This procedure covers the removal and replacement of the direct-fit catalytic converter on a 2019-2024 Toyota RAV4 with the 2.5L I4 gasoline engine (FWD model).

Warnings

Tools required

Parts

• Direct-fit catalytic converter assembly × 1 — OEM or 49-state/CARB compliant aftermarket
• Exhaust flange gasket (manifold to catalytic converter) × 1 — Use OEM specification
• Exhaust flange gasket (catalytic converter to mid-pipe) × 1 — Use OEM specification
• Exhaust flange nuts/bolts × 1 — Replace if corroded

Preparation

1. Ensure engine and exhaust system are completely cool to the touch
2. Park vehicle on level, solid surface and engage parking brake
3. Place wheel chocks behind rear wheels
4. Raise front of vehicle using floor jack at designated lift points
5. Support vehicle securely on jack stands at manufacturer lift points
6. Spray all exhaust flange bolts, oxygen sensor, and hanger bolts with penetrating oil and allow 15-20 minutes soak time
7. Locate the catalytic converter - positioned between exhaust manifold and center exhaust pipe under engine bay

Procedure

1. 1

   Disconnect upstream oxygen sensor
   Locate the upstream (front) oxygen sensor threaded into the catalytic converter or exhaust manifold. Disconnect the electrical connector by pressing the release tab and pulling apart. Using a 22mm oxygen sensor socket, carefully rotate counterclockwise to remove the sensor. If sensor is seized, apply additional penetrating oil and allow more soak time.
2. 2

   Remove heat shield bolts (if equipped)
   If a heat shield is present over the catalytic converter, remove the retaining bolts using a 10mm socket. There are typically 2-4 bolts securing the shield. Set heat shield aside for reinstallation.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
3. 3

   Disconnect exhaust hanger supports
   Locate the rubber exhaust hangers supporting the catalytic converter and adjacent piping. Use a pry bar or large flathead screwdriver to carefully work the exhaust pipe hooks out of the rubber hangers. Support the exhaust system weight to prevent stress on remaining connections.
4. 4

   Remove upstream flange connection
   Locate the flange connection between the exhaust manifold and catalytic converter inlet. Remove the flange nuts/bolts (typically two 14mm fasteners) using a socket and ratchet. Support the catalytic converter weight as you remove the last fastener. Separate the flange connection and remove the old gasket.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
5. 5

   Remove downstream flange connection
   Locate the flange connection between the catalytic converter outlet and the center exhaust pipe. Remove the flange nuts/bolts (typically two 14mm fasteners). Once all fasteners are removed, carefully lower and remove the catalytic converter assembly from the vehicle. The unit may be heavy - use proper lifting technique.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
6. 6

   Clean mating surfaces
   Using a wire brush, thoroughly clean all exhaust flange mating surfaces on both the manifold and center pipe. Remove all old gasket material, carbon deposits, and corrosion. Ensure surfaces are flat and clean for proper sealing of new gaskets.
7. 7

   Install new catalytic converter - upstream connection
   Position a new exhaust flange gasket on the exhaust manifold flange. Carefully lift the new catalytic converter into position, aligning the inlet flange with the manifold. Thread flange bolts by hand to prevent cross-threading. Apply anti-seize compound to bolt threads as specified. Do not fully tighten yet.
8. 8

   Install downstream flange connection
   Position a new exhaust flange gasket between the catalytic converter outlet and center exhaust pipe. Align the flange bolt holes and thread bolts by hand. Apply anti-seize compound to bolt threads. Ensure all components are properly aligned before tightening.
9. 9

   Torque all flange connections
   Using a torque wrench, tighten the upstream manifold-to-catalytic converter flange bolts to specification in a criss-cross pattern. Then torque the downstream catalytic converter-to-center pipe flange bolts to specification, also in a criss-cross pattern. This ensures even gasket compression and prevents exhaust leaks.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
10. 10

    Reinstall exhaust hangers
    Lift exhaust system into proper position and reconnect all rubber exhaust hanger supports. Ensure pipes are not under stress and have adequate clearance from chassis components, heat shields, and fuel lines. Adjust position as needed before final tightening.
    Torque spec

    Hanger Bolts20 Nm (15 lb-ft)
11. 11

    Reinstall oxygen sensor
    Apply a thin coat of anti-seize compound to the oxygen sensor threads only - avoid getting anti-seize on the sensor tip. Thread the oxygen sensor into the catalytic converter by hand to prevent cross-threading. Tighten to specification using the 22mm oxygen sensor socket and torque wrench. Reconnect the electrical connector until it clicks.
    Torque spec

    O2 Sensor45 Nm (33 lb-ft)
12. 12

    Reinstall heat shield
    If a heat shield was removed, position it back over the catalytic converter and install retaining bolts. Torque heat shield bolts to specification. Ensure shield is properly seated and does not contact the catalytic converter body.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)

Reassembly

1. Verify all flange connections are torqued to specification and gaskets are properly seated
2. Confirm oxygen sensor electrical connector is fully engaged and secured
3. Check that all exhaust hangers are properly connected and system has adequate clearance
4. Verify heat shield (if equipped) is secure and properly positioned

Verification

• Lower vehicle from jack stands and remove wheel chocks
• Start engine and allow to idle - listen for exhaust leaks at all flange connections
• Check for visible exhaust smoke or fumes escaping from connections
• Rev engine to 2500 RPM and listen again for leaks under increased exhaust pressure
• After engine reaches operating temperature, perform visual inspection under vehicle for any signs of leaks or contact between exhaust and chassis
• Use OBD-II scanner to verify no catalyst efficiency codes (P0420/P0430) are present after test drive
• Perform 15-20 minute test drive including highway speeds to fully heat exhaust system, then recheck all connections for leaks

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