Visual and functional inspection of emissions control components to verify proper operation and compliance with EPA/state regulations for a 2019-2024 Toyota RAV4 2.5L I4 gas engine.

Warnings

Tools required

Preparation

1. Ensure vehicle has been driven through at least one complete drive cycle if recently serviced or battery disconnected
2. Park vehicle on level ground and engage parking brake
3. Allow engine and exhaust system to cool completely if vehicle was recently operated
4. Verify fuel cap is present and in good condition before beginning inspection
5. Have vehicle registration and previous inspection records available for reference

Procedure

1. 1

   Connect OBD-II scanner and verify readiness monitors
   Connect OBD-II scanner to the diagnostic port located under the driver side dashboard. Turn ignition to ON position without starting engine. Check for diagnostic trouble codes (DTCs) and verify all emissions readiness monitors are complete. For 2019-2024 RAV4, all monitors except EVAP may show ready immediately after drive cycle. Document any pending or stored codes.
2. 2

   Check for active Check Engine Light or MIL
   With ignition ON, verify the Malfunction Indicator Lamp (MIL/Check Engine Light) illuminates during bulb check, then turns off after engine start. If MIL remains illuminated or flashes during operation, emissions inspection will fail. Record any illuminated warning lights on instrument cluster related to emissions systems.
3. 3

   Inspect fuel cap and EVAP system integrity
   Remove and inspect fuel cap for damaged gasket, cracks, or improper sealing. Check that cap clicks at least 3 times when tightened. Inspect visible EVAP lines under hood for cracks, disconnections, or damage. Verify charcoal canister (located near fuel tank on passenger side) is not saturated or damaged.
4. 4

   Inspect air intake system for leaks
   Open hood and visually inspect air filter housing and intake ductwork from air box to throttle body. Check all clamps and connections are secure. Remove air box cover and inspect air filter condition. A severely restricted or damaged air filter can affect emissions. Ensure no aftermarket modifications bypass emissions controls.
5. 5

   Inspect PCV system and vacuum lines
   Locate PCV valve in valve cover and inspect connecting hoses for cracks or disconnection. Check all vacuum lines visible in engine bay for proper routing, secure connections, and absence of cracks or deterioration. Pay special attention to brake booster vacuum line and purge valve connections.
6. 6

   Inspect oxygen sensors and wiring
   Locate upstream oxygen sensor (before catalytic converter) and downstream sensor (after converter) on exhaust manifold and mid-pipe. Inspect sensor wiring harnesses for damage, melting, or contact with hot exhaust components. Verify connectors are fully seated and free from corrosion. Do not disconnect sensors unless replacement is needed.
7. 7

   Inspect catalytic converter and exhaust system
   Raise vehicle safely if needed to inspect catalytic converter for physical damage, dents, or signs of internal substrate failure (rattling). Check all exhaust connections from manifold to tailpipe for leaks, rust-through, or loose clamps. Inspect heat shields for security. Any exhaust leaks before the downstream oxygen sensor will cause emissions failure.
8. 8

   Verify EGR system operation (if equipped)
   The 2019-2024 RAV4 2.5L uses cooled EGR system. Visually inspect EGR valve and cooler assembly on rear of engine for carbon buildup at connections or signs of leakage. Check EGR vacuum lines and electrical connector for damage. Use scanner to command EGR valve if capable and listen for valve operation.
9. 9

   Check for fluid leaks affecting emissions
   Inspect engine oil level and condition using dipstick. Excessive oil consumption can damage catalytic converter. Check for engine oil leaks that could contaminate oxygen sensors. Verify coolant level is correct as engine temperature directly affects emissions control systems. Look for any fuel leaks from injectors, fuel rail, or fuel lines.
10. 10

    Perform final scanner check and document results
    With engine at operating temperature, perform final OBD-II scan to verify no new codes have set. Confirm all readiness monitors remain complete. Print or record freeze frame data if any codes are present. Document inspection findings including monitor status, DTC codes if any, and physical condition of all emissions components inspected.

Reassembly

1. Reinstall air box cover if removed and secure all clips properly
2. Ensure fuel cap is properly tightened with at least 3 clicks
3. Verify all electrical connectors inspected are fully seated
4. Lower vehicle if raised for undercarriage inspection

Verification

• Confirm OBD-II scanner shows no active DTCs and all required monitors are ready/complete
• Verify Check Engine Light is off with engine running
• Start engine and listen for exhaust leaks or abnormal operation
• Confirm all inspection documentation is complete with monitor status and visual inspection results
• If emissions testing station scan will be performed, ensure at least 50 miles have been driven since any repairs

More procedures for this vehicle