2021 Kia Niro Plug-In Hybrid EXFACTORY OEM SERVICE PROCEDURE

Repair Procedures: Removal

  1. Release the residual pressure in fuel line.

    (Refer to the Fuel Delivery System - "RELEASE RESIDUAL PRESSURE IN FUEL LINE ")

  2. Switch "OFF" the ignition and disconnect the negative (-) battery terminal.
  3. Remove the rear seat cushion.

    (Refer to Body - "REAR SEAT ASSEMBLY ")

  4. Fuel pump service cover (A).
    G13348938Courtesy of KIA MOTORS AMERICA, INC.
    NOTE:
    • When reinstalling a protective cover for a fuel pump, remove the existing butyl tape and apply a new one.
    • Before assembling the protective cover, ensure that the temperature of the butyl is about 30°C using a hair dryer or a heat gun.
    G13348939Courtesy of KIA MOTORS AMERICA, INC.
    NOTE:
    • When installing the protective cover for the fuel pump, pay attention to the installation direction of the grommet and the protective cover.
    • The arrow (A) should be in the forward direction of the car.
    • Align the bulging part of the vehicle body (B) with the hole of the protective cover.
    • Align the bulging part of the grommet (C) with the bulging part of the protective cover.
    G13348940Courtesy of KIA MOTORS AMERICA, INC.
  5. Remove the fuel pump control module connector (A).
  6. Disconnect the fuel pressure sensor connector (B).
  7. Disconnect the fuel tank pressure sensor (C).
  8. Disconnect the fuel feed tube quick-connector (D).
    G13348941Courtesy of KIA MOTORS AMERICA, INC.
  9. Remove the fuel pump plate cover (B) by using the special service tool (A) [SST NO.: 09310-B8100].
    G13348942Courtesy of KIA MOTORS AMERICA, INC.
  10. Remove the fuel pump (A).
G13348943Courtesy of KIA MOTORS AMERICA, INC.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.