Sienna FUEL

11-9
FUEL - FUEL INJECTOR ASSY
FUEL INJECTOR ASSY

110SZ-01
COMPONENTS
FR Wiper Arm RH
Front Wiper Arm

Head Cover FR Wiper Arm LH
20 (205, 15)
20 (205, 15)
Front Wiper Arm Head Cover
Cowl Top Ventilator Louver

Sub-assy
Windshield Wiper Motor

Assy
Cowl Top to Cowl Brace Inner No. 1 5.5 (56, 49 in.⋅lbf)
x2 x4
7.5 (76, 66 in.⋅lbf)
7.5 (76, 66 in.⋅lbf)

x7
Windshield Wiper Motor
Connector
Cowl Top Panel Sub-assy
Outer Front
N·m (kgf·cm, ft·lbf) : Specified torque

A79467
2005 SIENNA REPAIR MANUAL (RM1163U)
Author: Date: 2258

11-10
x3
7.9 (81, 70 in.⋅lbf)
V-bank Cover Sub-assy
Fuel Vapor Feed Hose Assy
Mass
Air Flow Meter
Connector
Vacuum Hose
Air Cleaner Cap Sub-assy

5.0 (51, 44 in.⋅lbf)
Air Cleaner Filter Element Sub-assy

A81680
Author: Date: 2259

11-1 1
VSV Connector
x2 8.0 (82, 71 in.⋅lbf) 7.8 (80, 69 in.⋅lbf)
x2
Pressure Feed
Tube Assy
Fuel Vapor Feed Hose Assy
Emission Control Valve Set

28 (286, 21)
20 (199, 14)
x4 x2 20 (199, 14)
x2
x2
Emission Control Valve Bracket
Engine Hunger No. 1 Surge Tank Stay No. 1
x2
20 (199, 14)
Intake Air Surge Tank Surge Tank
Stay No. 2
Union to Check Valve Hose
Air Surge Tank

to Intake Manifold Throttle Motor Connector
Gasket
Water By-pass Hose No. 3

Water By-pass Hose No. 2

Non-reusable part A79468
Author: Date: 2260

11-12
Fuel Injector O-ring

Fuel Injector Grommet 10 (102, 7)
Fuel Injector Assy
Fuel Injector
Connector
Fuel Delivery Pipe
Injector Vibration Insulator Sub-assy
Delivery Pipe No. 1 Spacer
10 (102, 7)
Fuel Delivery Pipe No. 2

20 (199, 14)
Fuel Pump Harness Gasket

Fuel Pressure
Injector Vibration Insulator Pulsation Damper Assy
33 (331, 24)
Fuel Pipe Sub-assy no. 1

Fuel Pipe
No. 2 Gasket
33 (331, 24)
Delivery Pipe No. 1 Spacer Fuel Pipe No. 2 Union Bolt
Fuel Injector
Connector

Author: Date: 2261

11-18
FUEL - FUEL SUCTION TUBE ASSY W/ PUMP & GAGE
FUEL SUCTION TUBE ASSY W/ PUMP & GAGE

110T1-01
COMPONENTS
Vapor Pressure Sensor

Connector
Fuel Pump Connector
Fuel Tank Assy
Fuel Tank
Filler Hose Cover
33 (336, 24) x3
5.0 (51, 44 in.⋅lbf)

Charcoal Canister Protector
x6
5.0 (51, 44 in.⋅lbf)

A79513
Author: Date: 2267

11-19
Fuel Tank Main Tube Sub-assy
Fuel Pump Gauge Retainer
Tube Joint Clip
Fuel Suction Tube Assy

w/ Pump & Gage
Fuel Suction Tube

Set Gasket
Tank Suction Tube

Support
Fuel Tank
to Filler Pipe Hose
Non-reusable part
A80353
Author: Date: 2268

11-20

Tube Joint Clip
Fuel Suction Plate

Sub-assy
Fuel pump Harness
O-ring
Fuel Pump Spacer
Clip Fuel Pump

O-ring
Fuel Pressure
Fuel Tube Joint Regulator Assy
Fuel Filter Assy
No. 1 O-ring
O-ring
Clip
Fuel Suction Support No. 1
Fuel Sender Gage Assy
Author: Date: 2269

11-28
FUEL - FUEL TANK ASSY
FUEL TANK ASSY

110T3-01
COMPONENTS

Connector
Fuel Pump Connector
Fuel Tank Assy
Fuel Tank
Filler Hose Cover
33 (336, 24) x3
5.0 (51, 44 in.⋅lbf)

Charcoal Canister Protector
x6
5.0 (51, 44 in.⋅lbf)

A79513
Author: Date: 2277

11-29
Fuel Tank Main Tube Sub-assy
Fuel Pump Gauge Retainer
Tube Joint Clip
Fuel Suction Tube Assy

w/ Pump & Gage
Fuel Suction Tube

Set Gasket
Fuel Tank Vent Hose
Fuel Tank
to Filler Pipe Hose
Non-reusable part
A79514
Author: Date: 2278

