Exhaust Pipe - Rear Section

This procedure covers the removal and replacement of the rear exhaust section (resonator and muffler assembly) on a 2018-2024 Toyota Camry with the 2.5L I4 engine.

Warnings

Tools required

Parts

• Rear exhaust pipe assembly (muffler and resonator) × 1 — Use OEM specification or quality aftermarket equivalent
• Exhaust flange gasket × 1 — Use OEM specification
• Rubber exhaust hangers × 3 — Replace if cracked or damaged

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind front wheels
3. Allow exhaust system to cool completely (at least 30 minutes after engine shutdown)
4. Raise rear of vehicle using floor jack and support securely on jack stands under frame rails
5. Apply penetrating oil to all exhaust flange bolts and hanger hardware, allow to soak while preparing tools

Procedure

1. 1

   Locate rear exhaust section connection point
   Position yourself under the vehicle and locate the flange connection between the mid-pipe and rear exhaust section. This is typically located just forward of the rear axle beam. Identify the two flange bolts and spring-loaded nuts that secure this connection.
2. 2

   Remove flange bolts at mid-pipe connection
   Using a 14mm socket, remove the two bolts securing the exhaust flange connection. These bolts pass through a spring-loaded clamp. Support the rear exhaust section with one hand while removing the second bolt to prevent it from dropping suddenly. Note the condition of the exhaust gasket for replacement.
3. 3

   Separate flange connection
   Gently pry the flange connection apart using a pry bar if needed. The gasket may be stuck due to heat and corrosion. Use a twisting motion or light taps with a rubber mallet if necessary. Avoid damaging the flange surfaces on the mid-pipe.
4. 4

   Remove rear exhaust hanger at axle beam
   Locate the rubber exhaust hanger where the rear pipe connects to a bracket near the rear axle beam. Use a pry bar or push the pipe to compress the rubber hanger and slide it off the bracket hook. This may require significant force due to the tight fit of the rubber hanger.
5. 5

   Remove middle exhaust hanger
   Locate the next rubber exhaust hanger forward of the first one. Use the same technique to disconnect the rubber hanger from its bracket. The exhaust section should now be mostly free.
6. 6

   Remove final rear hanger and extract exhaust
   Disconnect the final rubber hanger at the rear of the muffler assembly. Carefully maneuver the entire rear exhaust section (resonator and muffler) out from under the vehicle. It may require angling and rotation to clear the rear suspension components and spare tire well.
7. 7

   Clean flange surface and inspect connection
   Using a wire brush, thoroughly clean the flange surface on the mid-pipe where the new rear section will connect. Remove all old gasket material, rust, and carbon deposits. Inspect the flange for cracks or damage. Clean the threads of the flange bolt holes.
8. 8

   Inspect and prepare hangers and brackets
   Inspect all three exhaust hanger brackets on the vehicle underbody for damage or excessive rust. Inspect the rubber hangers on the new exhaust section (or transfer good condition hangers from old section if reusing). Replace any cracked or deteriorated rubber hangers before installation.
9. 9

   Position new rear exhaust section
   Lift the new rear exhaust section into position under the vehicle. Begin by engaging the rearmost rubber hanger onto its bracket hook. Work forward, connecting each rubber hanger. The exhaust pipe should hang naturally from the hangers with the flange aligned to the mid-pipe connection. Use a rubber mallet to help seat stubborn rubber hangers.
10. 10

    Install new flange gasket
    Place the new exhaust flange gasket between the mid-pipe flange and the rear section flange. Ensure proper alignment with both flanges. The gasket should fit snugly without gaps.
11. 11

    Install and torque flange bolts
    Apply a thin coat of anti-seize compound to the threads of both flange bolts. Insert both bolts through the flange and spring clamp, threading them into the nuts on the opposite side. Hand-tighten both bolts first, then torque to specification in a cross pattern (alternating between bolts). Verify the flange connection is fully seated with no gaps.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
12. 12

    Verify exhaust alignment and hanger position
    Visually inspect the entire rear exhaust section to ensure it hangs evenly with adequate clearance from the fuel tank, rear suspension components, and underbody. There should be at least 25mm (1 inch) clearance from all components. Adjust by repositioning rubber hangers if needed. The tailpipe should exit centered in the rear bumper cutout.

Reassembly

1. Ensure all three rubber hangers are fully seated on their brackets and the exhaust hangs with proper clearance
2. Verify the flange connection shows no signs of exhaust leak (no gaps, gasket fully compressed)
3. Double-check that flange bolts are torqued to specification

Verification

• Lower vehicle to ground and remove jack stands
• Start engine and listen for exhaust leaks at the flange connection while engine is at idle
• Perform a brief test drive and verify no rattling or contact noises from the exhaust system
• Visually inspect the flange connection after test drive for any signs of exhaust soot indicating a leak
• Check that exhaust tips are properly positioned and aligned with bumper cutout

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