Last Modified: 04-05-2023 6.11:8.1.0 Doc ID: RM100000000VIEV
Model Year Start: 2016 Model: Sienna Prod Date Range: [12/2015 - 08/2016]
Title: 2GR-FE INTAKE / EXHAUST: EXHAUST MANIFOLD: INSTALLATION; 2016 MY Sienna [12/2015 - 08/2016]

INSTALLATION

PROCEDURE

1. INSTALL NO. 2 AIR FUEL RATIO SENSOR (for Bank 2 Sensor 1)

(a) Using SST, install the No. 2 air fuel ratio sensor (for Bank 2 Sensor 1) to the front exhaust manifold sub-assembly LH.

Text in Illustration

*a

Fulcrum Length of SST

*b

Fulcrum Length of Torque Wrench

SST: 09224-00010

Torque:

Specified tightening torque :

44 N·m {449 kgf·cm, 32 ft·lbf}

NOTICE:

If a component has been dropped or subjected to a strong impact, replace No. 2 air fuel ratio sensor (for Bank 2 Sensor 1).

HINT:

  • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench (See page 2016 MY Sienna [12/2015 - 08/2016]; INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION ).
  • When using SST (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 300 mm (11.8 in.)): 40 N*m (408 kgf*cm, 30 ft.*lbf).

2. INSTALL EXHAUST MANIFOLD TO HEAD GASKET LH

(a) Install a new exhaust manifold to head gasket LH.

3. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

(a) Temporarily install the exhaust manifold sub-assembly LH with the 6 nuts.

(b) Using a 12 mm deep socket wrench, tighten the 6 nuts in the order shown in the illustration.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

4. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

(a) Install the No. 2 exhaust manifold heat insulator, tightening the 3 bolts in the order shown in the illustration.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

(b) Connect the air fuel ratio sensor (for Bank 2 Sensor 1) connector and engage the 2 harness clamps.

5. INSTALL NO. 2 MANIFOLD STAY

(a) Install the No. 2 manifold stay, tightening the bolt and nut in the order shown in the illustration.

Torque:

34 N·m {347 kgf·cm, 25 ft·lbf}

6. INSTALL NO. 2 OIL LEVEL DIPSTICK GUIDE

(a) Install a new O-ring to the No. 2 oil level dipstick guide.

(b) Apply a light coat of engine oil to the O-ring.

(c) Push in the No. 2 oil level dipstick guide end into the oil level dipstick guide.

(d) Install the No. 2 oil level dipstick guide with the bolt.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

(e) Install the oil level dipstick.

7. INSTALL AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1)

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE (ENGINE CONTROL): AIR FUEL RATIO SENSOR: INSTALLATION+

8. INSTALL EXHAUST MANIFOLD TO HEAD GASKET

(a) Install a new exhaust manifold to head gasket.

9. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

(a) Temporarily install the exhaust manifold sub-assembly RH with the 6 nuts.

(b) Using a 12 mm deep socket wrench, tighten the 6 nuts in the order shown in the illustration.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

(c) Connect the air fuel ratio sensor (for Bank 1 Sensor 1) connector and engage the 2 harness clamps.

10. INSTALL MANIFOLD STAY

(a) Install the manifold stay with the bolt and nut.

Torque:

Bolt :

34 N·m {347 kgf·cm, 25 ft·lbf}

Nut :

35 N·m {357 kgf·cm, 26 ft·lbf}

11. INSTALL FRONT EXHAUST PIPE ASSEMBLY (for 2WD)

(a) Inspect the free length.

(1) Using a vernier caliper, measure the free length of the compression spring.

Free Length of Compression Spring:

Standard Length

Minimum Length

40.36 mm (1.59 in.)

38.86 mm (1.53 in.)

If the length is not as specified, replace the compression spring.

(b) Using a plastic hammer and a wooden block, tap in a new gasket until its surface is flush with the front exhaust pipe assembly.

Text in Illustration

*1

Gasket

*2

Front Exhaust Pipe Assembly

*a

Wooden Block

*b

Plastic Hammer

NOTICE:

  • Install the gasket in the correct direction.
  • Do not reuse the gasket.
  • Do not damage the gasket by dropping it, etc.
  • Do not damage the outer surface of the gasket.
  • Do not push in the gasket with the center exhaust pipe assembly when connecting it.

(c) Install 2 new gaskets to the front exhaust pipe assembly.

(d) Install the front exhaust pipe assembly to the exhaust manifold sub-assembly LH (TWC: front catalyst) and exhaust manifold sub-assembly RH (TWC: front catalyst) with 4 new nuts.

Torque:

62 N·m {632 kgf·cm, 46 ft·lbf}

(e) Connect the front exhaust pipe assembly to the center exhaust pipe sub-assembly (TWC: rear catalyst) with the 2 compression springs and 2 bolts.