11-7
FUEL - FUEL SYSTEM
110SY-02
INSPECTION
1. INSPECT FUEL INJECTOR ASSY
(a) Inspect injector resistance
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Resistance:13.4 to 14.2 Ω at 20C (68F)
If the resistance is not as specified, replace the injector.
(b) Inspect injector operation.
CAUTION:
This test involves high-pressure fuel and electricity. Take
every precaution regarding safe handling of both the fuel
and the electricity. Preform this test in a safe area, and
avoid any sparks or flame. Do not smoke.
(1) Obtain new No. 1 fuel pipe (part No. 23801-20171)

Fuel Tube Connector and remove the fuel tube connector from the pipe.
A50710
(2) Install the fuel tube connector to SST (hose), then

Fuel Tube Connector connect the tube connector and the fuel pipe.
SST 09268-41047 (95336-08070)
SST
CAUTION:
(Hose) Connect the fuel tube connector (quick type) after observ-
ing the precautions.
B12947
(3) Install the grommet and O-ring to the injector.

SST(Hose) (4) Connect SST (union and hose) to the injector, and
hold the injector and the union with SST (clamp).
SST(Union)
SST 09268- 41047 (09268- 41110, 09268- 41300,
O-Ring 95336-08070)
SST (5) Put the injector into a graduated cylinder.
(Clamp) CAUTION:
Vinyl Tube Install a suitable vinyl tube onto the injector to contain gas-
A51873 oline spray.
(6) Operate the fuel pump.(See Page 11-4 )
Author: Date: 2256

11-8
FUEL - FUEL SYSTEM
(7) Connect SST (wire) to the injector and the battery

for 15 seconds, and measure the injection volume
SST
with a graduated cylinder. Perform this test on each
injector 2 or 3 times.
SST 09842-30070
Injection volume:
Injection volume Difference between each injector
60 to 73 cm3 (3.7 to 4.5 cu in.)
13 cm3 (0.8 cu in.) or less
A52609
in 15 seconds
NOTICE:
Always do the switching at the battery side.
If the injection volume is not as specified,replace the injector.
(c) Inspect leakage

(1) In the condition above, disconnect the test probes
of SST (wire) from the battery and check the fuel
leakage from the injector.
Fuel drop: 1 drop or less in 12 minutes
B00069
2. INSPECT FUEL PUMP

(a) Inspect fuel pump resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Resistance: 0.2 to 3.0 Ω at 20C (68F)
(b) Inspect fuel pump operation
(1) Apply battery voltage to both the terminals. Check
that the pump operates.
A16628 A32859 NOTICE:
These tests must be done quickly (within 10 seconds)
to prevent damage to the pump.
Keep fuel pump as far away from the battery as pos-
sible.
Always do the switching at the battery side.
Author: Date: 2257

11-4
FUEL - FUEL SYSTEM
110SX-01
ON-VEHICLE INSPECTION
1. CHECK FUEL PRESSURE

Fuel Tube Connector (a) Discharge fuel system pressure.
(See page 11-1 )
(b) Check that the battery voltage is above 12 V.
(c) Disconnect the negative (-) battery cable.
(d) Pull out the connecter from a new fuel tube.
HINT:
Part No. 23801-20171
A50710
(e) Disconnect the fuel tube clamp from the fuel tube connec-
tor.
Fuel Pipe
Clamp No.1 A60083
(f) Disconnect the fuel tube connector from the fuel pipe
A while pinching part A with fingers as shown in the illustra-
tion.
CAUTION:
After taking the precautions, disconnect the fuel tube
connector (quick type).
A As there is retained pressure in the fuel line, prevent
it from splashing inside the vehicle compartment.
B12941
Author: Date: 2253

11-5
FUEL - FUEL SYSTEM
(g) Install SST (pressure gauge) using SST and a fuel tube
connector as shown in the illustration.
SST SST 09268-41047(95366-08070),09268-45014
(T-Joint) (09268-41250, 09268-41200, 09268-41220)
SST (h) Wipe up any gasoline.
SST (i) Reconnect the negative (-) battery cable.
(Hose) (j) Connect the hand-hand tester to the DLC3.
SST
(k) Measure the fuel pressure.
(Hose) Fuel pressure:
304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 psi)
If the pressure is high, replace the fuel pressure regulator.
If the pressure is low, check the fuel hoses connections, the fuel
Fuel Inlet Tube pump, the fuel filter and the fuel pressure regulator.
(l) Disconnect the hand-held tester from the DLC3.
(m) Start the engine.
(n) Measure the fuel pressure at idle.
Fuel Tube Fuel pressure:
Connector 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 psi)
A71359 (o) Stop the engine.
(p) Check that the fuel pressure remains as specified for 5
minutes after the engine has stopped.
Fuel pressure: 147 kPa (1.5 kgf/cm2, 21psi)
If the pressure is not as specified, check the fuel pump, the
pressure regulator and/or the injectors.
(q) After checking the fuel pressure, disconnect the negative
(-) battery cable and carefully remove SST and the fuel
tube connector to prevent gasoline from splashing.
(r) Reconnect the fuel inlet tube (fuel tube connector).
CAUTION:
After taking the precautions, connect the fuel tube con-
necter (quick type).
2. CHECK FUEL PUMP OPERATION AND FUEL LEAK
(a) When using hand-held tester.
(1) Connect the hand-held tester to the DLC3.
(2) Turn the ignition switch ON and hand-held tester
main switch ON.
NOTICE:
Do not start the engine.
(3) Select the ACTIVE TEST mode on the hand-held
tester. If you need a help to select the ACTIVE
TEST mode, refer to the hand-held tester user’s
manual.
Author: Date: 2254

