Do-it-yourself resonator repair on viburnum without dismantling

In the practical Russian subcompact Lada Kalina, the exhaust system consists of several important components, among which there is undoubtedly a resonator. It is designed to ensure timely removal of combustion products from the working chambers of the cylinders. If the resonator functions correctly, then the motor is characterized by the ability to demonstrate the declared power indicator. In some cases, breakdowns occur and the resonator needs to be replaced, and sometimes the muffler needs to be replaced.

Differences between spare parts

Today on the market you can find an extremely large number of Kalina mufflers, the prices of which are too low. However, you need to understand how much an original spare part costs (to do this, just go to the official Lada website) in order to be able to distinguish between components made by hand. They will most likely last several times less than the original and, quite possibly, due to non-compliance with the technology, will even pose a danger to the life and health of the driver. Spare parts for model 1118 differ in the following parameters:

• material. The original spare part is made of aluminum or stainless steel. A product made of stainless steel will be quite difficult to find; they are often made to order. If the muffler is made of any other material, it is a fake;
• price. The cost of the original component is estimated at a thousand rubles or more, while fakes can cost less;
• weight. For the original it is higher than for the fake, since the real model is equipped with thicker walls and also contains a soundproofing layer;

The difference between the Kalina sedan, station wagon and hatchback muffler is that in the first and second models the product tube is curved, and the last model is equipped with a muffler with straight inlet and outlet pipes.

Manufacturers

Parts for Lada 1118 can be purchased from the following manufacturers:

• Lada . The AL category factory part has all the necessary characteristics for installation. It is made of aluminized steel, and the addition of silicon to the mixture only better protects the product from rust and improves resistance to temperature changes and aggressive chemical compounds. You can purchase such a part from official representatives of the company or in company stores;

• BalakovoRezinoTechnika. This Russian manufacturer, in addition to spare parts for domestic cars (VAZ, KamAZ, GAZ), is engaged in the production of rubber products as its main activity;
• Auto kit . This company operates in St. Petersburg and produces, in particular, roll-up mufflers for the VAZ 1118;
• Melitopol plant of automobile and tractor mufflers "UTAS". Engaged in the manufacture of exhaust gas systems. The company's assortment includes 150 types of products, including intake and exhaust pipes, mufflers for the VAZ 1118. The products produced are excellent for Moskvich, VAZ, MTZ, GAZ, ZAZ and many other brands of vehicles;
• SKS . The company's products meet the declared characteristics and have the required thickness and standard size. It is made, like the factory components, from aluminized steel, and can be installed along with the factory components of Kalina 1118;

• Polmostrow . The products of this Polish company include muffler models for the Kalina sedan and fully comply with the factory requirements of the domestic manufacturer. The design has seams that are welded automatically, which eliminates the appearance of unevenness and roughness. Rolling takes place along the tank of the product, which is done using German equipment. After manufacturing, the product undergoes technical control, testing, and only after that it is sent for sale.

Features of replacing parts

After replacing the muffler on Kalina, in rare cases you may encounter the following problems:

After approximately 3-4 years of operation of the car, some elements of its exhaust become unusable. Of course, in this case we are not talking about foreign cars, but about cars from a domestic manufacturer. Why does the muffler fail so quickly? It's simple: firstly, it is usually made from low-quality metal, and secondly, constant exposure to various external factors contributes to the very rapid development of corrosion.

Be that as it may, in this article we will consider not the reasons for the rather rapid wear of the exhaust system, but the process of replacing its main elements: an additional muffler and a catalyst. An important point: the instructions for doing the work yourself are valid for Lada cars of the Kalina, Priora, Grant models.

Malfunctions

The following signs indicate a muffler malfunction:

• the engine makes a growling sound;
• Exhaust gases enter the interior from under the bottom of the car, which is easily determined by the smell.

The main causes of muffler malfunction:

• water, it causes corrosion in the muffler and, over time, holes form in it;
• a sharp change in temperature leads to the formation of condensation;
• mechanical damage (impacts from the muffler due to its low location);
• shaking on the roads leads to disruption of connections;
• muffler burnout.