Text in Illustration

*1

Front Exhaust Pipe Assembly

*2

Center Exhaust Pipe Assembly

*3

Gasket

*a

Space between flanges: 8.5 mm (0.335 in.)

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

NOTICE:

After the installation, check that the gaps between the flanges of the front exhaust pipe assembly and center exhaust pipe assembly are consistent front-to-rear and left-to-right.

(f) Connect the exhaust pipe clamp to the No. 1 exhaust pipe support bracket and tighten the bolt.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

(g) Engage the 6 clamps to connect the oxygen sensor (for bank 2 sensor 2) wire to the 2 wire harness clamp brackets.

(h) Connect the oxygen sensor (for bank 2 sensor 2) connector.

(i) Pass the connector through the hole to the inside of the vehicle and install the grommet of the oxygen sensor (for bank 1 sensor 2) wire.

(j) Connect the oxygen sensor (for bank 1 sensor 2) connector.

12. INSTALL FRONT EXHAUST PIPE ASSEMBLY (for AWD)

(a) Install a new gasket to the front exhaust pipe assembly.

(b) Install the front exhaust pipe assembly to the exhaust manifold sub-assembly LH (TWC: front catalyst) with the 2 nuts.

Torque:

62 N·m {632 kgf·cm, 46 ft·lbf}

(c) Inspect the free length.

(1) Using a vernier caliper, measure the free length of the compression spring.

Free Length of Compression Spring:

Standard Length

Minimum Length

42 mm (1.65 in.)

40.5 mm (1.59 in.)

If the length is not as specified, replace the compression spring.

(d) Using a plastic hammer and a wooden block, tap in a new gasket until its surface is flush with the front No. 3 exhaust pipe sub-assembly.

Text in Illustration

*1

Gasket

*2

Exhaust Manifold Converter Sub-assembly

*a

Wooden Block

*b

Plastic Hammer

NOTICE:

  • Install the gasket in the correct direction.
  • Do not reuse the gasket.
  • Do not damage the gasket by dropping it, etc.
  • Do not damage the outer surface of the gasket.
  • Do not push in the gasket with the front No. 3 exhaust pipe sub-assembly (TWC: rear catalyst) when connecting it.

(e) Install 2 new gaskets to the front No. 3 exhaust pipe sub-assembly.

(f) Install the front No. 3 exhaust pipe sub-assembly to the exhaust manifold sub-assembly RH (TWC: front catalyst) and front exhaust pipe assembly with 2 new nuts and 2 new bolts.

Torque:

Bolt :

43 N·m {438 kgf·cm, 32 ft·lbf}

Nut :

62 N·m {632 kgf·cm, 46 ft·lbf}

(g) Connect the front No. 3 exhaust pipe sub-assembly to the center exhaust pipe sub-assembly (TWC: rear catalyst) with the 2 compression springs and 2 bolts.

Text in Illustration

*1

Front No. 3 Exhaust Pipe Sub-assembly

*2

Center Exhaust Pipe Assembly

*3

Gasket

*a

Space between flanges: 8.5 mm (0.335 in.)

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

NOTICE:

After the installation, check that the gaps between the flanges of the front No. 3 exhaust pipe sub-assembly and center exhaust pipe assembly are consistent front-to-rear and left-to-right.

(h) Connect the exhaust pipe clamp to No. 1 exhaust pipe support bracket and tighten the bolt.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

(i) Engage the 6 clamps to connect the oxygen sensor (for bank 2 sensor 2) wire to the 2 wire harness clamp brackets.

(j) Connect the oxygen sensor (for bank 2 sensor 2) connector.

(k) Pass the connector through the hole to the inside of the vehicle and install the grommet of the oxygen sensor (for bank 1 sensor 2) wire.

(l) Connect the oxygen sensor (for bank 1 sensor 2) connector.

13. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD)

(See page 2016 - 2020 MY Sienna [12/2015 -        ]; DRIVE SHAFT / PROPELLER SHAFT: PROPELLER SHAFT ASSEMBLY: INSTALLATION )

14. INSTALL NO. 2 ENGINE UNDER COVER (for AWD)

(a) Install the No. 2 engine under cover with the 2 bolts, 2 screws and clip.

15. INSTALL NO. 1 ENGINE UNDER COVER

(a) Install the No. 1 engine under cover with the 2 bolts, 6 screws and 4 clips.

(b) Install the front wheel opening extension pad RH and front wheel opening extension pad LH with the 8 screws.

Torque:

Screw A :

7.0 N·m {71 kgf·cm, 62 in·lbf}

16. INSTALL INSTRUMENT PANEL FINISH PANEL END LH

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE INTAKE / EXHAUST: EXHAUST PIPE(for 2WD): INSTALLATION+

17. INSTALL V-BANK COVER SUB-ASSEMBLY

18. INSTALL RADIATOR ASSEMBLY

(See page 2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE COOLING: RADIATOR: INSTALLATION )

19. INSPECT FOR EXHAUST GAS LEAK