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.
- Tighten the bolts of the fuel tank band in the numerical order shown in the figure.
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) (H4DO)>FUEL DELIVERY AND EVAPORATION LINES>INSTALLATION>QUICK CONNECTOR CONNECTION (TYPE A) .
- Connect the vent tube (A) to the canister. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL DELIVERY AND EVAPORATION LINES>INSTALLATION>QUICK CONNECTOR CONNECTION (TYPE G) .
- Connect the circulate tube (B) to the fuel tank. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL DELIVERY AND EVAPORATION LINES>INSTALLATION>QUICK CONNECTOR CONNECTION (TYPE D) .
- Connect the fuel filler hose to the fuel filler pipe assembly. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL DELIVERY AND EVAPORATION LINES>INSTALLATION>FUEL FILLER HOSE CONNECTION .
- Install the rear differential. Ref. to DIFFERENTIALS>REAR DIFFERENTIAL (VA-TYPE)> INSTALLATION .
- Install the rear exhaust pipe and muffler.
Rear exhaust pipe:
Ref. to EXHAUST (H4DO)>REAR EXHAUST PIPE>INSTALLATION .
Muffler:
Ref. to EXHAUST (H4DO)>MUFFLER>INSTALLATION .
- Install the fuel tank protector. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>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.
- 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.
- Install the rear seat cushion. Ref. to SEATS>REAR SEAT>INSTALLATION .
- Connect the ground terminal to battery sensor. Ref. to REPAIR CONTENTS>NOTE>BATTERY .
Use the Manual With the Right Hardware
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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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