Toyota Sienna 2000-06

Fuel Injectors

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Outer front cowl top panel assembly
     
    Air cleaner cap with hose
     
    Negative battery cable. Work must be started approximately 90 seconds or longer after the negative battery cable has been disconnected, if equipped with an air bag.
     
    Coolant
     
    Accelerator and throttle cables
     
    V-bank cover
     
    Emission valve control set
     
    No. 2 EGR pipe
     
    Hydraulic motor pressure pipe from the water inlet and air inlet chamber
     
    Air intake chamber assembly
     
    Injector wiring
     
    Air assist pipe from the bracket on the No. 1 fuel pipe
     
    Air assist hoses from the intake manifold
     
    Fuel return hose from the No. 1 fuel pipe
     
    Fuel inlet hose for the fuel filter
     
    2 union bolts holding the No. 2 fuel pipe to the delivery pipes
     
    Fuel return hose from the fuel pressure regulator
     
    Union bolt for the right hand delivery pipe, 2 gaskets, 2 bolts, left hand delivery pipe together with the 3 injectors and the No. 2 fuel pipe
     
    Union bolt for the delivery pipe and 2 gaskets from the No. 2 fuel pipe
     
    The 3 bolts, right hand delivery pipe together with the 3 injectors and the No. 1 fuel pipe
     
    The 4 spacers from the intake manifold
     
    The 6 injectors from the delivery pipes
     
    The two O-rings and two grommets from each injector
     

  4.  

To install:

  1. Install or connect the following:

    2 new grommets to each injector
     
    New O-rings, with a light coat of fuel, to each injector
     
    Injectors
     
    The 4 spacers on the intake manifold
     
    Right hand delivery pipe and the No. 1 fuel pipe together with the 3 injectors in position on the intake manifold
     
    Bolt holding the right side delivery pipe, temporarily, to the intake manifold
     
    Left hand delivery pipe and the No. 2 fuel pipe together with the 3 injectors in position on the intake manifold
     
    Fuel return hose to the fuel pressure regulator
     

  2.  
  3. Temporarily install the 2 bolts holding the left hand delivery pipe to the intake manifold.
  4.  
  5. Temporarily install the No. 2 fuel pipe to the left side delivery pipe with the union bolt and 2 new gaskets.
  6.  
  7. Check that the injectors rotate smoothly. If they do not, Replace the O-rings.
  8.  
  9. Position the injector connector outward. Tighten the 4 bolts holding the delivery pipes to the intake manifold and tighten to 7 ft. lbs. (10 Nm). Tighten the bolt holding the No. 1 fuel pipe to the intake manifold to 14 ft. lbs. (20 Nm). Tighten the 2 union bolts holding the no. 2 fuel pipe to the delivery pipes to 24 ft. lbs. (32 Nm).
  10.  
  11. Install or connect the following:

    Fuel inlet and return hoses. Union bolt: 22 ft. lbs. (30 Nm)
     
    Fuel return hose to the No. 1 fuel pipe. Pass the fuel return hose under the heater hoses.
     
    Air assist hoses to the intake manifold
     
    Air assist pipe to the bracket on the No. 1 fuel pipe
     
    Fuel injector wiring connectors
     
    Air intake chamber assembly
     
    Hydraulic motor pressure pipe to the intake chamber. Bolts: 69 inch lbs. (8 Nm)
     
    No. 2 EGR pipe with new gaskets, tighten to 9 ft. lbs. (12 Nm)
     
    Emission control valve set
     
    V-bank cover
     
    Air cleaner hose
     
    Throttle and accelerator cables
     
    Coolant
     
    Air cleaner cap with hose
     
    Outer front cowl top panel assembly
     
    Negative battery cable
     

  12.  

3.0L Engine


Click image to see an enlarged view

Fig. Fuel injectors and related parts-3.0L engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Outer front cowl top panel assembly
     
    Air cleaner cap with hose
     
    Negative battery cable. Work must be started approximately 90 seconds or longer after the negative battery cable has been disconnected, if equipped with an air bag.
     
    Coolant
     
    Accelerator and throttle cables
     
    V-bank cover
     
    Emission valve control set
     
    No. 2 EGR pipe
     
    Hydraulic motor pressure pipe from the water inlet and air inlet chamber
     
    Air intake chamber assembly
     
    Injector wiring
     
    Air assist pipe from the bracket on the No. 1 fuel pipe
     
    Air assist hoses from the intake manifold
     
    Fuel return hose from the No. 1 fuel pipe
     
    Fuel inlet hose for the fuel filter
     
    2 union bolts holding the No. 2 fuel pipe to the delivery pipes
     
    Fuel return hose from the fuel pressure regulator
     
    Union bolt for the right hand delivery pipe, 2 gaskets, 2 bolts, left hand delivery pipe together with the 3 injectors and the No. 2 fuel pipe
     
    Union bolt for the delivery pipe and 2 gaskets from the No. 2 fuel pipe
     
    The 3 bolts, right hand delivery pipe together with the 3 injectors and the No. 1 fuel pipe
     
    The 4 spacers from the intake manifold
     
    The 6 injectors from the delivery pipes
     
    The two O-rings and two grommets from each injector
     

  4.  