11-6
FUEL - FUEL SYSTEM
Engine Room Relay Block (b) When not using hand-held tester.
(1) Remove the circuit opening relay.
Circuit Opening Relay
(2) Using a service wire, connect terminals FP and +B
of the relay block.
NOTICE:
Pay due attention to the terminal connecting position to
avoid a malfunction.
(3) Turn the ignition switch ON and check that the fuel
+B FP pump operates.
NOTICE:
Do not start the engine.
(c) Check that there are no fuel leaks after doing mainte-
nance anywhere on the fuel system.
A75336
Author: Date: 2255

11-1
FUEL - FUEL SYSTEM
FUEL SYSTEM
110SW-01
PRECAUTION
1. PRECAUTION
(a) Before working on fuel system, disconnect negative (-) battery cable.
(b) Do not smoke or work near fire when handling the fuel system.
(c) Keep gasoline away from rubber or leather parts.
(d) Replace the fuel tank with a new one if the vehicle has been damaged, resulting in airbag deployment.
2. DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:
Do not disconnect any part of the fuel system until
you have discharged the fuel system pressure.
Even after discharging the fuel pressure, place a
shop rag over fittings as you separate them to reduce
risk of fuel spray on yourself or in the engine compart-
ment.
Engine Room Relay Block (a) Remove the circuit opening relay from the engine room
relay block.
(b) Start the engine. After the engine stopped, turn the igni-
tion switch OFF.
HINT:
It is possible that DTC P0171 (system too lean) will be set.
(c) Check that the engine does not start.
Circuit Opening Relay (d) Remove the fuel tank cap, and let the air out of the fuel
A75349 tank.
(e) Disconnect the negative (-) battery cable.
(f) Reinstall the circuit opening relay.
3. FUEL SYSTEM
(a) When disconnecting the high fuel pressure line, a large
amount of gasoline will spill out, so observe these proce-
dures.
(1) Discharge fuel system pressure. (See step 2)
(2) Disconnect the fuel pump tube.
(See page 11-21 )
(3) Drain the fuel that remained inside the fuel pump
tube.
(4) Cover the disconnected fuel pump tubes with a vinyl
or a plastic bag to prevent damage and dirt.
(5) Place a tray under the vehicle or point of disconnec-
tion to catch any fuel that may spill.
Vinyl or Plastic Bag
B00679
Author: Date: 2250

11-2
FUEL - FUEL SYSTEM
CORRECT (b) Observe the following precautions when removing and

New O-ring
installing fuel injectors.
NOTICE:
Never reuse the O-ring.
Delivery Pipe (1) When installing a new O-ring to the injector, be
careful not to damage the injector.
WRONG (2) Coat the new O-ring with grease or gasoline before
Injector installing. Never use engine oil, gear oil or brake oil.
A51878
(c) Install the injector to the delivery pipe and the cylinder
Delivery Pipe head as shown in the illustration. Before installing the in-
O-ring jector, be sure to apply grease or gasoline on the place
Grommet where the delivery pipe contacts the O-ring of the injec-
Spacer tor.
Insulator
A62371
(d) Observe these precautions when disconnecting the fuel

tube connector.
(1) Disconnect the fuel pipe clamp from the connector.
(2) Check that there is no dirt or mud on the pipe and
around the connector before disconnecting them.
Clean them if necessary.
Fuel Pipe
Clamp No.1 A60083
(3) Disconnect the connector from the hose while

A pinching part A with fingers as shown in the illustra-
tion.
B12941
(4) When the connector and the pipe are stuck, push
and pull the connector to release and pull the con-
nector out from the pipe carefully.
(5) Inspect that there is no dirt or mud on the sealing
surface of the disconnected pipe. Clean it away if
necessary.
B12944
Author: Date: 2251

11-3
FUEL - FUEL SYSTEM
(6) To prevent the disconnected pipe and connector

Vinyl Bag or plastic Bag from being damaged and foreign objects from being
introduced,cover them with a vinyl or plastic bag.
A82344
(e) Observe these precautions when connecting the fuel

tube connectors (Quick Type):
(1) Check that there is no damage or foreign objects in
the connected part of the pipe.
(2) Match the axis of the connector with the axis of the
pipe, and push into the connector until the connec-
tor makes a ”click” sound. If the connection is tight,
apply little amount of fresh engine oil on the tip of the
Push B16534 pipe.
(3) After having finished connection, check if the pipe
and the connector are securely connected by pull-
ing on them.
(4) Check for fuel leaks.
Pull B16535
4. CHECK FOR FUEL LEAKS

