Asphalt pavement pothole repair with hot-mix asphalt (HMA) is one of common maintenance activities for transportation agencies, which requires considerable energy use and generates greenhouse gas emission (GHG) for production of HMA. This study investigated mechanical performance and environmental impact of an innovative pothole repair method using recycled asphalt pavement (RAP) and preheating. According to the common failure modes of asphalt patch, comprehensive laboratory tests were conducted on the lab-made and field-cored specimens, including indirect (IDT) strength, interface bonding strength, and abrasion resistance at dry, freeze-thaw, and pore pressure conditions. Based on laboratory testing results of the HMA with 0%–50% RAP contents, HMA with 30% RAP was selected for pothole repair in the field test section because it can lead to satisfactory moisture resistance and comparable interface bonding and abrasion resistance with traditional HMA. After repair, field cores were collected for additional laboratory analysis. The results show that moisture resistance of the patching materials decreased with the increase of RAP content. The freezing thaw (FT) effect was found to cause more degradation in IDT and interface shear strength than dynamic pore water pressure simulated in moisture induced stress tester (MIST), while the pore water pressure caused more abrasion loss of patching material. On the other hand, preheating the pothole before repair was found to be effective in enhancing mechanical performance and durability of asphalt patch under various environmental conditions. With the application of preheating, asphalt patching repaired by HMA with 30% RAP can achieve comparable or better performance than that made with traditional HMA, while reducing energy consumption and carbon emission.