This procedure covers the removal and replacement of the upstream oxygen sensor (Bank 1 Sensor 1) on the 2019-2024 Toyota RAV4 with 2.5L I4 gas engine.

Warnings

Tools required

Parts

• Upstream oxygen sensor (Bank 1 Sensor 1) × 1 — Use OEM specification
• Anti-seize compound × 1 — Nickel-based, sensor-safe

Preparation

1. Ensure engine is completely cold before beginning work
2. Park vehicle on level surface and engage parking brake
3. Place wheel chocks behind rear wheels
4. Raise front of vehicle using floor jack and secure on jack stands at manufacturer-specified lift points
5. Locate upstream oxygen sensor on exhaust manifold (forward-most sensor in exhaust system)

Procedure

1. 1

   Disconnect oxygen sensor electrical connector
   Locate the wiring harness connector attached to the upstream oxygen sensor. Press the release tab and carefully pull the connector apart. Do not pull on the wires themselves. The connector may be secured with a clip or bracket - remove if present.
2. 2

   Apply penetrating oil if needed
   If the sensor has not been replaced recently, spray penetrating oil around the sensor threads where it enters the exhaust manifold. Allow to soak for 5-10 minutes. This helps prevent thread damage during removal.
3. 3

   Remove the upstream oxygen sensor
   Using the 22mm oxygen sensor socket and ratchet with extension, carefully loosen the oxygen sensor by turning counterclockwise. The sensor socket has a slot to allow the wiring to pass through. Once loosened, unscrew by hand and remove the sensor from the exhaust manifold.
4. 4

   Inspect and clean threads
   Inspect the threads in the exhaust manifold for damage or excessive carbon buildup. Use a wire brush to clean the threads if necessary. Check that the new oxygen sensor matches the old unit in terms of connector type and thread pitch.
5. 5

   Apply anti-seize to new sensor
   Apply a thin coat of nickel-based anti-seize compound to only the first 2-3 threads of the new oxygen sensor. Do not apply anti-seize beyond this point, and never apply it to the sensor tip. Excess anti-seize can contaminate the sensor and cause premature failure.
   ⚠Use only nickel-based anti-seize rated for oxygen sensors. Standard copper anti-seize can damage the sensor.
6. 6

   Install new oxygen sensor
   Thread the new oxygen sensor into the exhaust manifold by hand, ensuring it starts straight and threads smoothly. Hand-tighten until snug, then use the oxygen sensor socket and torque wrench to tighten to specification.
   Torque spec

   O2 Sensor45 Nm (33 lb-ft)
7. 7

   Reconnect electrical connector
   Route the oxygen sensor wiring away from hot exhaust components and moving parts. Connect the electrical connector until it clicks into place. Secure any wiring clips or brackets that were removed earlier.
8. 8

   Lower vehicle
   Remove jack stands and carefully lower the vehicle to the ground. Remove wheel chocks.

Reassembly

1. Ensure oxygen sensor wiring is routed properly and secured away from heat and moving components
2. Verify electrical connector is fully seated and locked

Verification

• Start the engine and verify no exhaust leaks are present at the oxygen sensor location
• Using an OBD-II scanner, clear any stored diagnostic codes and verify no new oxygen sensor codes appear after a short test drive
• Monitor engine performance and verify the check engine light does not illuminate
• After engine reaches operating temperature, verify proper sensor operation through live data on scan tool (voltage should fluctuate between 0.1-0.9V for standard sensors)

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