(a) Check that there are no fuel leaks after doing maintenance anywhere on the fuel system.
(See page 11-4 )
Author: Date: 2252

11-21
110T2-02
Removal & Installation and Disassembly & Reassembly

1. DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1 )
2. REMOVE CHARCOAL CANISTER PROTECTOR (See page 12-1 1)
3. REMOVE FUEL TANK FILLER HOSE COVER (See page 11-30 )
4. REMOVE FUEL TANK ASSY (See page 11-30 )
5. REMOVE FUEL TANK TO FILLER PIPE HOSE (See page 11-30 )
6. REMOVE FUEL TANK MAIN TUBE SUB-ASSY

Tube Joint Clip (a) Remove the tube joint clip, and pull out the fuel main tube.
NOTICE:
Check if there is any dirt or mud around the connector
before this operation and remove the dirt as neces-
sary.
Be careful of mud because the quick connector has
an O-ring which seals the pipe and connector that
A79524 can be contaminated.
Do not use any tool in this operation.
Nylon Tube Do not bend or twist the nylon tube. Protect the con-
Fuel Tube Joint
nector by covering it with a vinyl or plastic bag.
When the pipe and connector are stuck, push and pull
the connector to release and pull the connector out
carefully.
O-ring
Tube Joint Clip

Fuel Suction Plate
A81635
(b) Unfasten the 4 claws and remove the fuel tank main tube
from the fuel tank.
A79526
7. REMOVE FUEL SUCTION TUBE ASSY W/ PUMP &

SST
GAGE
(a) Using SST, loosen the fuel pump gauge retainer.
SST 09808-14020 (09808-01410, 09808-01420,
09808-01430)
HINT:
A rib on the fuel pump gauge retainer can be fitted into a tip of
the SST.
Rib A79525 (b) Remove the fuel pump gauge retainer.
Author: Date: 2270

11-22
(c) Remove the fuel suction tube w/ pump & gage and the
gasket from the fuel tank.
NOTICE:
Be careful not bend the arm of the fuel sender gage.
8. REMOVE VAPOR PRESSURE SENSOR ASSY

Cover Tube Joint Clip
(a) Remove the cover.
(b) Remove the tube joint clip and pull out the vapor pressure
sensor.
A79767
Unlock 9. REMOVE FUEL SENDER GAGE ASSY

(a) Disconnect the fuel sender gage connector.
(b) Unlock the fuel sender gage and slide it to remove.
(a)
Slide
A79768
10. REMOVE FUEL SUCTION PLATE SUB-ASSY

Tape (a) Using a screwdriver with the tip wrapped in tape, discon-
nect the 4 snap-claws from the claw holes and remove
the fuel suction plate.
NOTICE:
Do not damage the fuel suction plate and the fuel suction
support No. 1.
A79769
Tape 11. REMOVE FUEL PUMP

(a)
(a) Disconnect the fuel pump connector.
(b) Using a small screwdriver with the tip wrapped in tape,
disconnect the 2 claws from the claw holes and pull out
the fuel pump.
NOTICE:
Do not damage the fuel pump and the fuel suction plate.
(c) Remove the O-ring and the fuel pump spacer from the
A79770 fuel pump.
Author: Date: 2271

11-23
12. REMOVE FUEL FILTER ASSY

(a) Using a small screwdriver, pry out the clip.
(b) Remove the fuel filter from the fuel pump.
A79771
13. REMOVE FUEL TUBE JOINT NO.1

Tape
(a) Remove the connector.
(b) Using a screwdriver with the tip wrapped in tape, discon-
nect the snap-claw from the claw hole and pull out the
fuel tube joint No. 1.
NOTICE:
(a)
Do not damage the fuel tube joint No. 1 and the fuel suction
plate.
A79772
14. REMOVE FUEL PUMP HARNESS

(a) Remove the fuel pump harness from the fuel tube joint
No. 1.
A79773
15. REMOVE FUEL PRESSURE REGULATOR ASSY

Clip (a) Remove the clip.
(b) Pull out the fuel pressure regulator from the fuel suction
plate.
(c) Remove the 2 O-rings from the fuel pressure regulator.
A79774
16. INSTALL FUEL PRESSURE REGULATOR ASSY

New O-ring (a) Apply a light coat of gasoline or spindle oil to the 2 new
O-rings, and install it to the fuel pressure regulator.
(b) Apply a light coat of gasoline or spindle oil to the 2 O-rings
again, and install the fuel pressure regulator to the fuel
tube joint No. 1.
(c) Install the clip.
17. INSTALL FUEL PUMP HARNESS
A79775
Author: Date: 2272

