Daewoo Nexia DIY muffler repair

Replacing the muffler for Daewoo Nexia

The composition and purpose of the exhaust system on the Daewoo Nexia

The exhaust system of the exhaust gases on the Daewoo Nexia (Daewoo Nexia) is one of the most important complexes for the correct functioning of a vehicle. With its trouble-free operation, the noise that inevitably arises from the operation of the car is minimized, the temperature threshold and the toxicity of exhaust engine gases are reduced.

This complex of exhaust exhaust outlet is under constant loads, which puts forward special requirements for the selection of materials of manufacture. It includes the following main components that work synchronously:

• Receiving manifold. It is the main component under the bulk of the system loads. The temperature range of exhaust gases reaches 1000 degrees Celsius.
• Resonator. Serves to reduce vibration defects, temperature and speed conditions of the exhaust gas flow.
• Silencer. A component of the exhaust gas system, which is installed in the rear of the car. The product is designed to absorb noise when the gas flow is removed using a special sound-absorbing filler.

The entire exhaust complex of exhaust gases additionally purifies the exhausted gas components from the increased concentration of carbon monoxide compounds based on carbon.

Features of the exhaust system of the Daewoo Nexia car

The engine range for Daewoo Nexia vehicles allows the use of both singular and double overhead camshafts. The exhaust systems of these engines with such gas distribution mechanisms are very similar, differing only in the configuration of the intake manifold with a flange and the fastening system. Almost all later modifications of this South Korean car are equipped with a catalyst to neutralize CO in the vehicle exhaust.

To prevent the heating of body elements from the exhaust system under the body, special screens with thermal protection are mounted above the main elements of this complex.

To reduce vibration transmissions from the engine to the exhaust pipe and chassis, a vibration friction compensator in the form of a corrugation braided with a thin metal wire, which is sometimes called a corrugated bellows, is provided in the intake manifold.

Sealing gaskets with metal reinforcement are used for flange connection of elements of the exhaust system.

All major components of the exhaust system are attached to the underbody using 3 rubber cushion pads.

Maintenance of the exhaust gas system of Daewoo Nexia

The Daewoo Nexia exhaust system does not need any special service. It is only necessary to occasionally check the tightness of the threaded connections, and also to look at the degree of wear of the suspension cushions made of rubber-like materials.

It is necessary to periodically test the operation of the exhaust system. With an increase in the operating noise of this system, it is required to check it for leaks.

To perform such a test, you must start the engine and inspect the entire exhaust system by running your hand over possible leaks. At the same time, it is forbidden to touch the components of the system in order to avoid getting burned.

Preparatory stage for the removal of the Daewoo Nexia muffler

Before starting to dismantle and repair this system, make sure that the motor has cooled down after operation.Taking into account the high toxicity of the exhaust gas mixture, repair work must be carried out in a room with an inflow of fresh air.

How to change a muffler on a Daewoo Nexia with your own hands

• Bend the wire holder of the muffler on the bracket of the clamp - tie and remove the part from the rubber damper.
• Loosen the clamp of the muffler with the resonator and move the car in the direction of travel.
• To facilitate the connection of the muffler with the resonator, it is necessary to bend the petals of the branch pipe on the muffler, which will make their connection less durable.
• Disconnect the muffler from the resonator with the "swinging" movements and dismantle it.
• Installing a new part is carried out in reverse order.

If the dismantling of the story fails because of the tight fitting of the muffler on the resonator pipe, then you must try to knock it down with a metal tool such as a heavy hammer. To preserve the part as a cushioning product, it is better to use a bar of wood for striking the end face.

When installing the muffler, to improve the tightness and prevent obturation of the exhaust gases, it is required to apply a layer of heat-resistant sealant to the pipe joints. If not available, a graphite-based lubricant can be used.

On Daewoo Nexia and Lanos there is a fairly common problem with the muffler clamp (rusts, disappears) or the exhaust burns out ... And in order to fix this breakdown, sooner or later you will have to change the muffler and damper rubber band. To cope with such a task on your own, it will be useful to watch the video “Removing / replacing the Daewoo Nexia muffler“.

