Last Modified: 05-08-2025 6.11:8.1.0 Doc ID: RM100000001FC53
Model Year Start: 2019 Model: RAV4 HV Prod Date Range: [11/2018 - 02/2019]
Title: A25A-FXS (INTAKE / EXHAUST): EXHAUST MANIFOLD: REMOVAL; 2019 MY RAV4 HV [11/2018 - 02/2019]

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during exhaust manifold removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure

Necessary Procedure

Effect/Inoperative Function when Necessary Procedure not Performed

Link
  • Replacement of air fuel ratio sensor
  • Gas leak from exhaust system is repaired

Inspection After Repair
  • Poor idle, etc.
  • Engine start function, etc.

2019 - 2020 MY RAV4 HV [11/2018 - 08/2020]; A25A-FXS (ENGINE CONTROL): SFI SYSTEM (w/o Canister Pump Module): INITIALIZATION

CAUTION:

  • To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.
  • To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.

PROCEDURE

1. REMOVE NO. 2 ENGINE UNDER COVER ASSEMBLY

Click here 2019 - 2025 MY RAV4 HV [11/2018 -        ]; A25A-FXS (LUBRICATION): OIL LEVEL SENSOR: REMOVAL+

2. REMOVE ENGINE UNDER COVER HEAT INSULATOR

Click here 2019 MY RAV4 HV [11/2018 - 02/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+

3. REMOVE FRONT EXHAUST PIPE ASSEMBLY

CAUTION:

To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.

(a) Detach the 2 wire harness clamps.

(b) Disconnect the air fuel ratio sensor (for Sensor 2) connector.

(c) Remove the 2 bolts, 2 nuts and disconnect the front exhaust pipe assembly from the exhaust manifold and tail exhaust pipe assembly.

(d) Remove the front exhaust pipe assembly from the 2 exhaust pipe supports.

(e) Remove the 2 gaskets from the front exhaust pipe assembly.

4. REMOVE AIR FUEL RATIO SENSOR (for Sensor 1)

Click here 2019 MY RAV4 HV [11/2018 - 02/2019]; A25A-FXS (ENGINE CONTROL): AIR FUEL RATIO SENSOR: REMOVAL+

5. REMOVE WIRE HARNESS CLAMP BRACKET

CAUTION:

To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

(a) Remove the bolt and wire harness clamp bracket.

6. SEPARATE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

CAUTION:

To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

(a) Remove the 5 bolts and separate the No. 1 exhaust manifold heat insulator from the exhaust manifold.

7. SEPARATE NO. 1 UPPER FRONT FLOOR HEAT INSULATOR

CAUTION:

To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

(a) Remove the 2 nuts and separate the No. 1 upper front floor heat insulator from the vehicle body.

8. REMOVE MANIFOLD STAY

CAUTION:

To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

(a) Remove the bolt, nut and manifold stay from the exhaust manifold and cylinder block sub-assembly.

9. REMOVE EXHAUST MANIFOLD

CAUTION:

To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

(a) Using a 12 mm deep socket wrench, remove the 7 nuts and separate the exhaust manifold from the cylinder head sub-assembly.

(b) Remove the No. 1 upper front floor heat insulator, No. 1 exhaust manifold heat insulator and exhaust manifold.

(c) Remove the exhaust manifold to head gasket from the cylinder head sub-assembly.

10. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

(a) Remove the 6 bolts and No. 2 exhaust manifold heat insulator from the exhaust manifold.