11-24
New O-ring 18. INSTALL FUEL TUBE JOINT NO.1

(a) Apply a light coat of gasoline or spindle oil to a new O-
ring, and install it to the fuel tube joint No. 1.
(b) Apply a light coat of gasoline or spindle oil to the O-ring
again, and install the fuel tube joint No. 1 to the fuel suc-
tion plate.
(c) Connect the connector.
19. INSTALL FUEL FILTER ASSY
A79776 (a) Install the fuel filter with a new clip.
20. INSTALL FUEL PUMP

New O-ring
(a) Install the fuel pump spacer to the fuel pump.
(b) Apply a light coat of gasoline or spindle oil to a new O-
ring, and install it to the fuel pump.
(c) Apply a light coat of gasoline or spindle oil to the O-ring
Fuel Pump again, and install the fuel pump to the fuel suction plate.
Spacer (d) Connect the fuel pump connector.
A81604
21. INSTALL FUEL SUCTION PLATE SUB-ASSY

(a) Apply a light coat of gasoline or spindle oil to a new O-
ring, and install it to the fuel tube joint No. 1.
New-O-ring
(b) Apply a light coat of gasoline or spindle oil to the O-ring
again, and install the fuel suction plate to the fuel suction
support No. 1.
22. INSTALL FUEL SENDER GAGE ASSY
A79777
23. INSTALL VAPOR PRESSURE SENSOR ASSY

Tube Joint Clip (a) Install the vapor pressure sensor with the tube joint clip.
NOTICE:
Check that there is no scratch or foreign objects on
the connecting parts.
Check that the fuel tube joint connector is fully in-
serted.
Collar Check that the fuel tube joint clip is on the collar of the
A81675 fuel tube joint.
After installing the tube joint clip, check if the fuel
tube joint connector is securely connected by pulling
it.
Author: Date: 2273

11-25
Arrow Mark 24. INSTALL FUEL SUCTION TUBE ASSY W/ PUMP &
GAGE
NOTICE:
Prior to assembly, all the new components must be stabi-
lized at room temperature for minimum 12 hours.
(a) Ensure gasket groove is clean and free of foreign par-
ticles.
(b) Install a new gasket to the fuel tank.
A79537 (c) Make sure that the gasket sits in the groove.
(d) Align the arrow mark of the fuel suction tube w/ pump &
gage tube and the tank suction support.
NOTICE:
Be careful not bend the arm of the fuel sender gage.
(e) Align marks on a new fuel pump gauge retainer and the
Mark fuel tank.
(f) Position the fuel pump gauge retainer on top of the fuel
suction w/ pump & gage flange while pushing down the
flange on center.
(g) While holding the fuel suction tube w/ pump & gage, tight-
en the pump gauge retainer one complete turn by hand.
NOTICE:
A79538 Make sure the fuel suction tube w/ pump & gage anti-
rotation tab is in the groove during above operation.
”S” arrow on the fuel tank indicates 0 degrees posi-
tion.
(h) Ensure that no cross threading occurred during installa-

SST
tion by checking the gap between the fuel pump gauge re-
tainer and the fuel tank. Confirm that the gap is even. If
cross threading occurred, remove the fuel pump gauge
retainer and repeat step (g).
(i) Using SST, tighten the fuel pump gauge retainer to the
specified torque.
SST 09808-14020 (09808-01410, 09808-01420,
Rib A79525 09808-01430)
Torque: 80 to 90 N⋅m (816 to 918 kgf⋅cm, 59 to 67 ft⋅lbf)
NOTICE:
Triangle No ratcheting effect allowed when tightening the fuel
Mark pump gauge retainer.
No grease or lubrication allowed on parts during
installation.
HINT:
A rib on the fuel pump gauge retainer can be fitted into a tip of
the SST.
A79539
Author: Date: 2274

11-26
(j) Install the fuel pump gauge retainer by one and half turn
so that the triangle mark on the fuel pump gauge retainer
is between 510 and 570 from the start position.
(k) If the triangle mark is not reached 510, confirm that no
cross threading occurred by measuring the gap between
the fuel pump gauge retainer and the fuel tank.
If cross threading occurred, replace the fuel pump gauge retain-
er, the gasket and the tank suction tube support.
(l) Replace the tank suction tube support.

(1) Remove the tank suction tube support from the fuel
tank.
A79527
(2) Install the tank suction tube support to the fuel tank
as shown in the illustration.
A79536
(m) Put a mark on the fuel pump gauge retainer and the fuel
tank with paint. This will be the evidence that the fuel
pump gauge retainer had been removed.
Paint Mark A81626
Tube Joint Clip 25. INSTALL FUEL TANK MAIN TUBE SUB-ASSY
(a) Install in the fuel return tube with the tube joint clip.
NOTICE:
Check that there is no scratch or foreign objects on
the connecting part.
Check that the fuel tube joint is inserted securely.
Collar Check that the tube joint clip is on the collar of the fuel
tube joint.
A81605 After installing the tube joint clip, check that the fuel
tube joint has not been pulled off.
Author: Date: 2275