When malfunctions occur, a problem arises - repair or replacement? In any case, measures must be taken, otherwise the powerful roar of the car will disturb others, get on the owner’s nerves and attract the attention of traffic police officers. If there is no experience in repair work, or the muffler is seriously damaged, then it is worth replacing it

If there is no experience in repair work, or the muffler is seriously damaged, then it is worth replacing it.

Replacing the muffler on Lada Kalina

The easiest way to replace a worn muffler is in the inspection hole. The main and additional mufflers are connected to each other by means of a metal clamp. To dismantle it, you will need two 13mm spanners or wrenches. With one wrench we hold the bolt nut, preventing it from turning, and with the second we unscrew it. After the bolts are unscrewed and removed, carefully remove the clamp.

Next, move the exhaust pipe of the muffler back a little and remove the connecting gasket (connecting ring). Then we move the exhaust system pipe to the rear suspension beam.

Now we remove the muffler mounting bracket from the first shock-absorbing rubber pad. Then, using a small pry bar, remove the muffler from the second cushion. We remove it, carefully removing it from under the rear suspension beam.

Replacing the resonator yourself

As when replacing the main muffler, to replace the resonator we will need to remove the mounting clamp. To do this, use two 13mm wrenches to unscrew the bolts that tighten it. By the way, if due to severe corrosion it is impossible to unscrew the bolts, you can go another way: cut them off using a grinder and subsequently replace them with new ones.

The resonator is bolted to the catalyst with two bolts. Before unscrewing, it is recommended to treat them with WD-40 and tap them with a hammer. After the nuts have loosened, use two wrenches to unscrew the bolts securing the resonator to the neutralizer. An important point: do not unscrew the nuts completely. If the car does not have a neutralizer, unscrew the bolts securing the resonator to the exhaust pipe.

Next, carefully lift the resonator and remove the rear rubber cushion from it, and then the front one.

After this, holding the resonator, finally unscrew the nuts and remove the spring washers. Remove the bolts and dismantle the resonator.

Installing a new resonator is done in the reverse order.

It should be noted that in case of severe corrosion of the mounting bolts, clamp and the resonator itself, a somewhat non-standard method can be used: the faulty unit is cut off using a grinder from the corrugation to the main muffler. The new resonator is installed in place of the old one using electric welding.

How to replace the resonator?

Replacing the resonator involves performing a certain list of actions, which we will discuss further.

1. We unscrew the nuts that hold the clamp that secures the butt connection of the muffler pipe and the resonator unit of the system. We recommend that you first treat the threaded connections with a penetrating substance or its equivalent, since they tend to stick and, in a non-soaked state, are very difficult to unscrew. If this approach does not have the desired effect, then the clamp will have to be “trimmed” with a special tool.
2. Next, using gentle taps with a hammer, knock the marked clamp off the joint. In some cases, fasteners can be removed without using a hammer.
3. Now we remove the muffler from two rubber suspension elements, the first of which is located in the rear beam area, and the second in the area of ​​the main exhaust pipe.
4. We remove the muffler.
5. In the Lada Kalina, the resonator itself is attached to the neutralizer using three steel nuts, which are also prone to sticking. In order to “fight” this phenomenon, it would be useful to pre-treat them with the same penetrating composition. If the effect is unattainable, then a grinder will “help”.
6. When the resonator is dismantled, the installation of a new analogue is carried out in accordance with the algorithm reverse to the removal procedure. You can also resort to another option for replacing the exhaust circuit assembly we are considering.
7. An exhausted system element should be cut out within the range: from the corrugated component to the main muffler pipe.
8. Now you will have to resort to welding, through which the new resonator is “mounted” in place of the removed product.

Replacing the resonator Lada Kalina

The car became painfully loud. The muffler was new (see how to replace it here), but I still decided to crawl under the car and check the tightness of the entire exhaust system. It turned out that the resonator pipe (additional muffler) was rotten in the place between the main and additional mufflers.

In such a situation, the resonator must be replaced. To replace the resonator on Kalina, it must be removed (this is obvious). To do this, you will have to unscrew three nuts securing it to the exhaust manifold and 2 nuts of the clamp connecting the resonator to the main muffler. The work is best done from the pit.

