Last Modified: 04-05-2023 6.11:8.1.0 Doc ID: RM100000000VIEX
Model Year Start: 2016 Model: Sienna Prod Date Range: [12/2015 - 08/2016]
Title: 2GR-FE INTAKE / EXHAUST: EXHAUST MANIFOLD: REMOVAL; 2016 MY Sienna [12/2015 - 08/2016]

REMOVAL

PROCEDURE

1. REMOVE RADIATOR ASSEMBLY

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

2. REMOVE V-BANK COVER SUB-ASSEMBLY

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL+

3. REMOVE INSTRUMENT PANEL FINISH PANEL END LH

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

4. REMOVE NO. 1 ENGINE UNDER COVER

(a) Remove the 8 screws, front wheel opening extension pad RH and front wheel opening extension pad LH.

(b) Remove the 2 bolts, 6 screws, 4 clips and No. 1 engine under cover.

5. REMOVE NO. 2 ENGINE UNDER COVER (for AWD)

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

6. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD)

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

7. REMOVE FRONT EXHAUST PIPE ASSEMBLY (for 2WD)

(a) Disconnect the oxygen sensor (for bank 1 sensor 2) connector.

(b) Remove the oxygen sensor (for bank 1 sensor 2) wire grommet and pass the connector through the hole to the outside of the vehicle.

(c) Disconnect the oxygen sensor (for bank 2 sensor 2) connector.

(d) Disengage the 6 clamps to disconnect the oxygen sensor (for bank 2 sensor 2) wire from the 2 wire harness clamp brackets.

(e) Loosen the bolt and separate the exhaust pipe clamp from the No. 1 exhaust pipe support bracket.

(f) Remove the 2 bolts and 2 compression springs to separate the front exhaust pipe assembly from the center exhaust pipe sub-assembly (TWC: rear catalyst).

(g) Remove the 4 nuts and front exhaust pipe assembly from the exhaust manifold sub-assembly LH (TWC: front catalyst) and exhaust manifold sub-assembly RH (TWC: front catalyst).

(h) Remove the 3 gaskets from the front exhaust pipe assembly.

8. REMOVE FRONT EXHAUST PIPE ASSEMBLY (for AWD)

(a) Disconnect the oxygen sensor (for bank 1 sensor 2) connector.

(b) Remove the oxygen sensor (for bank 1 sensor 2) wire grommet and pass the connector through the hole to the outside of the vehicle.

(c) Disconnect the oxygen sensor (for bank 2 sensor 2) connector.

(d) Disengage the 6 clamps to disconnect the oxygen sensor (for bank 2 sensor 2) wire from the 2 wire harness clamp brackets.

(e) Loosen the bolt and separate the exhaust pipe clamp from the No. 1 exhaust pipe support bracket.

(f) Remove the 2 bolts and 2 compression springs to separate the front No. 3 exhaust pipe sub-assembly from the center exhaust pipe sub-assembly (TWC: rear catalyst).

(g) Remove the 2 nuts, 2 bolts and front No. 3 exhaust pipe sub-assembly from the exhaust manifold sub-assembly RH (TWC: front catalyst) and front exhaust pipe assembly.

(h) Remove the 3 gaskets from the front No. 3 exhaust pipe sub-assembly and front exhaust pipe assembly.

(i) Remove the 2 nuts and front exhaust pipe assembly from the exhaust manifold sub-assembly LH (TWC: front catalyst).

(j) Remove the gasket from the front exhaust pipe assembly.

9. REMOVE MANIFOLD STAY

(a) Remove the bolt, nut and manifold stay.

10. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH

(a) Disconnect the air fuel ratio sensor (for Bank 1 Sensor 1) connector and disengage the 2 harness clamps.

(b) Using a 12 mm deep socket wrench, remove the 6 nuts and exhaust manifold sub-assembly RH.

11. REMOVE EXHAUST MANIFOLD TO HEAD GASKET

(a) Remove the exhaust manifold to head gasket from the cylinder head sub-assembly.

12. REMOVE AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1)

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

13. REMOVE NO. 2 OIL LEVEL DIPSTICK GUIDE

(a) Remove the oil level dipstick.

(b) Remove the bolt and No. 2 oil level dipstick guide.

(c) Remove the O-ring from the No. 2 oil level dipstick guide.

14. REMOVE NO. 2 MANIFOLD STAY

(a) Remove the bolt, nut and No. 2 manifold stay.

15. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

(a) Disconnect the air fuel ratio sensor (for Bank 2 Sensor 1) connector and disengage the 2 harness clamps.

(b) Remove the 3 bolts and No. 2 exhaust manifold heat insulator.

16. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH

(a) Using a 12 mm deep socket wrench, remove the 6 nuts and exhaust manifold sub-assembly LH.

17. REMOVE EXHAUST MANIFOLD TO HEAD GASKET LH

(a) Remove the exhaust manifold to head gasket LH from the cylinder head sub-assembly.

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

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

SST: 09224-00010

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).