11-27
26. INSTALL FUEL TANK TO FILLER PIPE HOSE (See page 11-30 )
27. INSTALL FUEL TANK ASSY (See page 11-30 )
28. CHECK FOR FUEL LEAKS (See page 11-4 )
29. INSTALL FUEL TANK FILLER HOSE COVER (See page 11-30 )
30. INSTALL CHARCOAL CANISTER PROTECTOR (See page 12-1 1)
Author: Date: 2276

11-30
110T4-01
Removal & Installation and Disassembly & Reassembly

2. REMOVE CHARCOAL CANISTER PROTECTOR (See page 12-1 1)
3. REMOVE FUEL TANK FILLER HOSE COVER

(a) Remove the 3 bolts and the fuel tank filler hose cover.
A81606
4. REMOVE FUEL TANK ASSY

A Push (a) Disconnect the fuel tank vent hose.
(1) Deeply push the connector to release the locking
tab.
A (2) Pinch portion A.
Pinch
(3) Pull out the connector.
Pinch
A79517
(b) Disconnect the fuel tank main tube.

(1) Pinch the tube connector and then pull out the fuel
Pinch tank main tube.
NOTICE:
sary.
Pinch Be careful of mud because the quick connector has
A79518 an O-ring which seals the pipe and connector that
can be contaminated.
Tube Connector Do not bend or twist the nylon tube. Protect the con-
Nylon Tube
When the pipe and the connector are stuck, push and
pull the connector to release and pull the connector
out carefully.
O-ring Pipe
A75650
Author: Date: 2279

11-31
(c) Disconnect the fuel tank to filler pipe hose.

(1) Loosen the hose clamp bolt and disconnect the fuel
tank to filler pipe hose.
A79519
(d) Disconnect the fuel tube.

(1) Pinch the tube connector and then pull out the fuel
Pinch tank main tube.
NOTICE:
Pinch sary.
Be careful of mud because the quick connector has
A79520 an O-ring which seals the pipe and connector that
can be contaminated.
Tube Connector Do not bend or twist the nylon tube. Protect the con-
Nylon Tube
When the pipe and the connector are stuck, push and
pull the connector to release and pull the connector
out carefully.
O-ring Pipe
A75650
(e) Remove the 2 wire harness clamps.
A79521
(f) Set up a transmission jack under the fuel tank.

(g) Remove the 6 set bolts of the 3 fuel tank bands.
A79522
Author: Date: 2280

11-32
Vapor Pressure Sensor (h) While operating the transmission jack, unfasten the 4
Connector claws for the wire harness and disconnect the fuel pump
connector and vapor pressure sensor connector, then re-
move the fuel tank and the 3 fuel tank bands from the ve-
hicle
5. REMOVE FUEL TANK MAIN TUBE SUB-ASSY
(See page 11-21 )
Fuel Pump 6. REMOVE FUEL SUCTION TUBE ASSY W/ PUMP &
Claw Connector
A79523 GAGE (See page 11-21 )
SST 09808-14020 (09808-01410, 09808-01420,
09808-01430)
7. DRAIN FUEL
8. REMOVE FUEL TANK TO FILLER PIPE HOSE

(a) Loosen the hose clamp bolt and remove the fuel tank to
filler pipe hose from the fuel tank.
A81607
9. REMOVE FUEL TANK VENT HOSE

(a) Remove the hose of the fuel tank vent hose from the 3
hose clamps.
(b) Remove the fuel tank vent hose.
(1) Deeply push the connector to release the locking
tab.
(2) Pinch portion A.
(3) Pull out the connector.
(b)
Push Pinch
A
Pinch
A
(a)
(a)
(a)
A79528
Author: Date: 2281

11-33
10. CONNECT FUEL TANK VENT HOSE

11. INSTALL FUEL TANK TO FILLER PIPE HOSE
(a) Install a new fuel tank to filler pipe hose as shown in the
illustration.
Upper
15.5 mm (0.6102 in.) 2 mm

35 mm (1.378 in.) (0.079 in.)
Stopper Location
A81608
12. INSTALL FUEL SUCTION TUBE ASSY W/ PUMP &

GAGE (See page 11-21 )
SST 09808-14020 (09808-01410, 09808-01420,
09808-01430)
13. INSTALL FUEL TANK MAIN TUBE SUB-ASSY
(See page 11-21 )
14. INSTALL FUEL TANK ASSY
(a) Set up the fuel tank to the transmission jack.
(b) While operating the transmission jack, fasten the 4 claws
for the wire harness and connect the fuel pump connector
and vapor pressure sensor connector, then install the fuel
tank and the 3 fuel tank bands to the vehicle.
(c) Tighten the 6 set bolts of the 3 fuel tank bands.
Torque: 33 N⋅m (336 kgf⋅cm, 24 ft⋅lbf)
(d) Install the 2 wire harness clamps.
(e) Connect the fuel tube.
Push (1) Push in the fuel tube connector to the pipe until fuel
tube connector makes ”click” sound.
NOTICE:
Check if there is any damage or foreign objects on the
connected part.
After connecting, check if the connector and the pipe
are securely connected by pulling on them.
A81610
Author: Date: 2282

11-34
(f) Connect the fuel tank to filler pipe hose as shown in the
illustration.
33 to 35 mm
View A Triangle Shape Must
(1.299 to 1.417 in.)
Be Within 5 mm (0.197 in.)
Upper
View A 2 mm
14.5 mm (0.5709 in.) (0.079 in.)
Stopper Location
A81609
(g) Connect the fuel tank main tube.

