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Home >> Toyota >> 2019 >> Sienna SE, AWD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Intake System / Exhaust System [2GR-FKS] (Service Information) >> Exhaust Manifold & Catalytic Converter >> Removal [08/2016 - ] >> Procedure

Removal [08/2016 - ]: Procedure

  1. REMOVE RADIATOR ASSEMBLY 

    Refer to REMOVAL [08/2016 - 11/2017] , or refer to REMOVAL [11/2017 - ]

  2. REMOVE V-BANK COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 18

  3. REMOVE INSTRUMENT PANEL FINISH PANEL END LH 
    • for 2WD:

      See step  1

    • for AWD:

      See step  1

  4. REMOVE NO. 1 ENGINE UNDER COVER 
    1. Remove the 8 screws, front wheel opening extension pad RH and front wheel opening extension pad LH.
      GTY298373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts, 6 screws, 4 clips and No. 1 engine under cover.
  5. REMOVE NO. 2 ENGINE UNDER COVER (for AWD) 
    1. Remove the 2 bolts, 2 screws, clip and No. 2 engine under cover.
      GTY298374Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD) 

    Refer to REMOVAL [12/2015 - ]

  7. REMOVE FRONT EXHAUST PIPE ASSEMBLY (for 2WD) 
    1. Disconnect the heated oxygen sensor (for bank 1) connector.
      GTY723375Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the heated oxygen sensor (for bank 1) wire grommet and pass the connector through the hole to the outside of the vehicle.
    3. Disconnect the heated oxygen sensor (for bank 2) connector.
      GTY724254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disengage the 2 clamps to disconnect the heated oxygen sensor (for bank 2) wire from the wire harness clamp bracket.
      GTY739228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Loosen the bolt and separate the exhaust pipe clamp from the No. 1 exhaust pipe support bracket.
      GTY724252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. 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).
      GTY739222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. 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).
    8. Remove the 3 gaskets from the front exhaust pipe assembly.
  8. REMOVE FRONT EXHAUST PIPE ASSEMBLY (for AWD) 
    1. Disconnect the heated oxygen sensor (for bank 1) connector.
      GTY723375Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the heated oxygen sensor (for bank 1) wire grommet and pass the connector through the hole to the outside of the vehicle.
    3. Disconnect the heated oxygen sensor (for bank 2) connector.
      GTY724254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disengage the 2 clamps to disconnect the heated oxygen sensor (for bank 2) wire from the wire harness clamp bracket.
      GTY739228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Loosen the bolt and separate the exhaust pipe clamp from the No. 1 exhaust pipe support bracket.
      GTY724252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. 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).
      GTY724250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. 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.
    8. Remove the 3 gaskets from the front No. 3 exhaust pipe sub-assembly and front exhaust pipe assembly.
    9. Remove the 2 nuts and front exhaust pipe assembly from the exhaust manifold sub-assembly LH (TWC: front catalyst).
      GTY724258Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Remove the gasket from the front exhaust pipe assembly.
  9. REMOVE MANIFOLD STAY 
    1. Remove the bolt, nut and manifold stay from the exhaust manifold sub-assembly RH (TWC: front catalyst) and rear engine mounting bracket.
      GTY724256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH (TWC: Front Catalyst) 
    1. Disconnect the air fuel ratio sensor (for bank 1) connector and disengage the 3 harness clamps.
      GTY724255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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.
      GTY739223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE EXHAUST MANIFOLD TO HEAD GASKET (for Bank 1) 
    1. Remove the exhaust manifold to head gasket from the cylinder head sub-assembly RH.
      GTY724248Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE AIR FUEL RATIO SENSOR (for Bank 1) 

    Refer to PROCEDURE - Step 13

  13. 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.
      GTY724259Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Disconnect the air fuel ratio sensor (for bank 2) connector and disengage the 2 harness clamps.
      GTY739224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts and No. 2 exhaust manifold heat insulator.
      GTY724275Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE AIR FUEL RATIO SENSOR (for Bank 2) 

    Refer to PROCEDURE - Step 3

  16. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH (TWC: Front Catalyst) 
    1. Using a 12 mm deep socket wrench, remove the 4 nuts and exhaust manifold sub-assembly LH (TWC: front catalyst).
      GTY724274Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE EXHAUST MANIFOLD TO HEAD GASKET (for Bank 2) 
    1. Remove the exhaust manifold to head gasket from the cylinder head sub-assembly.
      GTY724273Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE STUD BOLT 

    HINT: 

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

    1. Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the exhaust manifold sub-assembly RH (TWC: front catalyst).
      GTY739227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the exhaust manifold sub-assembly LH (TWC: front catalyst).
      GTY724277Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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