And so in order to remove the muffler, the first thing you need to do is to unscrew the clamp connecting the muffler to the resonator pipe, and also to lower the clamping clamp of the muffler to the body. And tapping with a hammer on the muffler (through a wooden spacer), we disconnect the exhaust pipe from the resonator, and then remove the muffler from the mount and we can start replacing either the pipe clamp or damper rubber bands, or replacing the muffler itself.

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The exhaust pipe knocks on the body on the Daewoo Nexia

Two types of DOHC and SOHC engines were installed on Daewoo Nexia cars by the manufacturer. The exhaust system for them practically does not differ in design. Differences will be only in the form of the receiving pipe, the flange located on it and the general structure for its fastening.

For the exhaust system of the Daewoo Nexia, the installation of a catalytic converter for exhaust gases is used. To protect the base of the body from heating of the system elements, the car is equipped with special thermal screens located above the catalyst, resonator and muffler.

To reduce the transmission of vibrations from the engine to the exhaust system and the body, a corrugation in a metal braid is mounted in a part of the intake pipe. It is also called a corrugated bellows that compensates for vibrations.

On some Daewoo Nexia vehicles with an earlier model year and a non-feedback engine management system, an exhaust gas catalytic converter was not installed. For such models, it was decided to install a spacer pipe instead of the catalyst, the length equal to the length of the catalyst. Metal-reinforced sealing gaskets are used to connect the flanges that secure the front pipe, the catalyst and the resonator.

The elements of the exhaust system are suspended from the body using three rubber pads.

The exhaust system of a Daewoo Nexia car does not require additional maintenance. It is necessary to periodically check the degree of tightening of threaded connections, as well as monitor the condition of the rubber suspension pads.If one of the system elements fails, severe damage, through corrosion or burnout, then it should be replaced with a new one.

1. Bend the tendril on the bracket for the retaining strap that secures the muffler and remove the bracket from the pillow.
2. Loosen the clamp connecting the muffler to the resonator and move the clamp back towards the muffler pipe.
3. To make it easier to separate the muffler from the resonator, you should slightly bend the pipe segments on the muffler, this will help to loosen their connection.
4. Disconnect the muffler from the resonator with swinging movements and remove it.
5. Install a new muffler upside-down.

If you cannot remove the muffler from the pipe, try using a heavy hammer. Knock down the muffler by hitting the front end with a hammer using a block of wood.

When installing the muffler, apply a layer of heat-resistant sealant to the pipe joint surfaces. If there is no sealant on hand, regular graphite grease will do.

1. Remove the four nuts of the bolts that secure the resonator flange to the catalytic converter flange, or, as it is called, the exhaust gas converter.
2. Remove the bolts. Disconnect the flanges and remove the gasket.
3. Loosen the clamp connecting the muffler to the resonator and move the clamp back towards the muffler pipe.
4. To make it easier to separate the muffler from the resonator, you should slightly bend the pipe segments on the muffler, this will help to loosen their connection.
5. Remove the suspension pads from the resonator bracket.
6. Remove the resonator by disconnecting its pipe from the muffler pipe.
7. Install the new resonator in reverse order. Use heat resistant exhaust sealant or graphite grease during installation.

Important! The gasket between the resonator flange and the catalyst flange is disposable and must be replaced with a new one whenever this connection is disassembled.

The rubber cushions are intended for suspension of parts of the exhaust system. They require replacement in case of damage and wear, as well as if their deformation is too strong and at the same time the components of the system begin to hit the body or other vehicle units. For the suspension of the resonator, two identical pillows are used, and for the suspension of the muffler - one, which has an original shape.

1. Disconnect the muffler retainer bracket from the cushion.
2. Bend the tendrils of the brackets fixed to the body and remove the cushion from them.
3. To remove the resonator suspension cushions, bend the bracket antennae on the muffler and, slightly pulling the cushion, remove it from the bracket and from the body. The second resonator suspension cushion can be removed in the same way.
4. Install new rubber pads for suspension of individual parts of the exhaust system in reverse order. After completing the installation work, bend the tendrils of the brackets located on the body and the muffler to their original position.

Check the exhaust system periodically. If, during the operation of the car, the noise emitted by the exhaust system increases, then it should be checked for leaks. This will require starting the engine and inspecting the entire system. It is worthwhile to gently move your hand over those places where leakage is possible, just do not touch the nodes, you will feel the places where the node is rusted or burned out.

