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

Last Modified: 04-05-2023	6.11:8.1.0	Doc ID: RM100000000VIF1
Model Year Start: 2016	Model: Sienna	Prod Date Range: [12/2015 - 08/2016]
Title: 2GR-FE INTAKE / EXHAUST: EXHAUST PIPE(for 2WD): 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 ).
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 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 oxygen sensor (for bank 1 sensor 2).

HINT:

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench (See page ).
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 2 new gaskets to the front exhaust pipe assembly.

(b) 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}

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.

(f) 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.

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

4. INSTALL EXHAUST PIPE DAMPER

(a) Install the exhaust pipe damper to the center No. 2 exhaust pipe sub-assembly with the 2 new bolts.

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

5. 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
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 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.

(c) 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.

(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
40.36 mm (1.59 in.)	38.86 mm (1.53 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 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.

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

(g) Install the center exhaust pipe assembly to the front exhaust pipe assembly with the 2 compression springs and 2 bolts.

Text in Illustration

*1	Center Exhaust Pipe assembly
*2	Front 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 center exhaust pipe assembly and front exhaust pipe assembly are consistent front-to-rear and left-to-right.

6. INSTALL TAIL EXHAUST PIPE ASSEMBLY

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

(b) Connect the 3 exhaust pipe supports to install the tail exhaust pipe assembly to the vehicle.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

7. 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.

8. INSPECT FOR EXHAUST GAS LEAK