rubber pipe and the black fuel line. To detach the black fuel line, locate and push the buttons on both sides of the connector. A small amount of fuel may spray out, so have a towel nearby to catch it.

At this point, you should be able to see the black outer ring that holds the fuel unit in place. This ring has marks around its rim, and you will need to use tools to carefully turn and remove it. Place two screwdrivers at opposite sides of the ring and then carefully hammer them in opposite directions to get the ring turning. An extra pair of hands may be helpful for this step.

Once all the cables and the black ring have been removed, carefully pull out the fuel unit from the petrol tank. As you do this, pay attention to the level float attached to the bottom of the fuel unit, as you will need to angle the unit accordingly to remove it successfully.

Now that the fuel unit is out, you can place a black plastic cap over the fuel tank to prevent any dirt or debris from entering. These detailed steps should provide a comprehensive guide to removing the rear seat of a Kia Picanto to access the fuel pump.

Disconnecting the fuel pump connector

Begin by turning off the ignition switch and disconnecting the negative battery cable. This is an important safety precaution to prevent any accidents. Next, remove the rear seat of your car. You can refer to the Kia Picanto JA 2017-2024 Service & Repair Manual for detailed instructions on how to do this. Once the rear seat is removed, you will have access to the fuel pump assembly.

Now, locate the fuel pump service cover and remove it. This will expose the fuel pump connector. To disconnect the fuel pump connector, carefully detach the electrical cables, rubber pipes, and fuel lines connected to it. Make sure you have a towel nearby to catch any small sprays of fuel that may occur due to the release of pressure.

At this point, you should also disconnect the fuel feed tube quick-connector, the vapor tube quick-connector, and the vapor hose. These components are crucial for the fuel delivery system and need to be handled with care. Once all the connections are detached, you can proceed to remove the fuel pump plate cover using the special service tool (No.: 09310-2S100 or 09310-3P100).

It is important to be cautious and take your time during this process to avoid any damage to the surrounding components and fuel lines. Ensure that you follow the instructions in the service manual or seek assistance from a qualified mechanic if you are unsure about any steps.

With these steps completed, you will have successfully disconnected the fuel pump connector and can proceed to the next stage of changing the fuel pump in your Kia Picanto. Remember to refer to the service manual or seek professional advice if needed.

Removing the fuel pump plate cover

To remove the fuel pump plate cover of your Kia Picanto, you will need a special service tool (No.: 09310-2S100 or 09310-3P100).

First, turn off the ignition switch and disconnect the negative battery cable. Then, remove the rear seat and the fuel pump service cover. Disconnect the fuel pump connector, the fuel feed tube quick-connector, the vapor tube quick-connector, and the vapor hose. Now, you can remove the fuel pump plate cover using the special service tool.

It is important to note that the installation process is the reverse of the removal process. When reinstalling the fuel pump, be sure to note the fuel pump direction and refer to the groove on the fuel tank for proper alignment.

Frequently asked questions