LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2018 >> Prius Two Eco >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Exhaust/ Intake System - Service Information >> Exhaust Manifold & Catalytic Converter >> Removal [11/2015 - 12/2018] >> Procedure

Removal [11/2015 - 12/2018]: Procedure

  1. REMOVE AIR FUEL RATIO SENSOR 

    Refer to REMOVAL [11/2015 -]

  2. REMOVE REAR MOTOR UNDER COVER LH 

    Refer to PROCEDURE - Step 7 [11/2015 - 08/2016] , or refer to PROCEDURE - Step 7 [08/2016 - 12/2018]

  3. REMOVE NO. 1 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 6 [11/2015 - 08/2016] , or refer to PROCEDURE - Step 6 [08/2016 - 12/2018]

  4. REMOVE NO. 2 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 9 [11/2015 - 08/2016] , or refer to PROCEDURE - Step 9 [08/2016 - 12/2018]

  5. DRAIN ENGINE COOLANT (w/ Exhaust Heat Recirculation System) 

    Refer to PROCEDURE - Step 2 [11/2015 - 08/2016] , or refer to PROCEDURE - Step 2 [08/2016 - 07/2020]

  6. REMOVE FRONT FLOOR COVER LH 
    1. Remove the 2 bolts and 3 clips and disengage the 5 clamps to remove the front floor cover LH from the vehicle body.
      GTY609399Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Clip
  7. REMOVE FRONT FLOOR COVER RH 

    HINT: 

    Perform the same procedure as for the front floor cover LH.

  8. REMOVE FRONT CENTER FLOOR BRACE 
    1. Remove the 12 bolts and 3 front center floor braces from the vehicle body.
      GTY544047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst) 
    WARNING:

    To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.

    1. w/ Exhaust Heat Recirculation System:
      1. Slide the 2 clips and disconnect the outlet heater water hose B and outlet heater water hose C from the inlet water pipe and No. 2 outlet water pipe.
        GTY578405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Outlet Heater Water Hose B
        *2 Outlet Heater Water Hose C
        *a No. 2 Outlet Water Pipe
        *b Inlet Water Pipe
    2. Disconnect the heated oxygen sensor connector.
      GTY556353Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the wire harness clamp.
    4. Remove the 4 bolts and 4 compression springs and disconnect the front exhaust pipe assembly (TWC: Rear Catalyst) from the exhaust manifold (TWC: Front Catalyst) and tail exhaust pipe assembly.
      GTY561974Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A w/ Exhaust Heat Recirculation System
      *B w/o Exhaust Heat Recirculation System
    5. Remove the front exhaust pipe assembly (TWC: Rear Catalyst) from the 2 exhaust pipe supports.
    6. Remove the 2 exhaust pipe gaskets from the exhaust manifold (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst).
  10. REMOVE WIRING HARNESS CLAMP BRACKET 
    WARNING:

    To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.

    1. Disengage the clamp and remove the bolt and wiring harness clamp bracket from the cylinder head sub-assembly.
      GTY544062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 
    WARNING:

    To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.

    1. Remove the 6 bolts and No. 1 exhaust manifold heat insulator from the exhaust manifold (TWC: Front Catalyst).
      GTY598726Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE MANIFOLD STAY 
    WARNING:

    To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.

    1. Remove the 3 bolts and manifold stay from the exhaust manifold (TWC: Front Catalyst) and cylinder block sub-assembly.
      GTY544060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE EXHAUST MANIFOLD (TWC: Front Catalyst) 
    WARNING:

    To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.

    1. w/ Exhaust Heat Recirculation System:
      1. Remove the nut and disconnect the water pipe and hose sub-assembly A from the bracket.
        GTY544063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Disconnect the engine coolant temperature sensor connector.
    2. Release the lock lever and disconnect the brake booster pump assembly connector as shown in the illustration.
      GTY556977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Release
      Disconnect
      NOTE:

      Be careful not to allow any brake fluid to enter the connector.

    3. Disengage the clamp.
    4. Remove the 7 nuts and exhaust manifold (TWC: Front Catalyst) from the cylinder head sub-assembly.
      GTY544061Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the exhaust manifold to head gasket and EGR cooler gasket from the cylinder head sub-assembly.
      GTY550950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Exhaust Manifold To Head Gasket
      *2 EGR Cooler Gasket
  14. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Remove the 4 bolts and No. 2 exhaust manifold heat insulator from the exhaust manifold (TWC: Front Catalyst).
      GTY544161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
scientia non olet · About LEMON Manuals