2004 Toyota Sienna CEFACTORY OEM SERVICE PROCEDURE

Fuel Injector Assembly: Replacement

  1. DISCHARGE FUEL SYSTEM PRESSURE, see  PRECAUTION  . 
  2. DRAIN ENGINE COOLANT, see  REPLACEMENT  . 
  3. REMOVE FRONT WIPER ARM HEAD CAP, see  WINDSHIELD WIPER MOTOR ASSY  . 
  4. REMOVE FR WIPER ARM LH, see  WINDSHIELD WIPER MOTOR ASSY  . 
  5. REMOVE FR WIPER ARM RH, see  WINDSHIELD WIPER MOTOR ASSY  . 
  6. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY, see  WINDSHIELD WIPER MOTOR ASSY  . 
  7. REMOVE WINDSHIELD WIPER MOTOR ASSEMBLY, see  WINDSHIELD WIPER MOTOR ASSY  . 
  8. REMOVE COWL TOP TO COWL BRACE INNER NO. 1 
    1. Remove the 2 bolts and the cowl top to cowl brace inner No. 1.
    Fig 1: Removing Bolts And Cowl Top To Cowl Brace Inner
    G03061986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE COWL TOP PANEL SUB-ASSEMBLY OUTER FRONT 
    1. Remove the wire harness clamp.
    2. Remove the grommet.
    3. Remove the 7 bolts and the cowl top panel outer front.
    Fig 2: Removing Bolts And Cowl Top Panel Outer Front
    G03061987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE V-BANK COVER SUB-ASSEMBLY, see  REPLACEMENT  . 
  11. REMOVE AIR CLEANER CAP SUB-ASSEMBLY, see  REPLACEMENT  . 
  12. REMOVE EMISSION CONTROL VALVE SET 
    1. Disconnect the 2 VSV connectors.
    2. Remove the wire harness clamp.
      Fig 3: Removing Wire Harness Clamp
      G03061988Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the fuel vapor feed hose.
    4. Disconnect the fuel vapor feed hose No. 2.
    5. Disconnect the 2 vacuum hoses.
    6. Remove the clamp.
    7. Remove the 2 nuts and the emission control valve set.
    Fig 4: Removing Nuts Of Emission Control Valve Set
    G03061989Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE INTAKE AIR SURGE TANK 
    1. Disconnect throttle motor connector.
    2. Disconnect the water by-pass hose No. 3.
    3. Disconnect the water by-pass hose No. 2.
    4. Disconnect the union to check valve hose.
      Fig 5: Disconnecting Hose
      G03061990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the ventilation hose.
      Fig 6: Disconnecting Ventilation Hose
      G03061991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 2 set nuts of the pressure feed tube.
      Fig 7: Removing Set Nuts Of Pressure Feed Tube
      G03061992Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the 2 bolts and the engine hunger No. 1.
    8. Remove the 2 bolts and the surge tank stay No. 1.
    9. Remove the 2 bolts and the surge tank stay No. 2.
      Fig 8: Removing Bolts And Surge Tank Stay
      G03061993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Using a socket hexagon wrench 8, remove the 4 bolts.
    11. Remove the 2 nuts, the emission control valve bracket and the intake air surge tank.
      12. Fig 9: Removing Intake Air Surge Tank
      G03061994Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Remove the gasket from the intake air surge tank.
  14. SEPARATE FUEL PIPE SUB-ASSEMBLY NO. 1 
    1. Remove the bolt and the fuel pipe No. 1.
    2. Remove the fuel pressure pulsation damper and the 2 gaskets.
    3. Remove the fuel pipe No. 2 union bolt and the 2 gaskets.
    Fig 10: Removing Fuel Pipe Union Bolt And Gaskets
    G03061995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE FUEL INJECTOR ASSEMBLY 
    1. Disconnect the 6 fuel injector connectors.
      Fig 11: Disconnecting Fuel Injector Connectors
      G03061996Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 bolts and the 2 fuel delivery pipes together with the 6 fuel injectors.
      NOTE: Be careful not to drop the fuel injectors when removing the delivery pipe.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.