This procedure covers the removal and replacement of the intermediate exhaust pipe on a 2019-2024 Toyota RAV4 with the 2.5L I4 gasoline engine.

Warnings

Tools required

Parts

• Intermediate pipe assembly × 1 — Use OEM specification
• Exhaust flange gasket (front connection) × 1 — Use OEM specification
• Exhaust flange gasket (rear connection) × 1 — Use OEM specification
• Exhaust flange bolts/nuts × 1 — Recommended to replace

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. Allow exhaust system to cool completely (minimum 1 hour after last operation)
4. Apply penetrating oil to all exhaust flange bolts and hanger bolts if vehicle has corrosion
5. Raise vehicle using floor jack and support securely on jack stands at manufacturer-specified lift points
6. Verify vehicle is stable before working underneath

Procedure

1. 1

   Remove front heat shield (if equipped)
   Locate the heat shield covering the intermediate pipe. Remove the heat shield mounting bolts using a 12mm socket. Some models may have multiple heat shield sections that need to be removed or loosened for access. Set bolts aside for reinstallation.
   Torque spec

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

   Disconnect oxygen sensor connector
   Locate the downstream oxygen sensor mounted on the intermediate pipe. Press the connector release tab and carefully disconnect the electrical connector. Move the wiring harness out of the work area to prevent damage.
3. 3

   Remove oxygen sensor from intermediate pipe
   Using a 22mm wrench or oxygen sensor socket, remove the downstream oxygen sensor from the intermediate pipe. Turn counterclockwise to remove. Inspect sensor condition and threads. Set aside in a safe location if reusing.
   ⚠Oxygen sensor threads are delicate. Do not force or cross-thread during removal or installation.
   Torque spec

   O2 Sensor45 Nm (33 lb-ft)
4. 4

   Disconnect front flange connection
   Locate the front flange where the intermediate pipe connects to the catalytic converter or front pipe. Remove the two 14mm flange bolts/nuts securing this connection. Use penetrating oil if bolts are seized. Support the intermediate pipe weight as you remove the last fastener.
   Torque spec

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

   Disconnect rear flange connection
   Locate the rear flange where the intermediate pipe connects to the rear exhaust section. Remove the two 14mm flange bolts/nuts securing this connection. Keep the intermediate pipe supported to prevent it from dropping.
   Torque spec

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

   Release exhaust hangers
   The intermediate pipe is supported by rubber exhaust hangers. Using an exhaust hanger removal tool or pry bar, carefully pry the intermediate pipe studs from the rubber hangers. Work from front to back, supporting the pipe as hangers are released. Note hanger positions for reinstallation.
   ⚠Rubber exhaust hangers are under tension. Use controlled force to prevent the pipe from dropping suddenly when released.
7. 7

   Remove intermediate pipe
   With all connections and hangers released, carefully lower and remove the intermediate pipe from the vehicle. Maneuver it past any crossmembers or suspension components. Inspect the old pipe for damage or excessive corrosion to verify replacement is needed.
8. 8

   Clean flange surfaces and inspect hangers
   Using a wire brush, thoroughly clean both front and rear flange mating surfaces on the remaining exhaust components. Remove all old gasket material and corrosion. Inspect rubber exhaust hangers for cracks or deterioration and replace if damaged.
9. 9

   Prepare new intermediate pipe
   Unpack the new intermediate pipe and verify it matches the original. Install new flange gaskets on both the front and rear connections. Apply anti-seize compound to the oxygen sensor threads (threads only, not the sensor tip).
   ⚠Do not apply anti-seize to the oxygen sensor tip or ceramic element as this will damage the sensor.
10. 10

    Install intermediate pipe into position
    Position the new intermediate pipe into the vehicle, maneuvering it past suspension components. Align the pipe so the front and rear flanges are approximately positioned. Insert the pipe studs into the rubber exhaust hangers, working from front to back.
11. 11

    Install front flange connection
    Align the front flange with the catalytic converter or front pipe connection. Install new flange bolts/nuts with anti-seize compound applied to threads. Hand-tighten only at this stage to allow for alignment adjustment.
    Torque spec

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

    Install rear flange connection
    Align the rear flange with the rear exhaust section. Install new flange bolts/nuts with anti-seize compound applied to threads. Hand-tighten only. Verify the entire intermediate pipe is properly aligned with no binding or stress on connections.
    Torque spec

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

    Torque flange bolts
    Using a torque wrench, tighten the front flange bolts to 45 Nm (33 lb-ft) in a cross pattern. Then torque the rear flange bolts to 45 Nm (33 lb-ft) in a cross pattern. Verify all exhaust hangers are properly seated and the pipe hangs correctly with no contact to undercarriage components.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
14. 14

    Install oxygen sensor
    Install the oxygen sensor into the intermediate pipe. Thread it in by hand first to prevent cross-threading. Once hand-tight, use a 22mm wrench or oxygen sensor socket to torque the sensor to 45 Nm (33 lb-ft). Connect the electrical connector until it clicks into place.
    Torque spec

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

    Reinstall heat shield
    Position the heat shield(s) back over the intermediate pipe. Install and torque the heat shield bolts to 10 Nm (7 lb-ft). Ensure the heat shield does not contact the exhaust pipe and has proper clearance.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)

Reassembly

1. Double-check all flange bolts are torqued to specification
2. Verify oxygen sensor electrical connector is fully seated and locked
3. Ensure all exhaust hangers are properly engaged and pipe has adequate clearance from undercarriage
4. Verify heat shields are secure and properly positioned

Verification

• Lower vehicle from jack stands
• Start engine and listen for exhaust leaks at flange connections (should be no hissing or ticking sounds)
• Verify no exhaust odor in cabin or around vehicle
• Check that oxygen sensor is reading properly (no check engine light or pending codes)
• Perform a short test drive and recheck all connections for leaks or rattles
• Visually inspect underneath vehicle after test drive to confirm no contact between exhaust and undercarriage components

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