The task at first glance is simple, but there is one “but” - the nuts on the manifold could become very stuck and it will be very difficult to unscrew them. Spray them with WD-40, use strong wrenches. For convenience, you can remove the engine protection.

After everything is unscrewed, remove it from the hangers and pull it out. The resonator itself was in good condition, but the two elbows going to the clamp were rotten. Therefore, I decided not to spend money and buy a new one, but to try to solve the problem with the help of welding and a grinder. If things are much worse for you or you just don’t want to fool your head, then buy a new resonator and install it in the reverse order (you don’t have to read further).

What is needed to replace the muffler corrugation for Kalina

To replace the corrugation quickly and efficiently you will need:

• Conditions for the procedure. The street and the jack are not the best combination for such a case. When the muffler pipe is removed, the old one is dismantled with a grinder and a new corrugation is installed by welding, it is better to use a lift or inspection hole, and carry out the work in a dry and warm room with sufficient lighting and compliance with safety regulations.
• Equipment. Any test benches, etc. It is not necessary to replace the muffler corrugation. But at a minimum, you need a cutter and a welding machine.
• Tool. The minimum set is open-end wrenches, screwdrivers, a hammer, that is, everything that is included in a standard repair kit.
• Additional details. You will need WD-40 lubricant, anti-corrosion agents, new gaskets, O-rings, clamps, and replacement bolts.
• Experience in welding work, as well as experience in replacing corrugations. Without it, it is better not to try to experiment - in the best case, you will soon have to install a new corrugation again, in the worst case, you will have to change the entire muffler and resonator.

Exhaust system "Lada Kalina"

After processing the air-fuel mixture, residual substances must be released from the engine cavity. An exhaust system is used for these purposes. Without it, operating any car is simply impossible.

The exhaust system of the Lada Kalina car consists of several elements:

• an exhaust manifold;
• exhaust pipe;
• main muffler;
• additional;
• catalytic converter.

All parts of the exhaust system not only allow you to safely and quickly remove exhaust gases from the engine, but also reduce noise levels . And the neutralizer serves to reduce carbon monoxide emissions, that is, it reduces the toxicity of exhaust on the Lada Kalina.

It should be noted that the mufflers for Lada Kalina sedans, hatchbacks and station wagons will be slightly different. Thus, the device labeling must fully comply with the VAZ labeling. For example, VAZ-1117 (Lada Kalina hatchback) requires model 1117, and VAZ-1118 (Lada Kalina sedan) requires muffler 1118. For the Lada Kalina station wagon modification, a device marked 1118-1200010 is installed.

What does the muffler consist of?

The main part of the exhaust system serves to absorb noise. On the Lada Kalina car, this function is performed by a pipe, which includes the muffler itself and its resonator.

The thickening is the resonator, the end is the muffler itself

The pipe has a completely sealed body, which is manufactured using the rolling method, that is, without the use of a welding machine. Thanks to this, the muffler is durable and does not corrode. And the resonator, which is also located in the pipe, consists of several closed chambers. These chambers are connected to each other by small tubes with holes in them. Thanks to this structure, the resonator can quickly smooth out all acoustic vibrations. In the latest modifications of the Lada Kalina, the inside of the resonator is lined with sound-absorbing material.

The three-chamber device allows you to reduce the noise level in the car

Unfortunately, the quality of mufflers for Kalina leaves much to be desired. Often their service life does not exceed 40–50 thousand kilometers. Therefore, the car owner has to think about which “gluker” to choose. Today, mechanisms for the Lada Kalina are presented at a variety of prices - from the cheapest to the most expensive. However, it is better to navigate the world of auto parts using the following parameters:

• muffler material: original spare parts are made of stainless steel or aluminum, they will last as long as possible and ensure high-quality exhaust removal;
• cost: you should not purchase a device below the 1 thousand ruble mark;
• weight: an original and high-quality “glushak” will weigh more than a fake, since the chambers are equipped with thicker walls and sound-proofing materials.

Professional work

Pros: selection of the best and inexpensive part, quick replacement of the muffler corrugation, diagnostics of other parts (including the catalyst - the main culprit of corrugation failures), guarantee for all types of work.

