Toyota Sienna 2000-06

Fuel Pump

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel pressure.
  4.  
  5. Disconnect the negative battery cable. Wait at least 90 seconds before proceeding on models with an airbag.
  6.  
  7. Drain the fuel tank.
  8.  
  9. Remove or disconnect the following:

    Fuel tank
     
    Access plate bolts
     
    Fuel pump assembly
     
    Fuel pump electrical connectors.
     

  10.  
  11. Pull the bracket from the lower side of the fuel pump.
  12.  
  13. Remove or disconnect the following:

    Fuel pump from the fuel hose
     
    Rubber cushion, the clip and the fuel filter from the bottom of the fuel pump.
     

  14.  


    Click image to see an enlarged view

    Fig. Exploded view of the fuel pump, bracket and related components- 2001-02



    Click image to see an enlarged view

    Fig. Exploded view of the fuel pump and related components-2003


To install:

  1. Install or connect the following:

    Fuel pump filter to the fuel pump using a new clip
     
    Fuel pump to the bracket using new gaskets
     
    Fuel hose to the outlet port of the fuel pump
     
    Fuel pump bracket. Tighten the bolts to 26 inch lbs. (3 Nm) for 2001-02; 35 inch lbs. (4 Nm) for 2003.
     
    Fuel tank
     
    All electrical and fuel harness
     
    Negative battery cable
     

  2.  
  3. Refill the fuel tank and check for leaks.
  4.  



Click image to see an enlarged view

Fig. Fuel pump module exploded view-2004

  1. Discharge the fuel system pressure.
  2.  
  3. Remove the charcoal canister cover.
  4.  
  5. Remove the fuel tank filler hose cover.
  6.  
  7. Disconnect the fuel tank vent hose.
  8.  
  9. Disconnect the fuel tank main tube.
  10.  
  11. Disconnect the filler hose.
  12.  
  13. Remove the wire harness clamps.
  14.  
  15. Place a jack under the tank, remove the bolts and the support bands.
  16.  
  17. Disconnect all remaining wiring and lower the tank.
  18.  
  19. Remove the tube joint clip and pull out the fuel main tube from the fuel pump module.
  20.  
  21. Remove the main tube from the tank.
  22.  
  23. Using tool 09808-14020, or equivalent lock ring tool, remove the lockring from the fuel pump module.
  24.  
  25. Remove the module from the tank.
  26.  
  27. Remove the joint clip and remove the pressure sensor.
  28.  
  29. Remove the sender assembly.
  30.  
  31. Wrap the tip of a small screwdriver with tape and disconnect the 4 snap retainers, and remove the fuel suction plate.
  32.  
  33. Disconnect the snap retainers, disconnect the connector, and remove the fuel pump.
  34.  
  35. Remove the O-ring and spacer from the pump.
  36.  
  37. Installation is the reverse of removal. Use a new O-ring coated with clean gasoline.
  38.  


NOTE
Prior to assembly, all new parts must be stored at room temperature for a minimum of 12 hours.

  1. Make sure that the gasket groove is clean. Use a new gasket. Align the arrow on the fuel suction tube and the tank suction support.
  2.  
  3. Align the marks on the fuel pump module retainer and the fuel tank.
  4.  
  5. Position the retainer on the module and push down. Hold the module and turn the retainer by hand, one complete turn.
  6.  


    Click image to see an enlarged view

    Fig. Module alignment marks-2004



    Click image to see an enlarged view

    Fig. Retainer alignment marks-2004



    Click image to see an enlarged view

    Fig. Tightening reference-2004



NOTE
Make sure that the anti-rotation tab is in the groove during tightening. The -S- arrow on the fuel tank indicates -0- degrees position. Make sure that the retainer isn-t cross-threaded.

  1. Using the special tool, torque the retainer to 59-67 ft. lbs. (80-90 Nm). The triangle mark on the retainer should be about 112
  2.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel pressure.
  4.  
  5. Disconnect the negative battery cable. Wait at least 90 seconds before proceeding on models with an airbag.
  6.  
  7. Drain the fuel tank.

    Click image to see an enlarged view

    Fig. Exploded view of the fuel pump, bracket and related components

  8.  
  9. Remove or disconnect the following:

    Fuel tank
     
    Access plate bolts
     
    Fuel pump assembly
     
    Fuel pump electrical connectors.
     

  10.  
  11. Pull the bracket from the lower side of the fuel pump.
  12.  
  13. Remove or disconnect the following:

    Fuel pump from the fuel hose
     
    Rubber cushion, the clip and the fuel filter from the bottom of the fuel pump.
     

