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Home >> Toyota >> 2017 >> Highlander XLE, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 209 (Intake / Exhaust System (2GR-FXS) - Service Information - (Hybrid)) >> Exhaust Manifold & Catalytic Converter >> Removal [11/2016 - ] >> Procedure

Removal [11/2016 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE NO. 1 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 11

  2. REMOVE NO. 2 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 12

  3. 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.
  4. DRAIN ENGINE COOLANT (for Engine) 

    Refer to PROCEDURE - Step 1

  5. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to REMOVAL [02/2014 - ]

  6. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  7. REMOVE V-BANK COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 22

  8. SEPARATE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 

    Refer to PROCEDURE - Step 32

  9. REMOVE RESERVOIR BRACKET 

    Refer to PROCEDURE - Step 33

  10. DISCONNECT WIRE HARNESS 

    Refer to PROCEDURE - Step 11

  11. REMOVE NO. 2 EGR PIPE 

    See step  15

  12. REMOVE NO. 2 EGR PIPE GASKET 

    See step  16

  13. DISCONNECT WATER BY-PASS HOSE ASSEMBLY 

    Refer to PROCEDURE - Step 14

  14. DISCONNECT NO. 6 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 15

  15. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY 
    1. Disconnect the heated oxygen sensor (for Bank 1) connector.
      GTY691202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 3 wire harness clamps.
    3. Remove the 4 bolts, 2 nuts, 2 compression springs and front No. 3 exhaust pipe sub-assembly from the front exhaust pipe assembly and center exhaust pipe sub-assembly (TWC: Rear Catalyst).
      GTY618915Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    4. Remove the 3 gaskets from the front No. 3 exhaust pipe sub-assembly.
  16. REMOVE EGR VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 16

  17. REMOVE EGR INLET GASKET 

    Refer to PROCEDURE - Step 17

  18. REMOVE MANIFOLD STAY 
    1. Remove the bolt, nut and manifold stay from the exhaust manifold (TWC: Front Catalyst) and rear engine mounting bracket.
      GTY696661Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
  19. REMOVE AIR FUEL RATIO SENSOR (for Bank 1) 

    Refer to PROCEDURE - Step 6

  20. REMOVE EXHAUST MANIFOLD (TWC: Front Catalyst) 
    1. Using a 12 mm deep socket wrench, remove the 4 nuts and exhaust manifold (TWC: Front Catalyst) from the cylinder head sub-assembly RH.
      GTY650215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE EXHAUST MANIFOLD TO HEAD GASKET (for Bank 1) 
    1. Remove the exhaust manifold to head gasket (for Bank 1) from the cylinder head sub-assembly RH.
      GTY650216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE FRONT EXHAUST PIPE ASSEMBLY 

    See step  11

  23. REMOVE NO. 1 ENGINE COVER 

    Refer to PROCEDURE - Step 2

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

    Refer to PROCEDURE - Step 3

  25. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Remove the 3 bolts and No. 2 exhaust manifold heat insulator from the exhaust manifold assembly LH (TWC: Front Catalyst).
      GTY691195Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE NO. 2 MANIFOLD STAY 
    1. Remove the bolt, nut and No. 2 manifold stay from the exhaust manifold assembly LH (TWC: Front Catalyst) and cylinder block sub-assembly.
      GTY656737Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
  27. REMOVE EXHAUST MANIFOLD ASSEMBLY LH (TWC: Front Catalyst) 
    1. Using a 12 mm deep socket wrench, remove the 4 nuts and exhaust manifold assembly LH (TWC: Front Catalyst) from the cylinder head sub-assembly LH.
      GTY691196Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE EXHAUST MANIFOLD TO HEAD GASKET (for Bank 2) 
    1. Remove the exhaust manifold to head gasket (for Bank 2) from the cylinder head sub-assembly LH.
      GTY691198Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE STUD BOLT 

    HINT: 

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

    1. Using an E8 "TORX" socket wrench, remove the 2 stud bolts (A) from the exhaust manifold (TWC: Front Catalyst).
      GTY671582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using an E6 "TORX" socket wrench, remove the 2 stud bolts (B) from the exhaust manifold (TWC: Front Catalyst).
    3. Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the exhaust manifold assembly LH (TWC: Front Catalyst).
      GTY627947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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