Exhaust Intermediate Pipe

Exhaust Intermediate Pipe - 2.5L, Hybrid





Removal

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Vehicle Jacking and Lifting.

2.5L

2. Remove and discard the 3 exhaust intermediate pipe-to-exhaust downpipe nuts.

2.5L hybrid

3. Remove and discard the 3 exhaust intermediate pipe-to-catalytic converter manifold nuts.

All vehicles

4. NOTICE: Only use hand tools when removing or installing the spring nuts or damage may occur to the exhaust intermediate pipe flange studs.

NOTE: When loosening the exhaust intermediate pipe spring nuts, alternately loosen the nuts from side to side.

Remove and discard the two 10-mm catalytic converter-to-exhaust intermediate pipe spring nuts and remove the intermediate pipe.

Installation

All vehicles

1. Inspect the exhaust intermediate pipe flange studs for damage.
- If damaged, replace stud(s), or if stud comes out when removing nut(s), replace the stud(s).

2. If replacing the exhaust intermediate pipe flange stud(s), use the C-Frame and Screw Installer/Remover to push the 10-mm stud out of the flange.





3. NOTE: When positioning the new 10-mm stud in the exhaust intermediate flange, make sure to line up the new stud seat knurls with witness knurl grooves in the exhaust intermediate flange.

If replacing the exhaust intermediate pipe flange stud(s), use a C-clamp and a deep well socket to push the 10-mm stud fully into the flange.

- Make sure the stud is fully and evenly seated into the flange.





4. NOTICE: Replace the gasket by hand. Do not rotate the gasket back and forth during installation. Doing so may lessen the gaskets ability to seal and stay correctly positioned during assembly.

NOTE: Thoroughly clean the sealing surfaces of the flanges using a finishing pad. Inspect the cleaned sealing surface for nicks and scratches and replace as necessary.

Install a new converter-to-exhaust intermediate pipe gasket by hand.

5. Install the 2 new 10-mm catalytic converter-to-exhaust intermediate pipe spring nuts and alternately tighten RH side to LH side in sequence in 3 stages:
- Stage 1: Tighten to 5 Nm (44 lb-in).

- Stage 2: Tighten to 15 Nm (133 lb-in).

- Stage 3: Tighten to 25 Nm (18 lb-ft).

2.5L hybrid

6. Install 3 new exhaust intermediate pipe-to-catalytic converter manifold nuts.
- Tighten to 25 Nm (18 lb-ft).

2.5L

7. Install 3 new exhaust intermediate pipe-to-exhaust downpipe nuts.
- Tighten to 25 Nm (18 lb-ft).