(1) Push in the fuel tube connector to the pipe until fuel
Push
tube connector makes ”click” sound.
NOTICE:
Check if there is any damage or foreign objects on the
connected part.
After connecting, check if the connector and the pipe
are securely connected by pulling on them.
A81611 (h) Connect the fuel tank vent hose.
15. ADD FUEL

17. INSTALL FUEL TANK FILLER HOSE COVER
Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf)
18. INSTALL CHARCOAL CANISTER PROTECTOR (See page 12-1 1)
Author: Date: 2283

11-13
110T0-03
REPLACEMENT
2. DRAIN ENGINE COOLANT (See page 16-8 )
3. REMOVE FRONT WIPER ARM HEAD CAP (See page 66-8 )
4. REMOVE FR WIPER ARM LH (See page 66-8 )
5. REMOVE FR WIPER ARM RH (See page 66-8 )
6. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY (See page 66-8 )
7. REMOVE WINDSHIELD WIPER MOTOR ASSY (See page 66-8 )
8. REMOVE COWL TOP TO COWL BRACE INNER NO.1

(a) Remove the 2 bolts and the cowl top to cowl brace inner
No. 1.
A79761
9. REMOVE COWL TOP PANEL SUB- ASSY OUTER

FRONT
(a) Remove the wire harness clamp.
(b) Remove the grommet.
(a) (c) Remove the 7 bolts and the cowl top panel outer front.
10. REMOVE V-BANK COVER SUB-ASSY
(See page 10-7 )
11. REMOVE AIR CLEANER CAP SUB-ASSY
(b)
A79760 (See page 10-7 )
12. REMOVE EMISSION CONTROL VALVE SET

(a) Disconnect the 2 VSV connectors.
(a) (b) Remove the wire harness clamp.
(b)
(a)
A79751
(c) Disconnect the fuel vapor feed hose.

(d) (d) Disconnect the fuel vapor feed hose No. 2.
(e) (e) Disconnect the 2 vacuum hoses.
(e)
(f) Remove the clamp.
(g) Remove the 2 nuts and the emission control valve set.
(f)
(c)
A79752
Author: Date: 2262

11-14
13. REMOVE INTAKE AIR SURGE TANK

(d) (a) Disconnect throttle motor connector.
(b) Disconnect the water by-pass hose No. 3.
(c) Disconnect the water by-pass hose No. 2.
(c) (a) (d) Disconnect the union to check valve hose.
(b)
A81623
(e) Disconnect the ventilation hose.
(e)
A79706
(f) Remove the 2 set nuts of the pressure feed tube.
A79707
(h) (g) Remove the 2 bolts and the engine hunger No. 1.
(g) (h) Remove the 2 bolts and the surge tank stay No. 1.
(i) Remove the 2 bolts and the surge tank stay No. 2.
(i)
A81674
(j) Using a socket hexagon wrench 8, remove the 4 bolts.

(k) Remove the 2 nuts, the emission control valve bracket
and the intake air surge tank.
(l) Remove the gasket from the intake air surge tank.
A81622
Author: Date: 2263

11-15
14. SEPARATE FUEL PIPE SUB-ASSY NO.1

(a) Remove the bolt and the fuel pipe No. 1.
(b) (b) Remove the fuel pressure pulsation damper and the 2
gaskets.
(c) Remove the fuel pipe No. 2 union bolt and the 2 gaskets.
(c) (a)
A79710
15. REMOVE FUEL INJECTOR ASSY

(a) Disconnect the 6 fuel injector connectors.
A79711
(b) Remove the 4 bolts and the 2 fuel delivery pipes together
with the 6 fuel injectors.
NOTICE:
Be careful not to drop the fuel injectors when removing the
delivery pipe.
A79712
2 (c) Remove the 4 delivery pipe No. 1 spacers (1) and the
6 insulators (2) from the intake manifold.
1
1
2
G39631
(d) Pull out the fuel injector from the fuel delivery pipe.
A81137
Author: Date: 2264

11-16
16. INSTALL FUEL INJECTOR ASSY

New O-ring
(a) Install new grommets to the each fuel injector.
(b) Apply a light coat of spindle oil or gasoline to new O-rings,
and install it to the each fuel injector.
New Grommet
A79762
(c) Apply a light coat of spindle oil or gasoline on the place

where the fuel delivery pipe contacts the O-ring.
Turn (d) Push the fuel injector while twisting it back and forth to
install it in the fuel delivery pipe.
NOTICE:
Push
Be careful not to twist the O-ring.
After installing the fuel injectors, check that they
turns smoothly. If not, reinstall it with a new O-ring.
A81139 (e) Install 6 new insulators and the 4 delivery pipe No. 1
spacers to the intake manifold.
(f) Place the 2 fuel delivery pipes and 6 fuel injectors togeth-
er to the intake manifold.
NOTICE:
Be careful not to drop the fuel injectors when installing the
fuel delivery pipe.
(g) Temporarily install 4 bolts which are used to attach the
fuel delivery pipe to the intake manifold.
(h) Check that the fuel injectors rotate smoothly.
Turn If fuel injectors do not rotate smoothly, the probable cause is in-
A81601
correct installation of O-ring. Replace with the O-ring.

