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Home >> Toyota >> 2025 >> RAV4 Plug-In Hybrid SE >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Intake / Exhaust System (A25A-FXS) - Service Information (PHEV) >> Exhaust Manifold >> Removal [06/2020 - ] >> Procedure

Removal [06/2020 - ]: Procedure

  1. REMOVE NO. 1 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 13 [06/2020 - 12/2021] , or refer to PROCEDURE - Step 13 [12/2021 - 10/2022] , or refer to PROCEDURE - Step 13 [10/2022 - ]

  2. REMOVE NO. 2 ENGINE UNDER COVER ASSEMBLY 

    Refer to PROCEDURE - Step 14 [06/2020 - 12/2021] , or refer to PROCEDURE - Step 14 [12/2021 - 10/2022] , or refer to PROCEDURE - Step 14 [10/2022 - ]

  3. REMOVE FRONT FLOOR COVER LH 

    Refer to PROCEDURE - Step 42 [06/2020 - 12/2021] , or refer to PROCEDURE - Step 42 [12/2021 - 10/2022] , or refer to PROCEDURE - Step 42 [10/2022 - ]

  4. REMOVE ENGINE UNDER COVER HEAT INSULATOR 

    Refer to PROCEDURE - Step 14 [06/2020 - 12/2021] , or refer to PROCEDURE - Step 14 [12/2021 - 10/2022] , or refer to PROCEDURE - Step 14 [10/2022 - ]

  5. REMOVE FRONT EXHAUST PIPE ASSEMBLY 
    WARNING:

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

    1. Detach the wire harness clamp.
      GTY996314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the air fuel ratio sensor (for Sensor 2) connector.
    3. Remove the 2 bolts, 2 nuts and disconnect the front exhaust pipe assembly from the exhaust manifold and tail exhaust pipe assembly.
      GTY996318Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the front exhaust pipe assembly from the 2 exhaust pipe supports.
    5. Remove the 2 gaskets from the front exhaust pipe assembly.
  6. REMOVE HEATER PROTECTOR 
    1. Remove the bolt, 2 nuts and heater protector.
      GTY996302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE AIR FUEL RATIO SENSOR (for Sensor 1) 

    Refer to PROCEDURE - Step 6

  8. REMOVE WIRE HARNESS CLAMP BRACKET 
    WARNING:

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

    1. Remove the bolt and wire harness clamp bracket.
      GTY996317Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. SEPARATE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 
    WARNING:

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

    1. Remove the 3 bolts and separate the No. 1 exhaust manifold heat insulator from the exhaust manifold.
      GTY996320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE NO. 1 FRONT FLOOR HEAT INSULATOR 
    WARNING:

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

    1. Remove the 2 nuts and No. 1 front floor heat insulator from the vehicle body.
      GTY995936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE MANIFOLD STAY 
    WARNING:

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

    1. Remove the bolt, nut and manifold stay from the exhaust manifold and cylinder block sub-assembly.
      GTY771566Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE EXHAUST MANIFOLD 
    WARNING:

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

    1. Using a 12 mm deep socket wrench, remove the 7 nuts and separate the exhaust manifold from the cylinder head sub-assembly.
      GTY996322Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the No. 1 exhaust manifold heat insulator and exhaust manifold.
    3. Remove the exhaust manifold to head gasket from the cylinder head sub-assembly.
      GTY996321Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Remove the 3 bolts and No. 2 exhaust manifold heat insulator from the exhaust manifold.
      GTY996840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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