Cons: slightly higher price. However, it is not as great as it might seem to those who want to save money.

Our car service offers exactly these services: quickly, efficiently, inexpensively, with a guarantee. Contact us, we will be happy to help!

Good evening everyone, dear friends! I haven’t written anything for a very long time, which is about a little over a month ago. At one moment there was nothing to write about, at another moment there was, but there was neither time nor desire. But now there was time and desire. As the title suggests, I replaced the resonator with a muffler.

I prepared in advance for the 20th of June and slowly stocked up on the resonator and muffler. I stocked up again at a friend’s store. Here are the prices for my parts.

Gasket - 50 RUR Resonator - 3950 RUR Muffler - 990 RUR Muffler clamp 1118 - 78 RUR Oil pressure sensor - 92 RUR Muffler rubber (5 pieces, SEVI company) - 96 RUR And I also bought copper nuts costing 15 rubles each. I bought 4 pieces, I think.

Early Saturday morning, June 20th, the exhaust line was scheduled to be replaced. In the morning I took my mother to the garden. And I went to the garage to repair it. As you remember, my muffler fell off and the pipe was bent over the beam. This made it easier for me to remove the exhaust system. He climbed into the hole and began to unscrew the nuts that secure the resonator to the catalytic collector. Two nuts unscrewed just more or less normally, but then something went wrong and now I have a nut with a piece of a hairpin in my hands.

It’s so good that not so long ago I got an angle grinder and an electric screwdriver.

We clean it, drill it out with a 8mm drill. The photo was taken of only the cleaned cat collector.

But this is where the fun begins. I didn’t find that I had an 8 bolt with a full thread, but only one that had half a thread, and the part that was without thread was larger in diameter. I didn't want to drill it out. I went to my neighbors’ garages, they also don’t have such bolts, but only those that I myself have. I went to the OLMI auto store, to the Cascade hardware store... The same story as in the garages. And then I remember the miracle store which is located a 15-minute walk from OLMI. Of course, this is a fastening tool. I went to this store. I show the bolt to the seller, which I grabbed as a sample from the garage, and say that I need a bolt of the same diameter with full thread and a little longer. Supplies bolt 8 and 55mm long. But knowing my beloved self, I take 4 bolts, just in case. But the cases are different. 4 such bolts cost 11 or 14 rubles, I don’t remember exactly. I leave the store, look at my watch and see that it’s approaching 12 noon, it’s not far from home, and I’m already hungry, and even more so I need to walk the dog. In general, at 12.00 in the afternoon I was already heading out to the garage with brand new bolts.

How to determine whether the muffler is faulty on a Lada Kalina

Domestic cars have a simplified exhaust system design. Thanks to this, the driver can easily determine malfunctions in the operation of the Lada Kalina muffler.

First of all, it is necessary to clarify exactly what risks are possible when using a faulty device:

• If a hole has formed in the plug, toxic gases can enter the cabin. The danger is that the exhaust gases are colorless and odorless. After even a short period of inhalation, the driver may feel headache, nausea and fatigue;
• If the system mechanism fails, loud popping noises in the resonator will immediately be noticeable. And today, many city districts and entertainment establishments limit the noise level on their territory, so the driver of a car can receive a fine;
• decreased comfort while traveling, since the noise level with a faulty muffler will not allow you to talk or listen to music.

Malfunctions can be determined independently. This does not require any special knowledge or equipment.

It is important that the muffler is always in a strictly horizontal position

Step-by-step instructions for diagnosing a malfunction

Proceed in the following order:

1. Listen carefully to the noises that arise when the car is moving. If the muffler is faulty, the car will run much louder than before. And also knocking or a characteristic gurgling sound while driving indicates a breakdown in the exhaust system.
2. Raise the car on a jack and inspect the body of the device. There should be no holes or even ordinary rust on it. If there are already rust marks on the case, then most likely there are also some defects inside the case.
3. When driving, carefully monitor the quality of the exhaust gases. If black and dense smoke periodically escapes from the muffler, then there is definitely something wrong with the exhaust system.
4. Start the engine and rev it up for a few minutes. Then turn off the ignition and check the engine temperature. After a short period of operation, the motor should not have time to heat up. If there is overheating, it means that the mechanism is not doing its job.

