Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Toyota Sienna 2004-2007 Approved SRM 04 11 20um5 w140001
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11-21
FUEL - FUEL SUCTION TUBE ASSY W/ PUMP & GAGE
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:
S Check if there is any dirt or mud around the connector
before this operation and remove the dirt as neces-
sary.
S Be careful of mud because the quick connector has
an O-ring which seals the pipe and connector that
A79524 can be contaminated.
S Do not use any tool in this operation.
Nylon Tube S Do not bend or twist the nylon tube. Protect the con-
Fuel Tube Joint
nector by covering it with a vinyl or plastic bag.
S 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.
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2270
11-22
FUEL - FUEL SUCTION TUBE ASSY W/ PUMP & GAGE
(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.
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2271
11-23
FUEL - FUEL SUCTION TUBE ASSY W/ PUMP & GAGE
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
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2272
11-24
FUEL - FUEL SUCTION TUBE ASSY W/ PUMP & GAGE
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:
S Check that there is no scratch or foreign objects on
the connecting parts.
S Check that the fuel tube joint connector is fully in-
serted.
Collar S Check that the fuel tube joint clip is on the collar of the
A81675 fuel tube joint.
S After installing the tube joint clip, check if the fuel
tube joint connector is securely connected by pulling
it.
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2273
11-25
FUEL - FUEL SUCTION TUBE ASSY W/ PUMP & GAGE
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 S Make sure the fuel suction tube w/ pump & gage anti-
rotation tab is in the groove during above operation.
S "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 Nm (816 to 918 kgfcm, 59 to 67 ftlbf)
NOTICE:
Triangle S No ratcheting effect allowed when tightening the fuel
Mark pump gauge retainer.
S 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
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2274
11-26
FUEL - FUEL SUCTION TUBE ASSY W/ PUMP & GAGE
(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:
S Check that there is no scratch or foreign objects on
the connecting part.
S Check that the fuel tube joint is inserted securely.
Collar S Check that the tube joint clip is on the collar of the fuel
tube joint.
A81605 S After installing the tube joint clip, check that the fuel
tube joint has not been pulled off.
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2275
11-27
FUEL - FUEL SUCTION TUBE ASSY W/ PUMP & GAGE
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)
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2276
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