Pump connects into the main tank breather hose to transfer fuel
Just had to do a notch in the protective cover and it almost looks like original x)
Now the filler... Obviously the first idea was to create a Y on the original filler at the rear left. But we had to a accept reality and this is way too tight to fit a double inlet, even more fitting it to place. Actually even the original filler tube I'm not so sure how it's installed, that's a hell of a tetris.
This is the placement of the reservoir under the chassis. As you can see it's surrounded by chassis rails, and as the Hiace (as every almost vans) is a uniframe construction, the body is soldered directly on the chassis. This means there is no gap to pass between the chassis and the frame as a regular 4x4 with separate chassis. So we had no way to get a filler breather from top of the reservoir to inlet without a low point... either we create a low point where liquid will be trapped or we place it mid-height to pass under the chassis...
The is the question of where to get out, on the right you can see the step of the sliding door, which is immediately continued by the leaves spring support, then the wheel arch. So there is no easy way to get the filler out on the side of the body...
So we had to take a decision... and decided to have the auxiliary filler (technically) inside the vehicle and going through the step.
(better grommet will be added for main tube)
Note that we used here an original Hiace inlet tube, almost the same than the one for my main tank (only difference this is one from a diesel so no reducer inside).
I had removed my internal setup for this project so you can't see it but the tube is not going out in the middle of the living area of the vehicle, it is inside my side cabinet, where was my grey water jerrycan until now.
The plan is already to have the water filler on this face (once I'll install a dedicated water tank inside) so this area of the cabinet will basically be a full technical area accessible from outside.
Note that the original fuel cap is not supposed to vent out but just in case I'll build a kind of box around the inlet pipe, that will seal with some rubber against the sliding door. And in the bottom part (where you can see some kind of door held by 3 bolts getting inside the chassis) I'll add a vent.
I know lot's of controversial choices here but we didn't find better ones!
Now I have to test it and verify the tank ventilation is ok to fill it full. Just a few bits are missing... a second 6mm T to connect to original EVAP line, a little electrical modification to route my cables correctly, and my 2nd fuel cap I forgot in my spare parts stash...
). For the problems it's on me to find solutions and take decisions... some discutable...