Exhaust Gasket - Rear

Replace the rear exhaust gasket between the exhaust manifold/front pipe and mid-pipe assembly on a 2019-2024 Toyota RAV4 2.5L I4 FWD.

Warnings

Tools required

Parts

• Rear exhaust gasket (donut gasket) × 1 — Use OEM specification
• Exhaust flange bolts × 2 — Replace if corroded

Preparation

1. Ensure engine and exhaust system are completely cool to the touch
2. Park vehicle on level ground and apply parking brake
3. Place wheel chocks behind rear wheels
4. Apply penetrating oil to all exhaust flange bolts and allow to soak for 15-20 minutes

Procedure

1. 1

   Raise and support vehicle
   Raise the front of the vehicle using a floor jack at the designated front jack point. Secure with jack stands under the frame rails. Ensure vehicle is stable before working underneath.
2. 2

   Locate rear exhaust connection
   Position yourself under the vehicle near the front passenger area. Locate the rear exhaust flange connection where the front pipe/catalytic converter assembly connects to the mid-pipe. This is approximately below the passenger seat area.
3. 3

   Remove heat shield (if equipped)
   If a heat shield is present covering the flange connection, remove the retaining bolts using a 10mm socket. Set aside heat shield and hardware for reinstallation.
   Torque spec

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

   Support mid-pipe
   Place a jack stand or wooden block under the mid-pipe approximately 12 inches behind the flange connection to support the weight of the rear exhaust section when disconnected. Do not allow exhaust to hang by hangers alone.
5. 5

   Remove exhaust flange bolts
   Using a 14mm socket, remove the two exhaust flange bolts connecting the front pipe to the mid-pipe. Apply steady pressure and avoid stripping bolt heads. If bolts are seized, apply additional penetrating oil and allow more soak time. Work bolts back and forth if necessary.
6. 6

   Separate exhaust sections
   Carefully separate the front pipe from the mid-pipe. The sections should pull apart once bolts are removed. If stuck, gently tap around the flange joint with a rubber mallet. Do not pry aggressively as this may damage flange surfaces.
7. 7

   Remove old gasket
   Remove the old donut-style exhaust gasket from between the flanges. It may be stuck to either the front pipe or mid-pipe flange. Inspect both flange surfaces for damage, cracks, or warping.
8. 8

   Clean flange surfaces
   Use a wire brush to thoroughly clean both exhaust flange surfaces, removing all carbon deposits, rust, and old gasket material. Flange surfaces must be clean and smooth for proper gasket sealing. Wipe clean with a rag.
9. 9

   Install new gasket
   Position the new donut gasket onto the front pipe flange. Ensure the gasket is properly centered and seated in the flange recess. The gasket should fit snugly without gaps around the perimeter.
10. 10

    Reconnect exhaust sections
    Align the mid-pipe flange with the front pipe flange, ensuring the gasket remains properly positioned. Carefully bring the two sections together, verifying proper alignment before inserting bolts.
11. 11

    Install and torque flange bolts
    Apply anti-seize compound to the threads of both flange bolts. Insert bolts through the flange and hand-tighten. Using a torque wrench, tighten bolts in a cross-pattern to specification. Verify both bolts are evenly tightened.
    Torque spec

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

    Reinstall heat shield
    If heat shield was removed, reposition it over the flange connection and install retaining bolts. Torque heat shield bolts to specification.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)
13. 13

    Remove support and lower vehicle
    Remove the support from under the mid-pipe. Inspect all exhaust hangers to ensure they are properly seated. Lower vehicle from jack stands and remove jack.

Reassembly

1. Ensure all exhaust hangers are properly seated and not stressed
2. Verify adequate clearance between exhaust components and vehicle underbody/fuel lines
3. Double-check that all fasteners are torqued to specification

Verification

• Start engine and allow to idle. Listen for exhaust leaks at the repaired flange connection
• Look for visible exhaust smoke or fumes escaping from the flange joint
• Rev engine to 2500-3000 RPM and verify no exhaust leaks under load
• After engine reaches operating temperature, re-inspect connection area for any signs of leaking
• Take a short test drive and verify no exhaust odor in cabin and no unusual exhaust sounds

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