This procedure covers the removal and replacement of the rear exhaust pipe section on a 2019-2024 Toyota RAV4 with the 2.5L I4 gas engine, including disconnection from the center pipe and removal from rubber hangers.

Warnings

Tools required

Parts

• Rear exhaust pipe section with muffler × 1 — Use OEM specification or aftermarket equivalent
• Exhaust flange gasket × 1 — Use OEM specification
• Exhaust rubber hangers (if damaged) × 2 — Use OEM specification

Preparation

1. Ensure engine and exhaust system are completely cool to the touch
2. Raise vehicle on lift or securely support on jack stands at appropriate lift points
3. Visually inspect exhaust system for damage and note routing of components
4. Apply penetrating oil to all exhaust flange bolts and hanger bolts, allow 15-30 minutes to soak
5. If equipped, remove rear heat shield bolts for access (retain for reinstallation)

Procedure

1. 1

   Remove rear heat shield if equipped
   Locate the rear exhaust heat shield bolts. Using a 10mm socket, remove the heat shield mounting bolts. Carefully lower the heat shield and set aside for reinstallation. Note the orientation and position of any clips or spacers.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
2. 2

   Support the rear exhaust section
   Position a floor jack with a block of wood under the rear muffler section to support its weight. Raise the jack just enough to take the weight off the rubber hangers but not to lift the vehicle. This prevents the exhaust from falling when disconnected.
   ⚠Ensure jack is stable and will not slip when exhaust weight is transferred to it.
3. 3

   Disconnect oxygen sensor connector
   Locate the rear oxygen sensor wiring connector near the mid-pipe to rear pipe flange connection. Press the release tab and disconnect the electrical connector. Route the wiring to prevent damage during exhaust removal. If the oxygen sensor will remain with the removed section, ensure wiring has adequate length.
4. 4

   Remove center-to-rear pipe flange bolts
   Locate the flange connection between the center exhaust pipe and rear section (typically just forward of the rear axle). Using a 14mm socket and ratchet, remove the two flange bolts and nuts. If bolts are seized, apply additional penetrating oil and use a wire brush to clean threads. Separate the flange connection slightly and remove the old gasket.
   ⚠Seized bolts may break. If a bolt breaks, the stud may need to be extracted or the flange section replaced.
   Torque spec

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

   Remove rear exhaust hangers
   Locate the two rubber exhaust hangers supporting the rear exhaust section. Using a pry bar or large screwdriver, carefully pry the exhaust hanger rod from each rubber isolator. Work the rod out of the rubber mount by pushing the exhaust to one side while prying. Inspect rubber hangers for cracking or deterioration.
6. 6

   Lower and remove rear exhaust section
   With all connections disconnected and hangers released, carefully lower the floor jack to bring down the rear exhaust section. Guide the exhaust pipes clear of the underbody and heat shields. Remove the section from under the vehicle. If the oxygen sensor remains installed, protect it from damage during handling.
7. 7

   Clean flange surfaces and inspect
   Using a wire brush and scraper, thoroughly clean the mating surface of the center pipe flange. Remove all old gasket material, rust, and debris to ensure a proper seal. Inspect the flange for cracks or warping. Clean the stud threads with a wire brush and apply anti-seize compound to the threads.
8. 8

   Install new rear exhaust section
   Position the new rear exhaust section under the vehicle and raise it into approximate position using the floor jack. Align the rear hanger rods with the rubber isolators but do not fully seat yet. Verify the oxygen sensor connector routing is correct and will reach without tension.
9. 9

   Install new flange gasket and connect pipes
   Place the new exhaust flange gasket onto the center pipe flange studs. Align the rear exhaust section flange with the center pipe flange, ensuring the gasket is properly positioned. Hand-thread the flange nuts onto the studs. Do not fully tighten yet.
10. 10

    Seat exhaust hangers
    With the flange connection hand-tight, manipulate the rear exhaust section to align the hanger rods with the rubber isolators. Push each hanger rod fully into its rubber mount. A lubricant such as soapy water on the rubber can ease installation. Ensure both hangers are fully seated and supporting the exhaust.
11. 11

    Verify alignment and clearance
    Before final tightening, verify the entire rear exhaust section has adequate clearance from the fuel tank, rear axle, body panels, and heat shields. Check that the tailpipe exit is properly aligned with the rear bumper cutout. Adjust position as needed by shifting at the flange connection.
12. 12

    Torque flange bolts to specification
    Using a torque wrench and 14mm socket, torque the exhaust flange bolts to specification in a cross-pattern. Verify anti-seize compound was applied to threads during installation. After torquing, recheck exhaust alignment and clearances.
    Torque spec

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

    Reconnect oxygen sensor connector
    Reconnect the rear oxygen sensor electrical connector. Ensure the connector clicks securely and that wiring is routed away from hot exhaust components and moving suspension parts. Secure any wiring clips to the vehicle body.
14. 14

    Reinstall heat shield if equipped
    Position the rear heat shield in its original location, aligning all mounting holes. Install the heat shield bolts and torque to specification using a 10mm socket and torque wrench. Ensure the heat shield has proper clearance from the exhaust pipe and does not contact moving components.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)

Reassembly

1. Double-check all flange bolts are torqued to specification
2. Verify all exhaust hangers are fully seated in rubber isolators
3. Confirm oxygen sensor connector is secure and wiring is properly routed
4. Ensure heat shields are reinstalled and have proper clearance
5. Remove floor jack and lower vehicle from lift or jack stands

Verification

• Start the engine and listen for exhaust leaks at the flange connection (hissing or ticking sounds indicate leak)
• With engine running, visually inspect the flange joint for escaping exhaust gases
• Allow engine to reach operating temperature and recheck for leaks under load
• Verify no exhaust buzzing or rattling noises from contact with body or suspension components
• Check that tailpipe exits properly through bumper cutout without contact
• Perform a short test drive and listen for any abnormal exhaust sounds or rattles over bumps
• After test drive, recheck flange bolts for tightness and inspect hangers for proper seating

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