Last Modified: 04-05-2023 6.11:8.1.0 Doc ID: RM100000000VIEY
Model Year Start: 2016 Model: Sienna Prod Date Range: [12/2015 - 08/2016]
Title: 2GR-FE INTAKE / EXHAUST: EXHAUST PIPE(for 4WD): INSTALLATION; 2016 MY Sienna [12/2015 - 08/2016]

INSTALLATION

PROCEDURE

1. INSTALL NO. 2 OXYGEN SENSOR (for Bank 2 Sensor 2)

(a) Using SST, install the No. 2 oxygen sensor (for bank 2 sensor 2) to the front exhaust pipe assembly.

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 oxygen sensor (for bank 2 sensor 2).

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 OXYGEN SENSOR (for Bank 1 Sensor 2)

(a) Using SST, install the oxygen sensor (for bank 1 sensor 2) to the front No. 3 exhaust pipe sub-assembly.

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 oxygen sensor (for bank 1 sensor 2).

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).

3. INSTALL FRONT EXHAUST PIPE ASSEMBLY

(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 2 new nuts.

Torque:

62 N·m {632 kgf·cm, 46 ft·lbf}

(c) 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}

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

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

4. INSTALL CENTER EXHAUST PIPE ASSEMBLY

(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

42 mm (1.65 in.)

40.5 mm (1.59 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 No. 3 exhaust pipe sub-assembly.

Text in Illustration

*1

Gasket

*2

Front No. 3 Exhaust Pipe 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 center exhaust pipe sub-assembly (TWC: rear catalyst) when connecting it.

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

Text in Illustration

*1

Center Exhaust Pipe Sub-assembly (TWC: Rear Catalyst)

*2

Front No. 3 Exhaust Pipe Sub-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 center exhaust pipe sub-assembly (TWC: rear catalyst) and front No. 3 exhaust pipe sub-assembly are consistent front-to-rear and left-to-right.

(d) 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.

(e) Using a plastic hammer and a wooden block, tap in a new gasket until its surface is flush with the center No. 2 exhaust pipe sub-assembly.

Text in Illustration

*1

Gasket

*2

Center No. 2 Exhaust Pipe 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 center exhaust pipe sub-assembly (TWC: rear catalyst) when connecting it.

(f) Install the center exhaust pipe sub-assembly (TWC: rear catalyst) to the center No. 2 exhaust pipe sub-assembly with the 2 compression springs and 2 bolts.

Text in Illustration

*1

Center Exhaust Pipe Sub-assembly (TWC: Rear Catalyst)

*2

Center No. 2 Exhaust Pipe Sub-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 center exhaust pipe sub-assembly (TWC: rear catalyst) and center No. 2 exhaust pipe sub-assembly are consistent front-to-rear and left-to-right.

(g) Install 2 new gaskets to the center exhaust pipe assembly and the front exhaust pipe assembly.

(h) Connect the 2 exhaust pipe supports to install the center exhaust pipe assembly to the vehicle.

(i) Install the center exhaust pipe assembly to the front exhaust pipe assembly with 2 new bolts and 2 new nuts.

Torque:

Bolt :

43 N·m {438 kgf·cm, 32 ft·lbf}

Nut :

62 N·m {632 kgf·cm, 46 ft·lbf}

(j) Engage the clamp to connect the oxygen sensor (for bank 1 sensor 2) wire to the vehicle.

(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.

5. INSTALL TAIL EXHAUST PIPE ASSEMBLY

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

(b) Connect the 4 exhaust pipe supports to install the tail exhaust pipe assembly to the vehicle.

(c) Install the tail exhaust pipe assembly to the center exhaust pipe assembly with 2 new bolts.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

6. INSTALL INSTRUMENT PANEL FINISH PANEL END LH

(a) Engage the 3 guides and install the instrument panel finish panel end LH.

(b) Install the clip.

7. INSPECT FOR EXHAUST GAS LEAK