  14.  

To install:

  1. Install or connect the following:

    Fuel pump filter to the fuel pump using a new clip
     
    Fuel pump to the bracket using new gaskets
     
    Fuel hose to the outlet port of the fuel pump
     
    Fuel pump bracket. Tighten the bolts to 26 inch lbs. (3 Nm).
     
    Fuel tank
     
    All electrical and fuel harness
     
    Negative battery cable
     

  2.  
  3. Refill the fuel tank and check for leaks.
  4.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Relieve the fuel pressure.
  4.  
  5. Disconnect the negative battery cable. Wait at least 90 seconds before proceeding on models with an airbag.
  6.  
  7. Drain the fuel tank.

    Click image to see an enlarged view

    Fig. Exploded view of the fuel pump, bracket and related components-2002



    Click image to see an enlarged view

    Fig. Exploded view of the fuel pump and related components-2003

  8.  
  9. Remove or disconnect the following:

    Fuel tank
     
    Access plate bolts
     
    Fuel pump assembly
     
    Fuel pump electrical connectors.
     

  10.  
  11. Pull the bracket from the lower side of the fuel pump.
  12.  
  13. Remove or disconnect the following:

    Fuel pump from the fuel hose
     
    Rubber cushion, the clip and the fuel filter from the bottom of the fuel pump.
     

  14.  

To install:

  1. Install or connect the following:

    Fuel pump filter to the fuel pump using a new clip
     
    Fuel pump to the bracket using new gaskets
     
    Fuel hose to the outlet port of the fuel pump
     
    Fuel pump bracket. Tighten the bolts to 26 inch lbs. (3 Nm) for 2002; 35 inch lbs. (4 Nm) for 2003.
     
    Fuel tank
     
    All electrical and fuel harness
     
    Negative battery cable
     

  2.  
  3. Refill the fuel tank and check for leaks.
  4.  



Click image to see an enlarged view

Fig. Fuel pump module exploded view-2004-06

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Discharge the fuel system pressure.
  4.  
  5. Remove the charcoal canister cover.
  6.  
  7. Remove the fuel tank filler hose cover.
  8.  
  9. Disconnect the fuel tank vent hose.
  10.  
  11. Disconnect the fuel tank main tube.
  12.  
  13. Disconnect the filler hose.
  14.  
  15. Remove the wire harness clamps.
  16.  
  17. Place a jack under the tank, remove the bolts and the support bands.
  18.  
  19. Disconnect all remaining wiring and lower the tank.
  20.  
  21. Remove the tube joint clip and pull out the fuel main tube from the fuel pump module.
  22.  
  23. Remove the main tube from the tank.
  24.  
  25. Using tool 09808-14020, or equivalent lock ring tool, remove the lockring from the fuel pump module.
  26.  
  27. Remove the module from the tank.
  28.  
  29. Remove the joint clip and remove the pressure sensor.
  30.  
  31. Remove the sender assembly.
  32.  
  33. Wrap the tip of a small screwdriver with tape and disconnect the 4 snap retainers, and remove the fuel suction plate.
  34.  
  35. Disconnect the snap retainers, disconnect the connector, and remove the fuel pump.
  36.  
  37. Remove the O-ring and spacer from the pump.
  38.  
  39. Installation is the reverse of removal. Use a new O-ring coated with clean gasoline.
    NOTE
    Prior to assembly, all new parts must be stored at room temperature for a minimum of 12 hours.

  40.  
  41. Make sure that the gasket groove is clean. Use a new gasket. Align the arrow on the fuel suction tube and the tank suction support.

    Click image to see an enlarged view

    Fig. Module alignment marks-2004-06



    Click image to see an enlarged view

    Fig. Retainer alignment marks-2004-06



    Click image to see an enlarged view

    Fig. Tightening reference-2004-06

  42.  
  43. Align the marks on the fuel pump module retainer and the fuel tank.
  44.  
  45. Position the retainer on the module and push down. Hold the module and turn the retainer by hand, one complete turn.
    NOTE
    Make sure that the anti-rotation tab is in the groove during tightening. The -S- arrow on the fuel tank indicates -0- degrees position. Make sure that the retainer isn-t cross-threaded.

  46.  
  47. Using the special tool, torque the retainer to 59-67 ft. lbs. (80-90 Nm). The triangle mark on the retainer should be about 1 1 / 2 turn from the start.
  48.  

 
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