Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM100000001QPY4
Model Year Start: 2021 Model: RAV4 Prod Date Range: [08/2020 -           ]
Title: A25A-FKS (INTAKE / EXHAUST): EXHAUST PIPE: INSTALLATION; 2021 - 2024 MY RAV4 [08/2020 -        ]

INSTALLATION

PROCEDURE

1. INSTALL NO. 7 EXHAUST PIPE SUPPORT BRACKET

(a) Install the No. 7 exhaust pipe support bracket to the body with the 2 bolts.

Torque:

29 N·m {296 kgf·cm, 21 ft·lbf}

(b) Install the exhaust pipe support to the No. 7 exhaust pipe support bracket.

2. INSTALL NO. 6 EXHAUST PIPE SUPPORT BRACKET

(a) Install the No. 6 exhaust pipe support bracket to the body with the 2 bolts.

Torque:

29 N·m {296 kgf·cm, 21 ft·lbf}

(b) Install the exhaust pipe support to the No. 6 exhaust pipe support bracket.

3. INSTALL NO. 2 EXHAUST PIPE SUPPORT BRACKET

Click here 2019 - 2024 MY RAV4 [11/2018 -        ]; FRONT SUSPENSION: FRONT SUSPENSION MEMBER (for Gasoline Model): INSTALLATION+

4. INSTALL TAIL EXHAUST PIPE BAFFLE SUB-ASSEMBLY

HINT:

  • Perform this procedure only when replacement of the tail exhaust pipe baffle sub-assembly is necessary.
  • If the tail exhaust pipe baffle sub-assembly is removed, replace it with a new one.
  • There are 2 types of shapes for the tail exhaust pipe assembly.

    *a

    2 protrusion type

    *b

    1 protrusion type

    *c

    Tail exhaust pipe end

    *d

    Protrusion

(a) 2 protrusion type:

(1) Align the cutout of a new tail exhaust pipe baffle sub-assembly with the protrusion (for position alignment) of the tail exhaust pipe assembly as shown in the illustration.

*a

Protrusion (for position alignment)

*b

Protrusion (for stopper)

*c

Cutout

(2) Insert the exhaust tailpipe baffle sub-assembly to the position where it can be pressed in by hand.

(3) Using a plastic-faced hammer and wooden block, uniformly tap the tail exhaust pipe baffle sub-assembly onto the tail exhaust pipe assembly.

NOTICE:

  • Lightly tap the top and bottom of the exhaust tailpipe baffle sub-assembly so that the exhaust tailpipe baffle sub-assembly is pressed in without a tilt.
  • Press the exhaust tailpipe baffle sub-assembly in until the protrusion (for stopper) on the exhaust tailpipe assembly is fit into the cutout area of the exhaust tailpipe baffle sub-assembly.
  • Check that there is no looseness in the exhaust tailpipe baffle sub-assembly.

*a

Baffle Edge

*b

Protrusion (for stopper)

*c

Cutout

*d

Wooden Block

(b) 1 protrusion type:

(1) Set a new tail exhaust pipe baffle sub-assembly to the tail exhaust pipe assembly.

(2) Insert the exhaust tailpipe baffle sub-assembly to the position where it can be pressed in by hand.

(3) Using a plastic-faced hammer and wooden block, uniformly tap the tail exhaust pipe baffle sub-assembly onto the tail exhaust pipe assembly.

NOTICE:

  • Lightly tap the top and bottom of the exhaust tailpipe baffle sub-assembly so that the exhaust tailpipe baffle sub-assembly is pressed in without a tilt.
  • Press the exhaust tailpipe baffle sub-assembly in until the protrusion on the exhaust tailpipe assembly is fit into the cutout area of the exhaust tailpipe baffle sub-assembly.
  • Check that there is no looseness in the exhaust tailpipe baffle sub-assembly.

*a

Baffle Edge

*b

Protrusion

*c

Cutout

*d

Wooden Block

5. INSTALL FRONT EXHAUST PIPE ASSEMBLY

(a) Install a new gasket to the front exhaust pipe assembly.

(b) Connect the front exhaust pipe assembly to the 2 exhaust pipe supports.

(c) Install the front exhaust pipe assembly to the exhaust manifold with 2 new nuts.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

6. INSTALL AIR FUEL RATIO SENSOR (for Sensor 2)

Click here 2021 - 2024 MY RAV4 [08/2020 -        ]; A25A-FKS (ENGINE CONTROL): AIR FUEL RATIO SENSOR: INSTALLATION+

7. INSTALL TAIL EXHAUST PIPE ASSEMBLY

(a) Install a new gasket to the front exhaust pipe assembly.

(b) Connect the tail exhaust pipe assembly to the 3 exhaust pipe supports.

(c) Install the tail exhaust pipe assembly to the front exhaust pipe assembly with 2 new bolts.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

8. INSPECT FOR EXHAUST GAS LEAK

If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

(a) Perform "Inspection After Repair" after repairing an exhaust gas leak.

Click here 2021 MY RAV4 RAV4 HV [08/2020 - 12/2021]; A25A-FKS (ENGINE CONTROL): SFI SYSTEM: INITIALIZATION 2022 - 2024 MY RAV4 RAV4 HV [12/2021 -        ]; A25A-FKS (ENGINE CONTROL): SFI SYSTEM: INITIALIZATION