How does a resonator work and its functions?

As mentioned above, the exhaust system includes a resonator. In a resonator, each of the constituent components has its own role. The main purpose of this unit is to dampen low-frequency sounds generated during the intensive movement of the exhaust gas stream inside the muffler circuit. Sounds of this nature occur for the following two reasons:

• from the effect of gas expansion;
• due to vibrations of components in the muffler line.

An important function of the resonator unit is reducing the speed of movement of the gas jet. Here fundamental physical laws come into play, indicating the inevitable damping of speed during the transition of a gas mass from a thin pipe into a volumetric cavity. It is precisely to achieve this effect that the design concept of the resonator is designed.

In the exhaust gas circuit, the resonator component is located in front of the main muffler, thereby being the primary link in the chain of damping low-frequency sounds.

Structurally, the product assumes the presence of a perforated section of pipe inside the metal body, where there is a throttle-type hole, designed to effectively dampen vibrations arising from the movement of the gas jet. The internal space of the housing has partitions that are oriented transversely to the perforated pipe. Now you have an idea of ​​what an exhaust system is.

In comparison with the resonators in the exhaust circuits of other models, this unit in the Lada Kalina has a corrugated element. The design necessity is due to the tendency of the device to move during the heating of the gas exhaust jet.

The manufacturer makes all resonator components only from high-quality steel. Otherwise, the car's exhaust system would constantly require repair work. But sometimes it is still necessary to replace the resonator, and in some cases, replace the muffler.

How to replace the Lada Kalina muffler with your own hands

Before we talk about replacing the muffler, you need to choose the right model. The device is matched to the car body. At the same time, it is best to purchase “Glushak” not at car markets, but in specialized stores. You can buy a model on the market for 500 rubles, but it is unlikely to last long. When in a car shop you can pick up an aluminum or stainless steel muffler housing for 1000–1500 rubles and be sure of its long service life. Typically, original exhaust system elements last for 50 thousand kilometers.

To successfully complete all procedures, it is best to immediately prepare the following tools:

• WD-40 lubricant;
• two open-end wrenches for 13;
• hammer;
• flat blade screwdriver.

Video: DIY replacement of the silencer

Dismantling procedure

Removing the resonator and plug can be considered the most labor-intensive part of the entire replacement procedure. The complexity is determined by the fact that it can be very difficult to disconnect the elements of the exhaust system from each other:

1. The first step is to jack up the rear of the car or drive it into a hole.
2. Then you will need to find the connecting clamp that connects the muffler and the resonator. It will be difficult to remove the clamp, since the bolted connections stick to the metal structures due to constant heating.
3. It is best to first lubricate all connections with lubricating fluid and then proceed with removal.
4. After dismantling the resonator, you need to remove the muffler itself.
5. It is usually easily removed, since it is attached to the bottom of the car using rubber hangers.

It is recommended to immediately remove all stickers and wrapping from a new product.

Therefore, removing the muffler may take about 20-30 minutes, depending on how difficult it is to remove the resonator bolts. In this case, all connecting elements and seals must also be removed - their further use on the new device is impossible.

The described operating procedure will be the same for all modifications of the Lada Kalina, regardless of body type.

How to change seals, rubber bands and corrugation

There are usually no problems when it comes to changing o-rings and rubber bands on the muffler. All components can be purchased along with the device and rubber bands can be put on in place of the old ones.

The rubber band for the silencer is inexpensive and can be changed in a minute.

Replacing the corrugation is considered a more complex procedure. In addition, the car owner does not always have a welding machine at hand and knows how to operate it.

To change the corrugation on a still working muffler, you must perform the following steps:

1. Using a grinder, cut off the remnants of the old corrugation (of course, the muffler will need to be removed before doing this).
2. On the new corrugation, neat cuts are made in those places to which the pipes will be joined.
3. The corrugation is pulled into place and must be fixed on both sides with clamps.
4. “Glushak” is installed under the bottom.

