This procedure covers removal and replacement of the intermediate exhaust pipe on a 2018-2024 Toyota Camry with the 2.5L I4 engine, connecting the catalytic converter to the rear muffler section.

Warnings

Tools required

Parts

• Intermediate exhaust pipe × 1 — Use OEM specification
• Exhaust flange gaskets × 2 — Front and rear flange gaskets
• Exhaust flange bolts and springs × 1 — Replace if corroded

Preparation

1. Ensure engine and exhaust system are completely cool to the touch
2. Park vehicle on level ground, engage parking brake, and chock rear wheels
3. Spray all exhaust flange bolts and hanger bolts with penetrating oil and allow to soak for 30 minutes minimum
4. Raise front of vehicle and support securely on jack stands at manufacturer-recommended lift points
5. Verify adequate working clearance under vehicle

Procedure

1. 1

   Support the exhaust system
   Position a floor jack with a block of wood under the rear muffler section to support the weight of the exhaust once the intermediate pipe is disconnected. Raise just enough to take the weight off the hangers without lifting the vehicle.
2. 2

   Remove front flange connection
   Locate the front flange connection between the catalytic converter outlet and the intermediate pipe inlet. Remove the two flange bolts and springs using a 14mm socket. Separate the flanges and remove the old gasket. If bolts are seized, apply additional penetrating oil and use heat if necessary.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
3. 3

   Remove rear flange connection
   Locate the rear flange connection between the intermediate pipe outlet and the rear muffler inlet pipe. Remove the two flange bolts and springs using a 14mm socket. Carefully separate the flanges and remove the old gasket.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
4. 4

   Disconnect exhaust hangers
   Locate the rubber exhaust hangers supporting the intermediate pipe (typically two hangers). Use a pry bar or exhaust hanger tool to carefully work the metal hanger loops out of the rubber isolators. Apply soapy water to hangers if needed to ease removal. Avoid cutting rubber isolators unless replacement is planned.
   ⚠Do not over-stress rubber isolators as they can tear. Use controlled force and work the hanger free gradually.
5. 5

   Remove intermediate pipe
   With all connections disconnected, carefully maneuver the intermediate pipe out from under the vehicle. May require slight twisting or angling to clear frame rails and suspension components. Lower the support jack slightly if needed to create clearance.
6. 6

   Clean flange surfaces
   Use a wire brush to thoroughly clean both flange surfaces on the catalytic converter outlet and rear muffler inlet. Remove all old gasket material, carbon deposits, and corrosion. Surfaces must be clean and flat for proper sealing. Inspect flange faces for warping or damage.
7. 7

   Inspect and prepare hardware
   Inspect all flange bolts and springs for excessive corrosion or damage. Replace if threads are damaged or springs are weakened. Apply anti-seize compound to the threads of all flange bolts before installation.
   ℹ️Do not apply anti-seize to gasket surfaces or flange faces, only to bolt threads.
8. 8

   Install new intermediate pipe
   Position new flange gaskets at the front and rear connections with the correct orientation. Maneuver the new intermediate pipe into position, aligning the flanges with both the catalytic converter and rear muffler connections. Insert hanger loops into rubber isolators, using soapy water if needed.
9. 9

   Install and torque flange bolts
   Install flange bolts with springs at both front and rear connections. Thread bolts by hand first to ensure proper alignment. Tighten bolts evenly in a cross pattern to the specified torque of 45.0 Nm (33 lb-ft). Verify flanges are seated evenly with no gaps.
   ⚠Tighten flange bolts gradually in a cross pattern to prevent warping flanges or cracking gaskets.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
10. 10

    Verify hanger alignment
    Remove the support jack from under the rear muffler. Verify that all exhaust hangers are properly seated in rubber isolators and that the exhaust system hangs level without binding or stress. Check clearance between exhaust and underbody components, fuel tank, and suspension parts. Minimum 25mm clearance required.

Reassembly

1. Ensure all flange connections are tight and gaskets are properly seated with no gaps
2. Verify exhaust system has proper clearance from fuel lines, brake lines, and suspension components throughout full suspension travel
3. Double-check that all rubber hanger isolators are properly engaged

Verification

• Lower vehicle and start engine, allowing it to warm to operating temperature
• Listen for exhaust leaks at both flange connections while engine is running. No hissing or popping sounds should be present
• Perform a test drive and verify no rattles, vibrations, or exhaust odors in cabin
• After test drive, re-inspect all connections for signs of leaks (soot marks) and verify torque specs if needed
• Check exhaust hangers after 50-100 miles of driving to ensure they remain properly seated

More procedures for this vehicle