Replacing Fuel Suction Tube In Toyota Sienna: Step-By-Step Guide

The fuel suction tube assembly is an important component of the fuel system in a car, and knowing how to replace it is essential for car maintenance. The process of replacing the fuel suction tube in a 2005 Toyota Sienna involves several steps, including discharging the fuel system pressure, disconnecting the cable from the negative battery terminal, and removing various components such as the engine under cover, wiper arms, and ventilator louver subassembly. It is important to refer to the Toyota Sienna service manual for detailed instructions on how to safely and correctly replace the fuel suction tube to avoid damage to the vehicle.

Removing the fuel tank filler pipe hose

Firstly, it is important to note that the fuel filter location on a Toyota Sienna varies depending on the model year. For the 2005 Toyota Sienna, the fuel filter is located inside the gas tank. Now, to remove the fuel tank filler pipe hose, you will need to follow these steps:

• Discharge the fuel system pressure.
• Remove the charcoal canister protector by removing the 6 bolts.
• Remove the rear floor No. 2 crossmember brace LH. This involves removing 2 bolts.
• Remove the fuel tank filler hose cover. There are 3 bolts that need to be removed for this step.
• Disconnect the fuel tank vent hose. To do this, push the connector deeply to release the locking tab, then pinch portion A and pull out the connector.
• Disconnect the fuel tank main tube sub-assembly. Pinch the tube connector and then carefully pull out the sub-assembly. Ensure that there is no dirt or mud around the connector before this step, and cover the connector with a plastic bag if necessary.
• Disconnect the fuel tank to filler pipe hose. Loosen the hose clamp bolt and carefully disconnect the hose.
• Disconnect the fuel tube by pinching the tube connector and pulling it out. Again, ensure there is no dirt or mud around the connector.
• Remove the 2 wire harness clamps.
• Set up a transmission jack under the fuel tank assembly.
• Remove the 6 set bolts of the 3 fuel tank bands.
• While operating the transmission jack, unfasten the 4 claws for the wire harness.

At this point, you will have successfully removed the fuel tank filler pipe hose and can proceed with further repairs or maintenance. Remember to refer to the Toyota Sienna service manual for detailed instructions and illustrations.

Removing the fuel tank main tube sub-assembly

To remove the fuel tank main tube sub-assembly of a 2005 Toyota Sienna, follow these steps:

Firstly, remove any dirt or mud from around the connector. It is important to prevent contamination of the O-ring, which seals the pipe and connector. Do not use any tools for this step. Protect the connector by covering it with a plastic or vinyl bag. If the pipe and connector are stuck, carefully push and pull the connector to release it, then pull the connector out.

Now, remove the tube joint clip and pull out the fuel main tube. Then, unfasten the four claws and remove the fuel tank main tube from the fuel tank.

• Do not bend or twist the nylon tube during this process.
• Only disconnect the quick connector by hand.
• If the pipe and connector are stuck, carefully wiggle or push and pull the connector to release it.

Removing the fuel suction tube assembly

To remove the fuel suction tube assembly of a 2005 Toyota Sienna, follow these steps:

Firstly, discharge the fuel system pressure. Then, disconnect the cable from the negative battery terminal. Next, remove the engine under cover. Following this, drain the engine coolant. Then, remove the front wiper arm head cap, front wiper arm RH, and front wiper arm LH. Subsequently, remove the cowl top ventilator louver subassembly, windshield wiper motor, and link assembly. After this, remove the No. 1 cowl top to cowl brace inner by removing the two bolts. Then, remove the cowl top panel sub-assembly outer front by first removing the wire harness clamp, then disconnecting the fuel pump resistor connector, and finally, removing the seven bolts and cowl top panel outer front.

Next, remove the V-bank cover sub-assembly. Following this, remove the air cleaner cap sub-assembly by disconnecting the three vacuum hoses, No. 2 ventilation hose, and air cleaner hose band. Then, disconnect the vacuum hose (EVAP) from the air cleaner hose, and remove the two bolts and air cleaner cap subassembly. After this, remove the intake air surge tank assembly by disconnecting the two water bypass hoses from the throttle with the motor body assembly, disconnecting the fuel vapour feed hose assembly, and then disconnecting the throttle with the motor body assembly connector and clamp. Subsequently, disconnect the No. 1 ventilation hose, union to check valve hose, and connector. Then, using a 5 mm socket hexagon wrench, remove the four bolts, two nuts, two bolts, and intake air surge tank. Finally, remove the gasket from the intake air surge tank.

Now, disconnect the fuel tube sub-assembly by removing the No. 2 fuel pipe clamp, pinching the tube connector, and pulling out the fuel pipe. Check that there is no dirt or other foreign objects around the connector before disconnecting it, and clean the connector if necessary. It is important to prevent mud or dirt from entering the quick connector as the O-rings may not seal properly. Only disconnect the quick connector by hand, and do not bend, kink or twist the nylon tubes. Protect the connector by covering it with a plastic bag. If the pipe and connector are stuck, carefully try wiggling, pushing, and pulling on the connector to release it, and then pull the connector off the pipe carefully.

Finally, to remove the fuel suction tube assembly, start by loosening the fuel pump gauge retainer using SST. A rib on the fuel pump gauge retainer can be fitted into the tip of the SST. Then, remove the fuel pump gauge retainer. Following this, remove the fuel suction tube assembly with the pump and gauge, and the fuel suction tube set gasket from the fuel tank. Be careful not to bend the arm of the fuel sender gauge.

Disconnecting the fuel sender gauge connector

To disconnect the fuel sender gauge connector, you will need to follow a few careful steps. Here is a detailed guide:

Firstly, it is important to note that you should be cautious throughout this process to avoid bending the arm of the fuel sender gauge. Now, to begin, you will need to loosen the fuel pump gauge retainer using SST. A helpful hint is that a rib on the fuel pump gauge retainer can be fitted into the tip of the SST.

Once you have loosened the retainer, you can proceed to the next step, which is to remove the fuel pump gauge retainer. After that, you will need to carefully remove the fuel suction tube assembly, which includes the pump, the gauge, and the fuel suction tube set gasket from the fuel tank. Ensure that you do not bend any components during this step.

Now, you are ready to focus on the fuel sender gauge. First, disconnect the fuel sender gauge connector. Then, unlock the fuel sender gauge and gently slide it out. These steps will allow you to successfully disconnect the fuel sender gauge connector.

It is important to refer to the official Toyota Sienna Service Manual for detailed instructions and safety precautions. This guide provides a general overview, but specific steps and tools may vary depending on your vehicle's model and year. Always prioritize your safety and consult a professional if you have any doubts about the procedure.

Removing the fuel suction plate sub-assembly

To remove the fuel suction plate sub-assembly of a 2005 Toyota Sienna, follow these steps:

Firstly, using a screwdriver with the tip wrapped in tape, disconnect the four snap-claws from the claw holes. This will allow you to remove the fuel suction plate. It is important to be cautious during this step to avoid damaging the fuel suction plate and the No. 1 fuel suction support.

Next, disconnect the fuel pump connector. This will involve using a small screwdriver, again with the tip wrapped in tape, to disconnect the two claws from the claw holes. Pull out the fuel pump, being careful not to damage the fuel pump and the fuel suction plate.

After this, remove the O-ring and the fuel pump spacer from the fuel pump.

These steps should enable you to successfully remove the fuel suction plate sub-assembly of a 2005 Toyota Sienna. It is important to refer to the official service manual for the most comprehensive and accurate instructions.

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