I got the tank out from under the lift/van and on to the floor where I would work on it. I moved it outside because of the gas fumes and fortunately the rain has stopped. I removed the 3 good screws quickly and easily. I then carefully used my vice grips on the 2 rounded out screws and proceeded to mangle the heads further and further. They would not budge. I already had one screw broken off and realized that I was about to have 3 of the 6 broken off. I had not choice so I chiseled off these 2 screw heads (and prayed I would not send a spark into the gas fumes thereby ending my life). So now I was able to remove the fuel pump.
These screws are incredibly small a soft.
Sure enough, there along the side of the fuel pump I could see the evil fuel temperature sensor.
At least I had not done this for nothing. But now came the difficult choice, how am I going to deal with the screws broken off. I sprayed them with liquid wrench, used the vice grips again with the hope I could back the screw shafts out but they proceeded to break off flush with the tank. *sigh*
Were this anything non flammable/explosive I would probably just drill the 3 screws out and re-tap the holes for new screws. But it is a gas tank, full of fumes. I debated back and forth and talked to my father about options. This what I came up with.
1) I could just try drilling the holes and hope nothing explodes
2) I could get a towel soaking wet with water, lay it over the hole where the fuel pump was, cover any other holes and try drilling them out and hope nothing explodes
3) I could empty the tank, fill the entire tank with water and then drill the holes out with the tank full of water (I do not think there is any risk of explosion if I did this but I would need to be confident that I could get all of the water out of all of the related hoses and the tank after).
4) I could buy a new gas tank and new screws to secure the fuel pump to the new tank.
5) Further investigate whether or not it is true that a solution is available that you could put in an empty gas tank and eliminate/reduce the risk of fumes thereby allowing me to do the repair
I tried to get an aftermarket gas tank. Not available on rockauto.com and when I called advance and autozone they both said they cannot get gas tanks for KIA vehicles.
I called the closest KIA dealer. Approximately $475 for a new tank (ouch!) and they do not have it in stock, they will not get it in until Wednesday if I order it.
Thinking it over, I have to be somewhere all day on Saturday and would have to deal with it on Sunday, if I try option 1, 2 or 3. I decided to bite the bullet and do number 4. I ordered the gas tank. Now I have to deal with alternate transportation for my wife through at least Wednesday and I still have to finish the repair and hope that the temporary kinking of the fuel lines did not cause a problem.
I will continue this post as I finish the job .............