Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Fuel Tank: Installation
- Check that the fuel tank cover has no deformation, cracks or other damages.CAUTION: If the fuel tank cover is faulty, remove the cover clamp and replace with a new fuel tank cover.
- Support the fuel tank with a transmission jack, set the fuel tank in place, and temporarily tighten the bolts of the fuel tank band.CAUTION: A helper is required to perform this work.
- Move the fuel tank so that the distance between the end of the reference hole for each body and the end of the fuel tank becomes the following, and tighten the bolts of the fuel tank bands in the sequence shown in the figure.CAUTION: To prevent the fuel tank from damage, after tightening the bolts of the fuel tank bands, make sure that the distance between the end of the reference hole for body and the end of the fuel tank is the following.
Distance LI between body reference hole end (A) - Fuel tank end (B):
90 mm (3.543 in) - 110 mm (4.331 in)
Distance L2 between body reference hole end (C) - Fuel tank end (D):
140 mm (5.512 in) - 160 mm (6.299 in)
Distance L3 between body reference hole end (E) - Fuel tank end (F):
116 mm (4.576 in) - 136 mm (5.354 in)
Tightening torque:
33 N.m (3.4 kgf-m, 24.3 ft-lb)
- Connect the fuel delivery tube to the fuel pipe assembly. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DOTC)>Fuel Delivery and Evaporation Lines>INSTALLATION>QUICK CONNECTOR CONNECTION (TYPE A) .
- Install the vent tube to the tube clamp.
- Connect the vent tube (C) to the canister. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DOTC)>Fuel Delivery and Evaporation Lines>INSTALLATION>QUICK CONNECTOR CONNECTION (TYPE E) .
- Connect the circulate tube (B). Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DOTC)>Fuel Delivery and Evaporation Lines>INSTALLATION>QUICK CONNECTOR CONNECTION (TYPE F) .
- Connect the fuel filler hose (A). Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DOTC)>Fuel Delivery and Evaporation Lines>INSTALLATION>FUEL FILLER HOSE CONNECTION .
- Install the rear differential. Ref. to DIFFERENTIALS>Rear Differential (VB-type)>INSTALLATION .
- Install the rear exhaust pipe and muffler.
Rear exhaust pipe:
Ref. to EXHAUST (H4DOTC)>Rear Exhaust Pipe>INSTALLATION .
Muffler:
Ref. to EXHAUST (H4DOTC)>Muffler>INSTALLATION .
- Install the fuel tank protector. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DOTC)>Fuel Tank Protector>INSTALLATION .
- Lower the vehicle.
- Connect the connector to the fuel sub level sensor.CAUTION: Before connecting, make sure that there are no foreign matters, water, etc. inside the connectors of fuel sub level sensor and harness. If any foreign matters, water, etc. are found, remove them with air blow and connect the connector after it has dried completely.
- Install the service hole cover of fuel sub level sensor and refit the floor mat.
- Connect the connector to the fuel pump.CAUTION: Before connecting, make sure that there are no foreign matters, water, etc. inside the connectors of fuel pump and harness. If any foreign matters, water, etc. are found, remove them with air blow and connect the connector after it has dried completely.
- Install the service hole cover of fuel pump and refit the floor mat.
- Install the second seats. Ref. to SEATS>Second Seat>INSTALLATION .
- Connect the ground terminal to battery sensor. Ref. to REPAIR CONTENTS>NOTE>BATTERY .
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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.
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