(i) Tighten the 4 bolts.
(j) Connect the 6 fuel injector connectors.
17. INSTALL FUEL PIPE SUB-ASSY NO.1
(a) Install 2 new gaskets and the fuel pipe No. 2 union bolt.
(b) Install 2 new gaskets and the fuel pressure pulsation damper.
(c) Install the fuel pipe No. 1 with the bolt.
18. INSTALL INTAKE AIR SURGE TANK
(a) Install a new gasket to the intake air surge tank.
(b) Install the intake air surge tank and the emission control valve bracket with the 2 nuts.
(c) Using a socket hexagon wrench 8, tighten the 4 bolts.
(d) Install the surge tank stay No. 2 with the 2 bolts.
(e) Install the surge tank stay No. 1 with the 2 bolts.
Author: Date: 2265

11-17
(f) Install the engine hunger No. 1 with the 2 bolts.

(g) Install the pressure feed tube with the 2 nuts.
(h) Connect the ventilation hose.
(i) Connect the union to check valve hose.
(j) Connect the water by-pass hose No. 2.
(k) Connect the water by-pass hose No. 3.
(l) Connect the throttle motor connector.
19. INSTALL EMISSION CONTROL VALVE SET
20. INSTALL AIR CLEANER CAP SUB-ASSY (See page 10-7 )
21. ADD ENGINE COOLANT (See page 16-8 )
23. CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 )
24. INSTALL V-BANK COVER SUB-ASSY (See page 10-7 )
25. INSTALL COWL TOP PANEL SUB-ASSY OUTER FRONT
26. INSTALL COWL TOP TO COWL BRACE INNER NO.1
27. INSTALL WINDSHIELD WIPER MOTOR ASSY (See page 66-8 )
28. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSY
29. INSTALL FR WIPER ARM RH (See page 66-8 )
30. INSTALL FR WIPER ARM LH (See page 66-8 )
31. INSTALL FRONT WIPER ARM HEAD CAP
Author: Date: 2266

Sienna FUEL

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11-9

FUEL - FUEL INJECTOR ASSY

FUEL INJECTOR ASSY

Front Wiper Arm

Cowl Top Ventilator Louver

Windshield Wiper Motor

7.5 (76, 66 in.⋅lbf)

N·m (kgf·cm, ft·lbf) : Specified torque

2005 SIENNA REPAIR MANUAL (RM1163U)

Author: Date: 2258

V-bank Cover Sub-assy

Fuel Vapor Feed Hose Assy

Air Cleaner Cap Sub-assy

Air Cleaner Filter Element Sub-assy

N·m (kgf·cm, ft·lbf) : Specified torque

2005 SIENNA REPAIR MANUAL (RM1163U)

Author: Date: 2259

x2 8.0 (82, 71 in.⋅lbf) 7.8 (80, 69 in.⋅lbf)

Emission Control Valve Set

Union to Check Valve Hose

Air Surge Tank

Water By-pass Hose No. 3

N·m (kgf·cm, ft·lbf) : Specified torque

2005 SIENNA REPAIR MANUAL (RM1163U)

Author: Date: 2260

Fuel Injector O-ring

Fuel Injector Assy

Fuel Delivery Pipe No. 2

Fuel Pump Harness Gasket

Fuel Pipe Sub-assy no. 1

N·m (kgf·cm, ft·lbf) : Specified torque

2005 SIENNA REPAIR MANUAL (RM1163U)

Author: Date: 2261

FUEL SUCTION TUBE ASSY W/ PUMP & GAGE

Vapor Pressure Sensor

Fuel Tank Assy

5.0 (51, 44 in.⋅lbf)

5.0 (51, 44 in.⋅lbf)

N·m (kgf·cm, ft·lbf) : Specified torque

2005 SIENNA REPAIR MANUAL (RM1163U)

Author: Date: 2267

Fuel Tank Main Tube Sub-assy

Fuel Pump Gauge Retainer

Tube Joint Clip

Fuel Suction Tube Assy

Fuel Suction Tube

Tank Suction Tube

2005 SIENNA REPAIR MANUAL (RM1163U)

Author: Date: 2268

Vapor Pressure Sensor

Fuel Suction Plate

Fuel pump Harness

Clip Fuel Pump

Fuel Suction Support No. 1

Fuel Sender Gage Assy

Non-reusable part A79705

2005 SIENNA REPAIR MANUAL (RM1163U)

Author: Date: 2269

FUEL TANK ASSY