🔧 Kona - Fuel Pump Replacement

Your Kona can have two “fuel pumps” people refer to: the in-tank low-pressure fuel pump module (inside the fuel tank, feeds fuel forward) and the engine-mounted high-pressure fuel pump (on the engine, boosts pressure for direct injection).

Before I give you the exact steps, we need to confirm which one you’re replacing so you don’t buy the wrong part or open the wrong system.

Difficulty Level: Intermediate | Estimated Time: 1.0-3.0 hours

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⚠️ Safety & Precautions

• ⚠️ Fuel is flammable—work outside or in a very well-ventilated area.
• ⚠️ No smoking, no sparks, no hot work lights near the car.
• ⚠️ Wear eye protection—fuel can spray when lines are opened.
• ⚠️ Disconnect the 12V battery negative terminal before unplugging fuel pump wiring.
• ⚠️ If working on the engine-mounted high-pressure pump, the fuel system can be at very high pressure—pressure must be relieved correctly before loosening any fittings.

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🔧 Required Tools

You'll need the following tools for this repair:

• Safety glasses
• Nitrile gloves
• Fire extinguisher Class B
• 10mm socket
• 3/8" drive ratchet
• 3/8" drive torque wrench
• Trim clip remover
• Flat-blade screwdriver
• Fuel line disconnect tool set
• Shop towels
• Catch pan
• Hand pump siphon
• Non-sparking brass punch (specialty)
• Small hammer

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Fuel pump (in-tank fuel pump module) - Qty: 1
• Fuel pump module seal O-ring - Qty: 1
• Fuel pump (engine-mounted high-pressure fuel pump) - Qty: 1
• High-pressure fuel line sealing washers/gaskets - Qty: 1

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📋 Before You Begin

• Park your Kona on level ground and set the parking brake.
• Lower the fuel level if possible (under 1/4 tank makes in-tank work safer and less messy).
• Disconnect the 12V battery using a 10mm socket (remove negative terminal first).
• Have plenty of shop towels ready for spilled fuel.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Confirm which “fuel pump” you mean

• If the pump is under the rear seat / cargo area behind an access cover, you mean the in-tank fuel pump module.
• If the pump is on the engine and has a metal fuel line going to the fuel rail, you mean the high-pressure fuel pump.
• Reply with: “in-tank” or “high-pressure”, and I’ll give you the exact Kona procedure with the correct line-release steps and tighten specs.

Step 2: Quick visual check (no disassembly yet)

• Use a flashlight to look under the rear seat area for a round/square service cover (in-tank access).
• Open the hood and look for a small pump on the engine with a rigid metal line attached (high-pressure pump).
• Take a photo and send it if unsure.

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✅ After Repair

• Once the correct pump is replaced, you’ll need to prime the fuel system and check carefully for leaks before driving.
• If any check-engine light appears, scan for codes and re-check connectors and line seating.

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💰 DIY vs Shop Cost

Shop Cost: $450-$1,400 (parts + labor)

DIY Cost: $150-$900 (parts only)

You Save: $300-$500+ by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 1-3 hours.

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🎯 Ready to get started?

HowToo makes it easy: same-day/2-day shipping on every part, plus all the tools and specialty tools you need! Check out the parts and tools sections below to add everything to your cart.