To install:

  1. Install or connect the following:

    2 new grommets to each injector
     
    New O-rings, with a light coat of fuel, to each injector
     
    Injectors
     
    The 4 spacers on the intake manifold
     
    Right hand delivery pipe and the No. 1 fuel pipe together with the 3 injectors in position on the intake manifold
     
    Bolt holding the right side delivery pipe, temporarily, to the intake manifold
     
    Left hand delivery pipe and the No. 2 fuel pipe together with the 3 injectors in position on the intake manifold
     
    Fuel return hose to the fuel pressure regulator
     

  2.  
  3. Temporarily install the 2 bolts holding the left hand delivery pipe to the intake manifold.
  4.  
  5. Temporarily install the No. 2 fuel pipe to the left side delivery pipe with the union bolt and 2 new gaskets.
  6.  
  7. Check that the injectors rotate smoothly. If they do not, Replace the O-rings.
  8.  
  9. Position the injector connector outward. Tighten the 4 bolts holding the delivery pipes to the intake manifold and tighten to 7 ft. lbs. (10 Nm). Tighten the bolt holding the No. 1 fuel pipe to the intake manifold to 14 ft. lbs. (20 Nm). Tighten the 2 union bolts holding the no. 2 fuel pipe to the delivery pipes to 24 ft. lbs. (32 Nm).
  10.  
  11. Install or connect the following:

    Fuel inlet and return hoses. Union bolt: 22 ft. lbs. (30 Nm)
     
    Fuel return hose to the No. 1 fuel pipe. Pass the fuel return hose under the heater hoses.
     
    Air assist hoses to the intake manifold
     
    Air assist pipe to the bracket on the No. 1 fuel pipe
     
    Fuel injector wiring connectors
     
    Air intake chamber assembly
     
    Hydraulic motor pressure pipe to the intake chamber. Bolts: 69 inch lbs. (8 Nm)
     
    No. 2 EGR pipe with new gaskets, tighten to 9 ft. lbs. (12 Nm)
     
    Emission control valve set
     
    V-bank cover
     
    Air cleaner hose
     
    Throttle and accelerator cables
     
    Coolant
     
    Air cleaner cap with hose
     
    Outer front cowl top panel assembly
     
    Negative battery cable
     

  12.  

3.3L Engine


Click image to see an enlarged view

Fig. Fuel injectors and related parts-3.3L engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the coolant.
  6.  
  7. Remove the wiper arms.
  8.  
  9. Remove the wiper motor.
  10.  
  11. Remove the cowl tops.
  12.  
  13. Remove the V-bank cover.
  14.  
  15. Remove the air cleaner assembly.
  16.  
  17. Remove the emission control valve set.
  18.  
  19. Remove the upper intake manifold (intake air surge tank). Discard the gasket.
  20.  
  21. Remove the fuel pipe sub-assembly.
  22.  
  23. Disconnect the wiring at the injectors.
  24.  
  25. Remove the 4 bolts and 2 delivery pipe along with the injectors.
  26.  
  27. Remove the delivery pipe spacers and insulators from the manifold.
  28.  
  29. Pull each injector from the pipe.
  30.  

To install:

  1. Install new O-rings on each injector. Apply a light coating of gasoline to the O-rings and mating points on the pipes.
  2.  
  3. Using a twisting motion, install the injectors on the pipes.
  4.  


NOTE
Be careful to avoid twisting the O-rings. After installation, check that the injectors turn smoothly. If not, use new O-rings.

  1. Install the pipes and injectors.
  2.  
  3. Loosely install the bolts and make sure that the injectors still turn freely. If not, replace the O-rings.
  4.  
  5. Torque the bolts to 84 inch lbs. (10 Nm).
  6.  
  7. The remainder of installation is the reverse of removal. Observe the following torques:

    Fuel line union bolt: 24 ft. lbs. (33 Nm)
     
    Pulsation damper: 24 ft. lbs. (33 Nm)
     
    Fuel feed pipe: 14 ft. lbs. (20 Nm)
     
    Upper intake manifold (air surge tank): 21 ft. lbs. (28 Nm)
     
    Upper intake manifold stays: 14 ft. lbs. (20 Nm)
     

  8.  

 
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