This simplified method of replacing the corrugation is considered quite practical, although, of course, welding work would make the replacement more durable.

Corrugation element increases muffler service life

Main malfunctions and the order of work to replace the muffler

The main malfunctions of Lada Kalina mufflers include:

• muffler corrugation burnout;
• catalyst malfunctions;
• gasket burnout;
• breakage of rubber fasteners, etc.

However, the main and defining defect remains muffler burnout. Therefore, we will study the issue of replacing the Lada Kalina muffler with our own hands, having previously prepared plumbing tools and the car itself for this. When preparing a vehicle for repair, we select a platform without slopes and install the car in the parking brake mode and first gear engaged.

The order of work when dismantling the muffler on the Lada Kalina:

1. Having prepared the necessary tools for the repair, we dismantle the clamp that tightens the muffler pipe at the junction with the resonator. This operation is carried out using a pair of keys set to “13”; for convenience, you can select a head with a knob and a ring wrench.
2. It happens that the nuts securing the plug are stuck to the base and are very difficult to unscrew even with the help of special liquids. When there is no longer any hope of safely dismantling the product, it is easier to prepare new fasteners, and the old nuts must be cut off with a grinder.
3. After dismantling the tightening clamp, it is necessary to apply several gentle blows with a mechanic’s hammer along the circumference of the muffler bend to facilitate complete removal of the product. After this, use your hands to press the muffler in the direction opposite to the direction of travel of the vehicle.
4. Then remove the rubber fasteners on the sides of the product.
5. We dismantle the “glushak”, set the unusable part aside and install a new part, and do everything according to the “reverse” principle.

The technological operation takes only a couple of hours, after which the car is ready for use again.

Typically, mufflers can withstand quite a long service life. In my memory, there were many cars, and almost all of them had the same muffler service life. For example, on the Twelfth we replaced it at about 50,000 km, and on the Seven the resonator recently burned out when the mileage was 60,000 km. So far I have driven a little more than 40 thousand on Kalina, but thank God, so far everything is fine and there are no signs of burnout.

I’ll say right away that I didn’t want to remove and put it back using Kalina as an example, I’ll just show from previous experience how this procedure is performed, but with photographs using the example of my station wagon. I’ll just show you clearly what needs to be removed and unscrewed and where.

So, to perform this repair, you will need:

1. WD-40 lubricant or its analogues, such as all kinds of liquid wrenches
2. Keys size 13, preferably a socket and a head with a knob
3. Hammer (may not always be needed)

First, I’ll show you where the clamp connecting the resonator and muffler is located, since it is this that will need to be unscrewed.

First of all, be sure to apply lubricant to the bolts and nuts securing the clamp, since they stick thoroughly and in some cases it is simply impossible to unscrew it. After 10 minutes, unscrew the nuts. On one side you can completely, and the other just slightly unscrew.

After this, we move the clamp to the side and now you can knock it off the junction with the resonator with small knocks on the bend of the muffler. Often there are no problems with this step and it can be easily knocked down or even removed without any extra effort.

After this, you need to free the muffler from the fasteners and remove it from the rubber bands that hold it. There are two of them in total. The first is located near the rear beam. Shown more clearly in the photo below:

And the second is in the back of the car, almost at the exhaust pipe. Its location is also shown in the picture:

After these steps, you can safely and without any obstacles remove the muffler and replace it with a new one. Installation occurs in the reverse order of removal. The price of this part in auto parts stores is approximately 1050 rubles.

How to install a new muffler on the Lada Kalina

The installation procedure will take no more than five minutes. Since all the elements are new, you won’t have to deal with rust and corrosion. The installation procedure looks like this:

1. First, the device itself is installed - two rubber hangers are used for this.
2. The resonator is mounted in place of the old device with 13 bolts.
3. The connection between the muffler and the resonator is secured with new clamps.
4. After which you can remove the car from the jacks and check the functionality of the device.

Table: tightening torques for threaded connections

Lada Kalina cars can be quite capricious in terms of wear and tear on exhaust system elements. However, the short service life of mufflers can be prevented by choosing a quality product and carrying out installation work yourself, since only in these cases can you be sure of the long-term operation of the muffler.