Before proceeding with the repair and dismantling of the exhaust system, be sure to allow time for it to cool down. When the engine is running, the exhaust system is very susceptible to heating up to high temperatures.

Open the door before starting the engine in the garage. Exhaust gases are very poisonous; poisoning by them can occur absolutely imperceptibly.

I replaced both mufflers (the last and the middle one) for a little over a month, but only today I got around to making a record ..... How did it happen that at one moment the beginning of the cross-section connection between the middle and the last one, I thought to tighten the clamp, but it was not there and decided to change both, I saw no reason to weld something. From the pictures, you can determine the places of burnout on the middle and on the last.

I changed it myself, without a pit and a lift, I ran over the spare wheel with my rear left wheel.

When comparing the shape of the cans and their location are visible immediately, the main thing is the bends of the pipes coincided.The photo shows which piece is missing (about 8-9 cm), it remained in the connecting pipe of the last muffler, which also came off when removed ..Well, you can see from the photo what piece is missing on the old muffler.

Price: 1300r / pc the last muffler, 1100r / pc average

time spent about 3 hours (it took a lot of time to unscrew the middle muffler)

Instead of a spacer (which also costs 800 rubles), you could buy an elongated resonator. Fewer connections.

p.s. That I do not see new gaskets for connecting the resonator and the catalyst

Instead of a spacer (which also costs 800 rubles), you could buy an elongated resonator. Fewer connections.

• Dollar - 58.85 rubles.
• Euro - 62.68 rubles.

1.11, 16, 24-bolts; 2-spring; 3-laying of the intake pipe; 4-outlet manifold; 5-exhaust manifold gasket; 6-oxygen concentration sensor (lambda probe); 7-gasket of the exhaust system; 8, 17, 23-nuts; 9-thermal screen of the exhaust gas neutralizer; 10 pillow; 12-thermal shield for an additional muffler; 13-additional muffler; 14-clamp of the exhaust system; 15-thermal shield of the main muffler; 18-tie collar for the main muffler; 19-main muffler; 20-intermediate pipe; 21-spacer; 22-catalytic converter of exhaust gases; 25-bellows; 26-intake pipe; 27-front pipe laying.

Now, let's move on to the replacement itself:

REPLACING THE MAIN MUFFLER OF THE VEHICLE DAEWOO NEXIA
1. Bend the tendril of the main muffler tie-strap bracket and disconnect the bracket from the muffler suspension cushion.

2. Loosen the clamp securing the secondary muffler pipe to the main muffler and slide the clamp back over the main muffler pipe.

3. To facilitate disconnection of the mufflers, slightly bend the segments of the main muffler pipe, thereby loosening the pipe-to-pipe connection.

4. Swinging from side to side, separate the pipe and muffler. Remove the main muffler.

NOTE:
If it is difficult to remove the muffler from the pipe, knock it down with a heavy hammer on the front end through a wooden gasket (block).

5. Install the main muffler in the reverse order of removal.

USEFUL ADVICE:
When installing, apply a layer of special heat-resistant exhaust system sealant to the surface of the pipe of the auxiliary muffler. If no sealant is available, graphite grease can be used.

REPLACING THE ADDITIONAL SILENCER OF THE VEHICLE DAEWOO NEXIA
1. Remove the nuts of the four bolts securing the additional muffler flange to the exhaust gas converter (or spacer) flange, remove the bolts.

2. Separate the flanges and remove the gasket.

3. Loosen the clamp securing the secondary muffler pipe to the main muffler and slide the clamp back over the main muffler pipe.

4. To facilitate the disconnection of the mufflers, slightly bend the segments of the main muffler pipe, thereby loosening the pipe-to-pipe connection.

5. Disconnect the suspension mounts from the muffler bracket.

6. Remove the additional muffler by removing its pipe from the main muffler branch pipe.

NOTE:
If it is difficult to disconnect the mufflers, hit the rear end of the additional muffler through a wooden gasket (block).

7. Install the additional muffler in the reverse order of removal.Pre-coat the end of its pipe with a layer of a special heat-resistant sealant for exhaust systems.

