Toyota RAV4 2000-05

Exhaust Manifold

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Removal & Installation





Click image to see an enlarged view

Fig. Exploded view of the exhaust manifold and components-RAV4

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Front exhaust pipe from the exhaust manifold, using a 14mm deep socket wrench; discard the gasket
     
    Main Oxygen (O 2 ) sensor and the sub Oxygen (O 2 ) sensor connectors
     
    6 bolts and the upper manifold heat insulator
     
    2 right-hand exhaust manifold stay-to-cylinder block bolts
     
    6 nuts, the exhaust manifold and the Three-Way Catalytic (TWC) converter assembly
     
    Exhaust manifold and front catalytic converter
     

  4.  

To install:

  1. Install or connect the following:

    Catalytic converter to the exhaust manifold. Tighten the nuts/bolts to 22 ft. lbs. (29 Nm).
     
    Exhaust manifold and the front TWC assembly. Tighten the 6 nuts, in several passes to 36 ft. lbs. (49 Nm).
     
    Right-hand manifold stay. Tighten both bolts to 31 ft. lbs. (42 Nm).
     
    Manifold upper heat insulator with the 6 bolts and attach the main Oxygen (O 2 ) and the sub Oxygen (O 2 ) sensor connectors
     
    Front exhaust pipe to the TWC, using a new gasket. Tighten the 3 nuts to 46 ft. lbs. (62 Nm).
     
    Negative battery cable
     

  2.  
  3. Start the engine and be sure that there are no exhaust leaks.
  4.  

2.0L Engine


Click image to see an enlarged view

Fig. Exploded view of the exhaust manifold and components-2.0L engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Front exhaust pipe from the exhaust manifold, using a 14mm deep socket wrench; discard the gasket
     
    Main Oxygen (O2) sensor and the sub Oxygen (O2) sensor connectors
     
    6 bolts and the upper manifold heat insulator
     
    2 right-hand exhaust manifold stay-to-cylinder block bolts
     
    6 nuts, the exhaust manifold and the Three-Way Catalytic (TWC) converter assembly
     
    Exhaust manifold and front catalytic converter
     

  4.  

To install:

  1. Install or connect the following:

    Catalytic converter to the exhaust manifold. Tighten the nuts/bolts to 22 ft. lbs. (29 Nm).
     
    Exhaust manifold and the front TWC assembly. Tighten the 6 nuts, in several passes to 36 ft. lbs. (49 Nm).
     
    Right-hand manifold stay. Tighten both bolts to 31 ft. lbs. (42 Nm).
     
    Manifold upper heat insulator with the 6 bolts and attach the main Oxygen (O2) and the sub Oxygen (O2) sensor connectors
     
    Front exhaust pipe to the TWC, using a new gasket. Tighten the 3 nuts to 46 ft. lbs. (62 Nm).
     
    Negative battery cable
     

  2.  
  3. Start the engine and be sure that there are no exhaust leaks.
  4.  



Click image to see an enlarged view

Fig. Exhaust manifold and components-2.0L engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Front exhaust pipe from the exhaust manifold, using a 14mm deep socket wrench; discard the gasket
     
    Main Oxygen (O 2 ) sensor and the sub Oxygen (O 2 ) sensor connectors
     
    6 bolts and the upper manifold heat insulator
     
    2 right side exhaust manifold stay-to-cylinder block bolts
     
    6 nuts, the exhaust manifold and the Three-Way Catalytic (TWC) converter assembly
     
    Exhaust manifold and front catalytic converter
     

  4.  

To install:

  1. Install or connect the following:

    Catalytic converter to the exhaust manifold. Tighten the nuts/bolts to 22 ft. lbs. (29 Nm).
     
    Exhaust manifold and the front TWC assembly. Tighten the 6 nuts, in several passes to 36 ft. lbs. (49 Nm).
     
    Right side manifold stay. Tighten both bolts to 31 ft. lbs. (42 Nm).
     
    Manifold upper heat insulator with the 6 bolts and attach the main Oxygen (O 2 ) and the sub Oxygen (O 2 ) sensor connectors
     
    Front exhaust pipe to the TWC, using a new gasket. Tighten the 3 nuts to 46 ft. lbs. (62 Nm).
     
    Negative battery cable
     

  2.  
  3. Start the engine and be sure that there are no exhaust leaks.
  4.  

 
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