how to troubleshoot a failing catalytic converter in Toyota RAV4 XA50 (2019-2024)

Solution

1. Preparation

• Gather necessary tools and parts.
• Disconnect the battery to ensure safety while working on the exhaust system.
• Allow the engine to cool if it has been running recently.

2. Remove the Catalytic Converter

• Tools Required: Socket set, torque wrench, exhaust pipe cutter (if necessary).
• Locate the catalytic converter and identify the mounting bolts.
• Using the socket set, remove the bolts securing the catalytic converter to the exhaust manifold and the exhaust pipe.
• If the bolts are rusted, apply penetrating oil and allow it to sit before attempting to remove them.
• Carefully lower the catalytic converter from its position. If necessary, cut the exhaust pipe to remove it.

3. Inspect and Clean

• Examine the catalytic converter for any signs of internal damage or clogging. If the substrate is broken or melted, replacement is necessary.
• If the catalytic converter is not damaged, consider cleaning it with a specialized catalytic converter cleaner as per the manufacturer's instructions.

4. Install New or Cleaned Catalytic Converter

• Position the catalytic converter back into place and align it with the exhaust manifold and exhaust pipe.
• Reinstall the mounting bolts and torque them to the manufacturer's specifications (typically around 30-40 lb-ft, but check the service manual for exact values).

5. Reconnect Battery and Test

• Reconnect the battery terminals.
• Start the engine and allow it to reach operating temperature.
• Monitor for any unusual sounds or leaks from the exhaust system.