USEFUL TIPS:
If no sealant is available, graphite grease can be used. Replace the gasket between the muffler and catalytic converter flanges with a new one each time the connection is disassembled.

The exhaust system of any car is designed to remove already exhaust gases from the engine cylinders. Another function is noise and toxicity reduction. Its other name is the exhaust system. It is a large complex of various elements that are located under the bottom of the machine.

The gases formed after the engine is running can quickly fill the space and poison everyone around. They also have a very high temperature. Such a system is designed in such a way that the accumulation of gas waste inside the space of the machine is minimized.

Modern exhaust systems in vehicles also have the effect of cleaning already exhaust gases and are necessarily made of heat-resistant materials.

The Daewoo Nexia brand has engines of two different brands - DOHC and SOHC. The parts working on the exhaust are very similar in both: the difference is noticeable only in the appearance of the exhaust pipe itself, as well as the flange located on it and the general structures that are used for fastening.

Any exhaust system will include the following mandatory elements:

• exhaust manifold;
• catalytic manifold;
• mufflers.

In general, the system includes a large number of parts. However, for Daewoo Nexia, a special catalytic converter is used, used for those gases that turn out to be exhaust. On earlier models of the Daewoo you will not see this here, a stand pipe is used, which is equal in length to a similar neutralizer.

Vibration reduction has also been thought out: for this purpose, a vibration-compensating corrugated material is specially mounted in the receiving pipe, placed inside a metal braid. To protect parts from overheating at the base of the body, special thermoelements will be used here - screens that are placed on top of the catalyst, muffler, and resonator.

For a longer service life, all flanges of the existing catalytic mount are additionally sealed with metal-reinforced gaskets. The exhaust system means that all parts in it are suspended from rubber cushions to the same body.

Special maintenance of the exhaust complex for a Daewoo Nexia car is not required. However, it is imperative to carry out such preventive measures:

1. Check how securely screwed connections are tightened.
2. Check the integrity of the airbags.
3. Check for system isolation with increased operating noise.

Before carrying out repair work on Nexia, it must be remembered that:

1. The exhaust system must be cooled down (while driving a car, it can heat up to very maximum temperature indicators).
2. Open garage doors wide before starting the engine to avoid poisoning from exhaust gases.

In case of established malfunctions, you can carry out an independent replacement of worn parts. To replace the muffler with Daewoo Nexia, you must adhere to the following operation algorithm:

1. Unfasten the clamping clamp bracket by bending the tendril - with it, it is attached to the muffler.
2. Loosen the clamp and push it back.
3. On the muffler, you can bend the segments at the nozzle, which will help to relax their connection with the resonator.
4. Disconnect the muffler with a swinging motion from the resonator itself (sometimes you can use a hammer) and pull it out.
5. Install a new muffler.
6. Assemble everything in the opposite order, using a sealant (necessarily heat-resistant) at the pipe joints.

The resonator of the Daewoo Nexia can be independently changed as follows:

1. Unscrew the 4 nuts that secure it to the catalytic converter flange.
2. Detach the flanges.
3. Remove the gasket.
4. Loosen the clamp connecting the muffler and the resonator by moving it a little further towards the pipe.
5. Bend back by loosening the “pipe” segments on the muffler.
6. Remove the cushions from the suspension at the resonator bracket.
7. Remove the resonating device and disconnect its pipe from the muffler pipe.
8. Install a new part (also replacing the disposable gasket in the middle of the catalyst and resonator flanges).
9. Collect everything in a "mirror" order.

It will not be difficult to change the airbags at the safety anchorage. This should be done when it was noticed that they begin to beat down on the body. It should be remembered here that a pair of identical pillows must be used for the resonator part, but the suspension for the muffler has a different shape.

Exhaust equipment Daewoo Nexia suggests that it is necessary to adhere to the following scheme:

1. We disconnect the fastening clamping clamp of the bracket at the muffler from the worn part.
2. We bend the mounts at the brackets - this is how we remove the pillow from them.
3. To remove the pillows from the resonator suspension, also bend the bracket mounts from the muffler. Then we pull back the pillow and remove it from the body.
4. After installing new parts, all work is carried out in the reverse order.