This procedure covers the replacement of a universal catalytic converter on a 2019-2024 Toyota RAV4 with a 2.5L I4 gas engine (FWD), including removal of heat shields, oxygen sensors, and exhaust flanges.

Warnings

Tools required

Parts

• Universal catalytic converter × 1 — Match inlet/outlet diameter and overall length to OEM specs
• Exhaust flange gaskets × 2 — Use OEM specification
• Exhaust clamps (if required by universal cat) × 2 — Appropriate size for pipe diameter
• Heat shield (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Allow exhaust system to cool completely (minimum 2 hours after engine operation)
4. Apply penetrating oil to all exhaust flange bolts, heat shield bolts, and oxygen sensor threads
5. Raise front of vehicle and support securely on jack stands at manufacturer-specified lift points
6. Verify clearance and identify catalytic converter location (positioned between exhaust manifold and mid-pipe on FWD models)
7. Inspect heat shields and identify all mounting points

Procedure

1. 1

   Disconnect upstream oxygen sensor
   Locate the upstream oxygen sensor (before catalytic converter). Disconnect the electrical connector by pressing the release tab. Using a 22mm oxygen sensor socket, carefully unthread the sensor from the exhaust pipe. Remove sensor completely and set aside in safe location.
   Torque spec

   O2 Sensor45 Nm (33 lb-ft)
2. 2

   Disconnect downstream oxygen sensor
   Locate the downstream oxygen sensor (after catalytic converter). Disconnect the electrical connector. Using a 22mm oxygen sensor socket, carefully unthread the sensor from the exhaust pipe. Remove sensor and set aside. Mark sensor locations if both sensors appear identical to ensure correct reinstallation.
   Torque spec

   O2 Sensor45 Nm (33 lb-ft)
3. 3

   Remove catalytic converter heat shields
   Using a 10mm socket, remove all heat shield mounting bolts. There are typically multiple shields covering the catalytic converter. Carefully remove shields and set aside. Inspect shields for damage or excessive corrosion and replace if necessary.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
4. 4

   Support catalytic converter assembly
   Position a jack or support stand under the catalytic converter to support its weight during removal. Ensure the support is stable and positioned to prevent the converter from falling when disconnected.
5. 5

   Disconnect front exhaust flange
   Locate the flange connection between the exhaust manifold and catalytic converter inlet. Using a 14mm socket, remove the flange bolts (typically 2 bolts with spring-loaded nuts). Separate the flange connection and remove the old gasket. Clean flange surfaces thoroughly with a wire brush.
   Torque spec

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

   Disconnect rear exhaust flange
   Locate the flange connection between the catalytic converter outlet and the mid-pipe. Using a 14mm socket, remove the flange bolts. Separate the flange connection and remove the old gasket. Clean both flange surfaces with a wire brush to ensure proper sealing.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
7. 7

   Remove exhaust hanger supports
   Identify any rubber exhaust hangers supporting the catalytic converter section. Using a 14mm socket, remove hanger bolts as needed to allow converter removal. Note hanger positions for reassembly.
   Torque spec

   Hanger Bolts20 Nm (15 lb-ft)
8. 8

   Remove catalytic converter
   With all connections disconnected, carefully lower and remove the catalytic converter assembly from the vehicle. Inspect mounting points and exhaust pipes for damage or excessive corrosion that may affect universal converter installation.
9. 9

   Prepare universal catalytic converter
   Test-fit the universal catalytic converter to verify inlet and outlet pipe diameters match. The universal converter may require cutting to length or may need adapter pipes welded. If welding is required, position the converter to match OEM placement and ensure adequate clearance from body panels, fuel lines, and brake lines. Mark cutting points if necessary.
10. 10

    Install universal catalytic converter
    Position the universal catalytic converter in place with new exhaust flange gaskets at both connections. Apply anti-seize compound to new flange bolt threads. Support the converter with a jack or stand. If using clamp-style universal converter, position clamps at inlet and outlet but do not fully tighten yet. If welding is required, tack-weld first and verify alignment before final welding.
11. 11

    Connect front exhaust flange
    Install new exhaust gasket at the front flange connection. Apply anti-seize compound to flange bolt threads. Hand-thread flange bolts and torque to specification using a torque wrench. Ensure flange surfaces are fully seated and gasket is properly compressed.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
12. 12

    Connect rear exhaust flange
    Install new exhaust gasket at the rear flange connection. Apply anti-seize compound to flange bolt threads. Hand-thread flange bolts and torque to specification. Verify flange alignment is correct and gasket is seated properly.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
13. 13

    Reinstall exhaust hangers
    Reconnect rubber exhaust hangers to support the catalytic converter section. Install and torque hanger bolts to specification. Verify that exhaust system has proper clearance from chassis, suspension components, and body panels throughout full suspension travel.
    Torque spec

    Hanger Bolts20 Nm (15 lb-ft)
14. 14

    Reinstall oxygen sensors
    Apply anti-seize compound to oxygen sensor threads only (avoid getting anti-seize on sensor tip). Thread upstream and downstream oxygen sensors into their respective bungs by hand to avoid cross-threading. Torque sensors to specification using 22mm oxygen sensor socket. Reconnect both electrical connectors, ensuring they click securely into place.
    Torque spec

    O2 Sensor45 Nm (33 lb-ft)
15. 15

    Reinstall heat shields
    Position heat shields over catalytic converter, ensuring proper alignment with mounting holes. Install heat shield bolts and torque to specification. Verify shields do not contact the converter or create rattle points.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)

Reassembly

1. Double-check all flange bolts, oxygen sensors, and hanger bolts are torqued to specification
2. Verify all electrical connectors for oxygen sensors are fully seated and locked
3. Inspect entire exhaust system for adequate clearance from fuel lines, brake lines, body panels, and suspension components
4. If universal converter was welded, verify all welds are complete and free of leaks
5. Lower vehicle from jack stands carefully

Verification

• Start engine and allow to idle. Listen for any exhaust leaks at flange connections - a ticking or hissing sound indicates a leak requiring re-torquing or gasket replacement
• Check for exhaust leaks around oxygen sensor installations
• Verify no exhaust components contact body, frame, or suspension during idle
• Rev engine moderately and verify no rattles from heat shields or exhaust contact points
• Test drive vehicle and monitor for check engine light. Oxygen sensor codes (P0420, P0430, P0130-P0141) may appear if sensors were damaged during removal or if universal converter is not functioning properly
• Use OBD-II scanner to verify oxygen sensor readings are responding properly (voltage cycling between 0.1-0.9V at operating temperature)
• Perform final under-vehicle inspection after test drive to check for any leaks or loose components

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