This procedure covers the removal and replacement of the tailpipe assembly on a 2019-2024 Toyota RAV4 with the 2.5L I4 engine, including disconnecting from the muffler and rubber hangers.

Warnings

Tools required

Parts

• Tailpipe assembly × 1 — Use OEM specification
• Exhaust flange gasket × 1 — Use OEM specification
• Exhaust flange bolts × 2 — Replace if corroded

Preparation

1. Ensure the exhaust system is completely cool to the touch
2. Raise the vehicle using a floor jack and support securely on jack stands at the rear subframe or designated jack points
3. Spray penetrating oil on the exhaust flange bolts and allow to soak for 10-15 minutes if fasteners appear corroded
4. Visually inspect the tailpipe routing and identify the connection point to the muffler and all rubber hanger locations

Procedure

1. 1

   Locate tailpipe connection point
   Position yourself under the rear of the vehicle. Locate the flange connection between the muffler outlet and the tailpipe inlet, typically positioned just forward of the rear axle. Identify the two flange bolts and spring-loaded nuts securing the connection.
2. 2

   Remove exhaust flange bolts
   Using a 14mm wrench to hold the spring-loaded nut and a 14mm socket on the bolt head, loosen and remove both exhaust flange bolts. Work slowly to avoid stripping corroded fasteners. If bolts are seized, apply additional penetrating oil and allow to soak. Remove and discard the old flange gasket.
3. 3

   Support the tailpipe
   Support the tailpipe weight with one hand or have an assistant hold it to prevent strain on the rubber hangers. The tailpipe will still be held in position by the rubber hangers at this point.
4. 4

   Disconnect rear rubber hanger
   Locate the rearmost rubber hanger that supports the tailpipe tip. Spray with penetrating oil if needed. Using a pry bar or by hand, twist and pull the tailpipe hanger rod out of the rubber isolator mounted to the vehicle body. Work the metal hanger rod side-to-side while pulling to release it from the rubber bushing.
5. 5

   Disconnect middle rubber hanger
   Move forward to the middle rubber hanger location. Using the same technique, twist and pull the tailpipe hanger rod out of the rubber isolator. The tailpipe should now be free to remove. Lower it carefully from under the vehicle.
6. 6

   Clean flange mating surface
   Using a wire brush, thoroughly clean the muffler outlet flange surface, removing all old gasket material, carbon deposits, and corrosion. The surface must be clean and flat for proper sealing with the new gasket.
7. 7

   Prepare new tailpipe
   Inspect the new tailpipe inlet flange for any shipping debris or protective coating. Clean the flange surface if needed. Apply a thin coat of anti-seize compound to the threads of the exhaust flange bolts only, not to the gasket or flange faces.
8. 8

   Install new flange gasket
   Position the new exhaust flange gasket onto the muffler outlet flange. Align the bolt holes and ensure the gasket seats flat against the flange face. Do not apply any sealant or anti-seize to the gasket itself.
9. 9

   Position new tailpipe
   Lift the new tailpipe into position under the vehicle. Insert the hanger rods into the rubber isolators, working from front to rear. You may need to manipulate the pipe and use a pry bar to stretch the rubber isolators enough to insert the hanger rods. Align the tailpipe inlet flange with the muffler outlet flange and gasket.
10. 10

    Install and torque flange bolts
    Insert both exhaust flange bolts through the flanges and start the spring-loaded nuts by hand. Tighten both bolts evenly in a cross pattern, first snug by hand, then torque to specification using a torque wrench. Ensure the flanges remain parallel during tightening.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
11. 11

    Verify tailpipe alignment
    Check that the tailpipe exits concentrically through the rear bumper cutout with even clearance all around. The pipe should not contact the bumper, body panels, or suspension components. Adjust by loosening the flange bolts slightly and repositioning if necessary, then re-torque.

Reassembly

1. Ensure all rubber hangers are fully seated and the tailpipe is properly supported
2. Verify adequate clearance between the tailpipe and all nearby components including the rear bumper, suspension, and fuel tank
3. Double-check that exhaust flange bolts are torqued to specification

Verification

• Lower the vehicle from jack stands and start the engine
• Listen for any exhaust leaks at the flange connection, indicated by a ticking or hissing sound
• Check for visible exhaust gases escaping from the flange area
• Rev the engine slightly and verify the tailpipe does not contact any body panels or suspension components during engine torque movement
• Take a short test drive and verify no rattles or abnormal exhaust noise
• Re-inspect the flange connection after the system has heated and cooled once to confirm the gasket has properly sealed

More procedures for this vehicle