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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 15 (Engine Intake / Exhaust System (A25A-FXS) - Service Information) >> Exhaust Manifold >> Removal [12/2019 - 10/2022] >> Procedure

Removal [12/2019 - 10/2022]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE NO. 2 ENGINE UNDER COVER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  2. DRAIN ENGINE COOLANT (for Engine) 
  3. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to REMOVAL [12/2019 - ]

  4. REMOVE FENDER SPLASH SHIELD SUB-ASSEMBLY REAR LH 

    Refer to PROCEDURE - Step 3

  5. REMOVE FENDER SPLASH SHIELD SUB-ASSEMBLY REAR RH 

    HINT: 

    Perform the same procedure as for the LH side.

  6. REMOVE FRONT FENDER SPLASH SHIELD SEAL FRONT LH 

    Refer to PROCEDURE - Step 5

  7. REMOVE FRONT FENDER SPLASH SHIELD SEAL FRONT RH 

    HINT: 

    Perform the same procedure as for the LH side.

  8. REMOVE FRONT UPPER SUSPENSION TO COWL BRACE SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 7

  9. REMOVE FRONT UPPER SUSPENSION TO COWL BRACE SUB-ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  10. REMOVE COWL VENTILATOR PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 9

  11. 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. Slide the 2 clips and disconnect the outlet heater water hose D and inlet heater water hose D from the No. 2 outlet water pipe and inlet water pipe.
      GTY1105754Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Outlet Heater Water Hose D
      *2 Inlet Heater Water Hose D
      *a No. 2 Outlet Water Pipe
      *b Inlet Water Pipe
    2. Disengage the 2 wire harness clamps.
      GTY935773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the air fuel ratio sensor (for sensor 2) connector.
    4. Remove the 2 bolts and 2 nuts and disconnect the front exhaust pipe assembly (TWC: Rear Catalyst) from the exhaust manifold (TWC: Front Catalyst) and tail exhaust pipe assembly.
      GTY880674Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the front exhaust pipe assembly (TWC: Rear Catalyst) from the 2 exhaust pipe supports.
    6. Remove the 2 gaskets from the front exhaust pipe assembly (TWC: Rear Catalyst).
  12. REMOVE AIR FUEL RATIO SENSOR (for Sensor 1) 

    Refer to REMOVAL [12/2019 - ]

  13. REMOVE WIRE HARNESS CLAMP BRACKET 
    WARNING:

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

    1. Remove the bolt and wire harness clamp bracket.
      GTY880676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. SEPARATE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 
    WARNING:

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

    1. for Type A:
      1. Remove the 5 bolts and separate the No. 1 exhaust manifold heat insulator from the exhaust manifold (TWC: Front Catalyst).
        GTY880677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for Type B:
      1. Remove the 3 bolts and separate the No. 1 exhaust manifold heat insulator from the exhaust manifold (TWC: Front Catalyst).
        GTY1180762Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE MANIFOLD STAY 
    WARNING:

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

    1. Remove the bolt, nut and manifold stay from the exhaust manifold (TWC: Front Catalyst) and cylinder block sub-assembly.
      GTY880713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE EXHAUST MANIFOLD (TWC: Front Catalyst) 
    WARNING:

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

    1. Remove the 7 nuts and separate the exhaust manifold (TWC: Front Catalyst) from the cylinder head sub-assembly.
      GTY880714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the No. 1 exhaust manifold heat insulator and exhaust manifold (TWC: Front Catalyst).
    3. Remove the exhaust manifold to head gasket from the cylinder head sub-assembly.
      GTY880706Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 
    1. for Type A:
      1. Remove the 6 bolts and No. 2 exhaust manifold heat insulator from the exhaust manifold (TWC: Front Catalyst).
        GTY880712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for Type B:
      1. Remove the 3 bolts and No. 2 exhaust manifold heat insulator from the exhaust manifold (TWC: Front Catalyst).
        GTY1180761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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