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Home >> Toyota >> 2017 >> Highlander XLE, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 54 (Intake / Exhaust System (2GR-FXE) (Service Information) (Hybrid)) >> Exhaust Manifold & Catalytic Converter >> Removal [02/2014 - 11/2016] >> Procedure

Removal [02/2014 - 11/2016]: Procedure

WARNING: This page is about a different car, the 2016 Toyota Highlander, 2015 Toyota Highlander, and 2014 Toyota Highlander. However, it is still accessible from the selected car via links, so may be relevant.
  1. REMOVE EGR COOLER ASSEMBLY 

    Refer to REMOVAL [02/2014 - 11/2016]

  2. REMOVE RADIATOR ASSEMBLY 

    Refer to REMOVAL [02/2014 - 11/2016]

  3. REMOVE NO. 2 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 12 , or refer to PROCEDURE - Step 12

  4. REMOVE FRONT FLOOR COVER LH 
    1. Remove the clip (A), 2 screws and 4 bolts from the front floor cover LH.
      GTY454210Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw
    2. Disconnect the 2 clips (B) to remove the front floor cover LH.
  5. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY 
    1. Disengage the 2 wire harness clamps.
      GTY304373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the heated oxygen sensor (for Bank 1) connector.
    3. Remove the 4 bolts, 2 nuts, 2 compression springs and front No. 3 exhaust pipe sub-assembly.
      GTY307525Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 3 gaskets from the front No. 3 exhaust pipe sub-assembly.
  6. REMOVE MANIFOLD STAY 
    1. Remove the bolt, nut and manifold stay from the exhaust manifold sub-assembly RH (TWC: Front Catalyst) and hybrid vehicle transaxle assembly.
      GTY307014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE NO. 1 EGR PIPE 
    1. Remove the bolt, 2 nuts, No. 1 EGR pipe and EGR inlet gasket from the exhaust manifold sub-assembly RH (TWC: Front Catalyst).
      GTY430426Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH (TWC: Front Catalyst) 
    1. Disconnect the air fuel ratio sensor (for Bank 1) connector.
      GTY304371Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 wire harness clamps.
    3. Using a 12 mm deep socket wrench, remove the 6 nuts and exhaust manifold sub-assembly RH (TWC: Front Catalyst) from the cylinder head sub-assembly RH.
      GTY304372Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE EXHAUST MANIFOLD TO HEAD GASKET 
    1. Remove the exhaust manifold to head gasket from the cylinder head sub-assembly RH.
      GTY446708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE AIR FUEL RATIO SENSOR (for Bank 1) 

    Refer to PROCEDURE - Step 5

  11. REMOVE FRONT EXHAUST PIPE ASSEMBLY 
    1. Disengage the 3 wire harness clamps.
      GTY451422Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the heated oxygen sensor connector.
    3. Loosen the bolt (A).
      GTY447391Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 2 bolts (B) and exhaust pipe support bracket from the front exhaust pipe assembly.
    5. Remove the 2 nuts and front exhaust pipe assembly from the exhaust manifold sub-assembly LH (TWC: Front Catalyst).
    6. Remove the gasket from the front exhaust pipe assembly.
  12. REMOVE AIR FUEL RATIO SENSOR (for Bank 2) 

    Refer to PROCEDURE - Step 1

  13. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE 

    Refer to PROCEDURE - Step 9

  14. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Remove the 3 bolts and No. 2 exhaust manifold heat insulator from the exhaust manifold sub-assembly LH (TWC: Front Catalyst).
      GTY452415Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE NO. 2 MANIFOLD STAY 
    1. Remove the bolt, nut and No. 2 manifold stay from the exhaust manifold sub-assembly LH (TWC: Front Catalyst) and cylinder block sub-assembly.
      GTY143218Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH (TWC: Front Catalyst) 
    1. Using a 12 mm deep socket wrench, remove the 6 nuts and exhaust manifold sub-assembly LH (TWC: Front Catalyst) from the cylinder head sub-assembly LH.
      GTY433061Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE EXHAUST MANIFOLD TO HEAD GASKET LH 
    1. Remove the exhaust manifold to head gasket LH from the cylinder head sub-assembly LH.
      GTY447233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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