Remove and replace the intermediate pipe section of the exhaust system, including disconnection from the catalytic converter and rear exhaust section.

Warnings

Tools required

Parts

• Intermediate pipe assembly × 1 — Use OEM specification
• Exhaust flange gaskets × 2 — Front and rear donut gaskets
• Exhaust flange nuts × 4 — 14mm flange nuts

Preparation

1. Park vehicle on level ground and allow exhaust system to cool completely (minimum 2 hours)
2. Disconnect negative battery terminal if working near any oxygen sensor wiring
3. Raise vehicle evenly and support on jack stands at manufacturer lift points
4. Spray all exhaust flange nuts with penetrating oil and allow to soak for 15-30 minutes
5. Inspect intermediate pipe routing and identify all hangers and connection points

Procedure

1. 1

   Remove heat shield if equipped
   Locate any heat shields covering the intermediate pipe. Remove retaining bolts using 10mm socket and set aside heat shield for reinstallation.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
2. 2

   Disconnect oxygen sensor if equipped
   If the intermediate pipe includes an oxygen sensor, disconnect the electrical connector by pressing the release tab. If removing sensor, use 22mm O2 sensor socket to carefully remove sensor from bung. Note sensor orientation for reinstallation.
   ⚠O2 sensors are fragile. Do not use excessive force or impact tools which may damage the sensor element.
   Torque spec

   O2 Sensor45 Nm (33 lb-ft)
3. 3

   Remove front flange connection
   Locate the front flange connecting the intermediate pipe to the catalytic converter or front pipe. Support the intermediate pipe with one hand or wire. Remove the two 14mm flange nuts. Carefully separate the joint using a pry bar if needed. Remove and discard the old gasket.
   ⚠Flange studs may break if nuts are seized. Apply heat carefully if penetrating oil is insufficient.
   Torque spec

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

   Remove rear flange connection
   Locate the rear flange connecting the intermediate pipe to the rear exhaust section. Remove the two 14mm flange nuts. Separate the joint carefully and remove old gasket. The intermediate pipe should now be free at both ends.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
5. 5

   Disconnect exhaust hangers
   Locate rubber exhaust hangers supporting the intermediate pipe (typically 1-2 hangers). Use a pry bar or lubricant to slide the pipe hooks out of the rubber isolators. Support the pipe to prevent it from falling.
   ⚠Exhaust hangers are under tension. Control the pipe as hangers are released to prevent injury.
6. 6

   Remove intermediate pipe
   Lower the intermediate pipe down and out from under the vehicle. Maneuver carefully around any nearby components such as fuel lines or brake lines. Inspect the removed pipe for damage or excessive corrosion.
7. 7

   Clean flange surfaces
   Use a wire brush to thoroughly clean both the front and rear flange surfaces on the mating exhaust components. Remove all old gasket material, carbon deposits, and rust. Clean the flange studs with a wire brush to ensure proper thread engagement.
   ℹ️Proper sealing requires clean, flat flange surfaces. Take time to remove all debris.
8. 8

   Prepare new intermediate pipe
   If installing oxygen sensor in new pipe, apply a thin coat of anti-seize compound to sensor threads only (avoid getting anti-seize on sensor tip). Thread sensor into bung and torque to specification. Install new flange gaskets on both front and rear connections.
   Torque spec

   O2 Sensor45 Nm (33 lb-ft)
9. 9

   Install intermediate pipe to hangers
   Lift new intermediate pipe into position and engage the hooks into the rubber exhaust hangers. Ensure pipe is properly aligned with front and rear flanges before fully seating hangers. You may need to temporarily support the pipe with wire or a helper.
10. 10

    Connect rear flange
    Align the rear flange with new gasket in place. Start both flange nuts by hand to ensure proper thread engagement. Apply anti-seize compound to the threads. Tighten nuts evenly in a cross pattern to the specified torque.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
11. 11

    Connect front flange
    Align the front flange with new gasket in place. Start both flange nuts by hand. Apply anti-seize compound to the threads. Tighten nuts evenly in a cross pattern to the specified torque.
    Torque spec

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

    Reinstall heat shield and connect O2 sensor
    If heat shield was removed, reinstall using original bolts and torque to specification. Reconnect oxygen sensor electrical connector if equipped, ensuring connector locks securely and wiring is routed away from exhaust heat.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)

Reassembly

1. Verify all flange nuts are torqued to specification and that anti-seize was applied
2. Ensure exhaust hangers are fully seated and pipe is not under stress or misaligned
3. Check that oxygen sensor wiring (if equipped) is properly routed and secured away from moving or hot components
4. Reconnect negative battery terminal if it was disconnected
5. Lower vehicle from jack stands carefully

Verification

• Start engine and listen for exhaust leaks at both flange connections while engine is cold
• Visually inspect all connections for signs of exhaust gas leakage (soot staining)
• After engine reaches operating temperature, re-check for leaks and unusual noises
• Take a short test drive and verify no exhaust rattles, drones, or check engine lights appear
• If oxygen sensor was disturbed, verify no check engine light for O2 sensor codes after several drive cycles

More procedures for this vehicle