Last Modified: 08-28-2024 6.11:8.1.0 Doc ID: RM100000000YQW8
Model Year Start: 2017 Model: Sienna Prod Date Range: [08/2016 -           ]
Title: 2GR-FKS (INTAKE / EXHAUST): EXHAUST MANIFOLD: REMOVAL; 2017 - 2020 MY Sienna [08/2016 -        ]

REMOVAL

PROCEDURE

1. REMOVE RADIATOR ASSEMBLY

Click here 2017 MY Sienna [08/2016 - 11/2017]; 2GR-FKS (COOLING): RADIATOR: REMOVAL 2018 - 2020 MY Sienna [11/2017 -        ]; 2GR-FKS (COOLING): RADIATOR: REMOVAL

2. REMOVE V-BANK COVER SUB-ASSEMBLY

Click here 2017 - 2020 MY Sienna [08/2016 -        ]; 2GR-FKS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+

3. REMOVE INSTRUMENT PANEL FINISH PANEL END LH

  • for 2WD:

    Click here 2017 - 2020 MY Sienna [08/2016 -        ]; 2GR-FKS (INTAKE / EXHAUST): EXHAUST PIPE(for 2WD): REMOVAL+

  • for AWD:

    Click here 2017 - 2020 MY Sienna [08/2016 -        ]; 2GR-FKS (INTAKE / EXHAUST): EXHAUST PIPE(for AWD): 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)

Click here 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 heated oxygen sensor (for bank 1) connector.

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

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

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

(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 heated oxygen sensor (for bank 1) connector.

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

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

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

(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 from the exhaust manifold sub-assembly RH (TWC: front catalyst) and rear engine mounting bracket.

10. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH (TWC: Front Catalyst)

(a) Disconnect the air fuel ratio sensor (for bank 1) connector and disengage the 3 harness clamps.

(b) Using a 12 mm deep socket wrench, remove the 4 nuts and exhaust manifold sub-assembly RH (TWC: front catalyst) from the cylinder head sub-assembly RH.

11. REMOVE EXHAUST MANIFOLD TO HEAD GASKET (for Bank 1)

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

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

Click here 2017 - 2020 MY Sienna [08/2016 -        ]; 2GR-FKS (ENGINE CONTROL): AIR FUEL RATIO SENSOR: REMOVAL+

13. REMOVE NO. 2 MANIFOLD STAY

(a) Remove the bolt, nut and No. 2 manifold stay from the exhaust manifold sub-assembly LH (TWC: front catalyst) and cylinder block sub-assembly.

14. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

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

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

15. REMOVE AIR FUEL RATIO SENSOR (for Bank 2)

Click here 2017 - 2020 MY Sienna [08/2016 -        ]; 2GR-FKS (ENGINE CONTROL): AIR FUEL RATIO SENSOR: REMOVAL+

16. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH (TWC: Front Catalyst)

(a) Using a 12 mm deep socket wrench, remove the 4 nuts and exhaust manifold sub-assembly LH (TWC: front catalyst).

17. REMOVE EXHAUST MANIFOLD TO HEAD GASKET (for Bank 2)

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

18. REMOVE STUD BOLT

HINT:

If a stud bolt is deformed or its threads are damaged, replace it.

(a) Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the exhaust manifold sub-assembly RH (TWC: front catalyst).

(b) Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the exhaust manifold sub-assembly LH (TWC: front catalyst).