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HOMESERVICE MANUALSTOYOTA2009SIENNA XLE, FWDREPAIR AND DIAGNOSISENGINE PERFORMANCEFUEL DELIVERYENGINE FUEL SYSTEMFUEL TANKINSTALLATION

2009 Toyota Sienna XLE, FWD

Fuel Tank: Installation

2009 Toyota Sienna XLE, FWDSECTION Installation

CONNECT FUEL TANK VENT HOSE
INSTALL FUEL TANK TO FILLER PIPE HOSE
1. Install a new fuel tank to filler pipe hose as shown in the illustration.
  
  Fig 1: Locating Fuel Tank To Filler Pipe Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE (See INSTALLATION )
INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY (See INSTALLATION )
INSTALL FUEL TANK ASSEMBLY
1. Set up the fuel tank assembly to the transmission jack.
2. While operating the transmission jack, fasten the 4 claws for the wire harness and connect the fuel pump connector, then install the fuel tank and the 3 fuel tank bands to the vehicle.
3. Tighten the 6 set bolts of the 3 fuel tank bands.
  Torque: 33 N*m (336 kgf*cm, 24 ft.*lbf)
4. Install the 2 wire harness clamps.
5. Connect the fuel tube.
  1. Push in the fuel tube connector to the pipe until fuel tube connector makes "click" sound.
    NOTE:
    Check if there is any damage or foreign objects on the connected part.
    
    After connecting, check if the connector and the pipe are securely connected by pulling on them.
    
    Fig 2: Pushing Fuel Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Connect the fuel tank to filler pipe hose as shown in the illustration.
  
  Fig 3: Identifying Filler Pipe Hose Dimension
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Connect the fuel tank main tube.
  1. Push in the fuel tube connector to the pipe until fuel tube connector makes "click" sound.
    NOTE:
    Check if there is any damage or foreign objects on the connected part.
    
    After connecting, check if the connector and the pipe are securely connected by pulling on them.
  Fig 4: Connecting Fuel Tank Main Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Connect the fuel tank vent hose.
ADD FUEL
INSPECT FOR FUEL LEAK (See ON-VEHICLE INSPECTION )
INSTALL FUEL TANK FILLER HOSE COVER
1. Install the 3 bolts and the fuel tank filler hose cover.
  Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
  
  Fig 5: Pushing Fuel Tank Main Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR FLOOR NO. 2 CROSSMEMBER BRACE LH
1. Install the rear floor No. 2 crossmember brace LH with 2 bolts.
  Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
Fig 6: Identifying Fuel Tank Filler Hose Cover And Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CHARCOAL CANISTER PROTECTOR (See INSTALLATION )

RENDER: 1.0x

NO RELATED

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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.