Repairing Toyota Sienna Air Filter Vacuum Connector Repair Guide

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                          30 minutes

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Repairing Toyota Sienna Air Filter Vacuum Connector
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Introduction

You might be able to tell from my clean, unmarred hands that I don’t work with my hands much, and in fact, this was my first automotive fix (I’m nearly 35), so if I can do it, anybody can do it. Fortunately, my wife is handy and had all of the necessary tools (though she joked that she was nervous about letting me use them).

What you need

Step 1

              Repairing Toyota Sienna Air Filter Vacuum Connector

Here’s what the broken connector looks like. If the broken end is still inside the hose, remove it. Insert the end of a a wire clothes hanger through the hole. Torque it to get a grip on the tip, and pull and turn until it comes out.

Here’s what the broken connector looks like. If the broken end is still inside the hose, remove it. Insert the end of a a wire clothes hanger through the hole. Torque it to get a grip on the tip, and pull and turn until it comes out.

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Step 2

To open the housing, you’ll need to loosen two bolts on the right side of the housing – one on the front, and one hiding in the back.
(My wife doesn’t think it was necessary to remove the housing, and she may be right. I think it probably made it easier to get the right angles for following steps.)

To open the housing, you’ll need to loosen two bolts on the right side of the housing – one on the front, and one hiding in the back.

(My wife doesn’t think it was necessary to remove the housing, and she may be right. I think it probably made it easier to get the right angles for following steps.)

Step 3

Use a socket wrench with an extension and 10mm socket. Loosen it with the wrench, then use your fingers to loosen the rest of the way. The bolts are captive, meaning they won’t come out all the way.
It takes some finagling to get to the back bolt, and it’s cozy, but it’s doable.
Once both bolts are loosened, grab the right side of the housing, and rotate it firmly but gently up toward the left side, and it should open.

Use a socket wrench with an extension and 10mm socket. Loosen it with the wrench, then use your fingers to loosen the rest of the way. The bolts are captive, meaning they won’t come out all the way.

It takes some finagling to get to the back bolt, and it’s cozy, but it’s doable.

Once both bolts are loosened, grab the right side of the housing, and rotate it firmly but gently up toward the left side, and it should open.

Step 4

Cut the remnants of the connector off to make it flush with the housing. This will make it easier to drill in the next step.
You can use a small, flat saw for this. I used my wife’s Dremel. Be careful not to damage other parts of the housing, hoses, etc.
I didn’t get a very good photo after the connector was off. You should be able to see the hole.

Cut the remnants of the connector off to make it flush with the housing. This will make it easier to drill in the next step.

You can use a small, flat saw for this. I used my wife’s Dremel. Be careful not to damage other parts of the housing, hoses, etc.

I didn’t get a very good photo after the connector was off. You should be able to see the hole.

Step 5

Using the hole to center the drill bit, drill out the old connector with a 1/2" bit. (If you’re an amateur like me, you might try using a smaller bit, say 1/4", first for practice, and to make the final hole easier.)
Go slowly so you don’t damage the housing, and be careful not to cut or damage any other parts. Be careful not to go too deep – just deep enough that the fitting will be able to go all the way in.
After your hole is done, use a vacuum cleaner to suck out any plastic bits that got into the hole.

Using the hole to center the drill bit, drill out the old connector with a 1/2" bit. (If you’re an amateur like me, you might try using a smaller bit, say 1/4", first for practice, and to make the final hole easier.)

Go slowly so you don’t damage the housing, and be careful not to cut or damage any other parts. Be careful not to go too deep – just deep enough that the fitting will be able to go all the way in.

After your hole is done, use a vacuum cleaner to suck out any plastic bits that got into the hole.

Step 6

Wrap the fitting with two layers of Teflon tape in a clockwise direction (if you’re looking at the threaded end – if you go the wrong way, the tape will unravel when you’re screwing the fitting in).
Put the fitting into the hole, and use a 9/16” wrench to screw it in until it’s flush with the housing.

Wrap the fitting with two layers of Teflon tape in a clockwise direction (if you’re looking at the threaded end – if you go the wrong way, the tape will unravel when you’re screwing the fitting in).

Put the fitting into the hole, and use a 9/16” wrench to screw it in until it’s flush with the housing.

Step 7

If you need to change your air filter, do so now.
Close the housing – get the tabs on the left slide into their slots first, and then you should be able to rotate the right side down to get it into place. Hand-tighten the bolts, then tighten them down with the socket wrench.
Slide the hose onto the barb as far as it will go, and voila, your Sienna is fixed! For under $10!
If I can fix it, anybody can.

If you need to change your air filter, do so now.

Close the housing – get the tabs on the left slide into their slots first, and then you should be able to rotate the right side down to get it into place. Hand-tighten the bolts, then tighten them down with the socket wrench.

Slide the hose onto the barb as far as it will go, and voila, your Sienna is fixed! For under $10!

If I can fix it, anybody can.

Clean up, put away your tools, and celebrate saving yourself a lot of money!

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                                                                                      4 other people completed this guide.

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                                      with 3 other contributors

                    Steven Paradise

Member since: 05/24/2014

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broadws - May 25, 2014

Nice job! I think anyone with this vehicle will get around to this repair sooner or later!!!

cliffordracz - Nov 30, 2014

Awesome post. I really appreciate it that you took the time to help everybody with this problem. I was not looking forward to buying an entirely new housing for this simple repair. I just didn’t know if it would work (I was worried about damaging the flow sensor or whatever it is just inside the housing.

gossamerica - Dec 1, 2014

Yeah, I don’t remember exactly what was on the other side from where I was drilling, but just drill carefully (and not too far) and you’ll be fine. Mine passed visual and functional inspection, and it hasn’t had any problems since.

Jim - Dec 29, 2014

Great guide. Took two trips to get first the Watt connector, and then a second trip when I realized I did not have a half inch drill. Note that you end up drilling right through the plastic – so any caution about not drilling too deeply is mostly for the benefit of the filter material found behind the cover.

Thanks!

phoenixwill - Apr 6, 2015

I took my Sienna to SMOG check, and failed initially due to a broken connection to the housing. I found your instruction and followed your step by step, and fixed my 2009 Sienna broken air filter housing. Went back for the 2nd SMOG within an hour, and passed without any problem. Thank you so much for saving me some $$$.

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Member-Contributed Guide

Introduction

What you need