This procedure covers the removal and replacement of the front exhaust pipe (catalytic converter to manifold) on a 2019-2024 Toyota RAV4 with the 2.5L I4 engine.

Warnings

Tools required

Parts

• Front exhaust pipe assembly × 1 — Use OEM specification
• Exhaust flange gasket (manifold to front pipe) × 1 — Use OEM specification
• Exhaust flange gasket (front pipe to center pipe) × 1 — Use OEM specification
• Oxygen sensor (if reusing old sensor) × 1 — Reuse existing or replace if damaged

Preparation

1. Ensure engine and exhaust system are completely cold
2. Park vehicle on level surface and engage parking brake
3. Apply penetrating oil to all exhaust flange bolts and allow to soak
4. Raise vehicle using floor jack and secure on jack stands at proper lift points
5. Remove plastic engine undercover if equipped using appropriate fastener tool

Procedure

1. 1

   Disconnect oxygen sensor
   Locate the oxygen sensor electrical connector on the front pipe upstream of the catalytic converter. Press the release tab and disconnect the connector. Unclip the wiring harness from any retaining clips along the front pipe.
2. 2

   Remove oxygen sensor
   Using a 22mm O2 sensor socket, carefully remove the oxygen sensor from the front pipe. Turn counterclockwise and remove completely. Inspect sensor threads and replace if damaged. Keep sensor clean if reusing.
   ⚠Do not drop the oxygen sensor or allow contaminants to contact the sensing element.
3. 3

   Remove heat shield bolts
   If equipped with heat shields around the front pipe, remove the mounting bolts using a 12mm socket. Some shields may have multiple sections. Set shields and hardware aside for reinstallation.
   Torque spec

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

   Disconnect front pipe from catalytic converter
   Locate the spring-loaded bolts or flange bolts connecting the front pipe to the downstream catalytic converter. Using a 14mm socket, remove the two or three flange bolts. Support the front pipe to prevent it from falling.
   ⚠The front pipe will become loose and may shift. Ensure it is properly supported.
   Torque spec

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

   Remove exhaust hanger bolts
   Locate any rubber exhaust hangers supporting the front pipe. Using a 12mm socket, remove the hanger mounting bolts or carefully pry the hanger loops off their mounting brackets using a pry bar. Note hanger positions for reassembly.
   Torque spec

   Hanger Bolts20 Nm (15 lb-ft)
6. 6

   Disconnect front pipe from exhaust manifold
   Using a 14mm socket, remove the three exhaust flange nuts/bolts connecting the front pipe to the exhaust manifold. Work evenly to prevent binding. If studs break, they will need to be extracted from the manifold.
   ⚠Corroded studs may break flush with the manifold, requiring stud extractor tools or drill-out procedures.
   Torque spec

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

   Remove front pipe assembly
   Carefully maneuver the front pipe assembly down and out from under the vehicle. It may require slight rotation and tilting to clear subframe components and steering linkage. Remove and discard old gaskets from both flange surfaces.
8. 8

   Clean mating surfaces
   Using a wire brush and gasket scraper, thoroughly clean the exhaust manifold flange surface and the catalytic converter flange surface. Remove all old gasket material, carbon deposits, and corrosion. Ensure surfaces are flat and smooth for proper sealing.
9. 9

   Install oxygen sensor in new front pipe
   Apply a thin coat of anti-seize compound to the oxygen sensor threads only, keeping compound away from the sensor tip. Thread the sensor into the new front pipe by hand, then torque to specification using the O2 sensor socket.
   Torque spec

   O2 Sensor45 Nm (33 lb-ft)
10. 10

    Position new front pipe and install manifold gasket
    Position the new exhaust flange gasket on the exhaust manifold studs or flange. Carefully lift the new front pipe into position, aligning the upper flange with the exhaust manifold. Support the pipe while starting fasteners.
11. 11

    Install manifold flange bolts
    Apply anti-seize compound to the exhaust flange bolt threads. Install all three flange bolts finger-tight first, then torque in a star pattern to the specified value using a torque wrench and 14mm socket.
    Torque spec

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

    Connect front pipe to catalytic converter
    Position the new exhaust flange gasket between the front pipe and catalytic converter. Align the flanges and install the flange bolts finger-tight. Torque to specification in a cross pattern.
    Torque spec

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

    Install exhaust hangers
    Reconnect all rubber exhaust hangers to their mounting brackets. If using bolted hangers, torque the hanger bolts to specification. Ensure the exhaust system hangs freely without binding or tension.
    Torque spec

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

    Reinstall heat shields
    Reposition any heat shields removed earlier and install their mounting bolts. Torque heat shield bolts to specification. Ensure shields do not contact the exhaust pipe directly and have proper clearance.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)
15. 15

    Connect oxygen sensor wiring
    Route the oxygen sensor wiring harness away from hot exhaust components and moving parts. Secure the harness to any factory retaining clips. Connect the electrical connector to the vehicle harness until it clicks into place.

Reassembly

1. Reinstall engine undercover if equipped
2. Lower vehicle from jack stands
3. Verify all tools and parts have been removed from under vehicle
4. Double-check all fasteners are properly torqued

Verification

• Start the engine and allow it to reach operating temperature while monitoring for exhaust leaks at all flange connections
• Listen for unusual exhaust noise or hissing sounds indicating gasket leaks
• Check that no exhaust components are touching the chassis, suspension, or steering components
• Verify the check engine light does not illuminate and oxygen sensor is functioning properly using an OBD-II scanner if available
• After a short test drive, re-inspect all connections for leaks and proper clearance

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