Do-it-yourself intake pipe repair

In detail: do-it-yourself repair of the intake pipe from a real master for the site my.housecope.com.

The muffler is an element of the exhaust system. The specified part, due to its location and functions performed during engine operation and driving, constantly experiences the negative effects of the environment and fuel combustion products. As a result, various muffler breakdowns are quite common. However, in most cases, you can repair the muffler yourself.

To understand the cause of a malfunction of a particular unit, it is necessary to clearly understand how it works and how it works. So, in general terms, almost everyone who has looked at the bottom of any car at least once has seen or familiar with the muffler is a kind of "reservoir" in front of the exhaust pipe. Technically speaking, a muffler is a part of the exhaust system of a car through which exhaust gases and combustion products of the fuel-air mixture pass, and sound vibrations that occur during the combustion of a fuel charge in the cylinders are damped. To put it simply, the main task of a muffler is to let the exhaust pass through itself and reduce the noise of a running engine.

The fact is that the exhaust gases from the internal combustion engine are removed under high pressure and also have a high temperature. At the same time, air vibrations are created, which the human ear perceives as roars, pops and explosions. Thanks to the muffler, air vibrations are damped, the temperature and speed of the gases are reduced and the noise level is significantly lower. This is achieved by repeatedly changing the direction of the exhaust gas flow, narrowing and expanding it, interference and absorption of sound waves. As a result, most of the energy of sound waves is converted into heat. A car, depending on its make and model, can have up to five mufflers at the same time. In the simplest version, there are two of them: a preliminary, also known as a resonator (of a smaller size, installed immediately after the exhaust manifold) and the main or rear one - the one that is most often seen by ordinary people.

Video (click to play).

The main muffler is not just a box through which the exhaust pipe goes. It has a rather complex internal structure: chambers of different volumes (from two to four, and sometimes more), sound-absorbing material (for example, fiberglass), metal nets (to hold this material), and in many modern cars there is a catalyst for reduction of harmful emissions into the atmosphere.

Some models are factory fitted with straight-through mufflers. They do not have chambers that create a labyrinth for changing the direction of the flow of gases and therefore reduce the noise level significantly less. Usually installed on sports cars in order to achieve an increase in power. Often, forward flow can be observed on inexpensive civilian vehicles. The fact is that drivers install an element for tuning the motor. Note that in this case, apart from the "sporty" roar of the engine, it is practically impossible to achieve any significant effect.

In order to understand that the muffler is faulty, you will not have to undergo a technical inspection. The most important and noticeable sign of a breakdown is the powerful roar of the car when the engine is running. In addition, in the most neglected case, the driver learns about the malfunction after a loud bang, similar to an explosion. This is the case when the muffler breaks in the literal sense of the word. The reason should be looked for under the hood, in the ignition system.When it works intermittently, the unburned fuel-air mixture enters the muffler chambers and accumulates there, and then explodes. This can also happen when starting the engine or on the road. In this case, repairing the muffler with your own hands without welding is unlikely to work, but if you have one, you can reassemble everything and use the device for a long time.

In the more common case, a part of the exhaust system simply burns out in some places. That is, holes appear in the case. The reason for this is corrosion, both external and internal. Outside, the body is affected by various abrasives (dust, sand), water, frost. And from the inside - the exhaust gases, which, as already mentioned, have a high temperature, as well as high-frequency vibration. And, unfortunately, on modern cars, especially budget cars, the muffler is not made of the best materials. Of course, beginners may immediately have a question about why anti-corrosion protection is not used on the muffler. The answer is simple: high exhaust gas temperature.

So, after a fistula (hole) has appeared in the body and its location has been established, the best way to eliminate this problem is to apply a patch. It can be a piece of sheet metal welded in the usual way, or it can be a plate made of a special material. We are talking about a tape made of fiberglass, impregnated with epoxy resin or other adhesives that can withstand heating up to 1000 degrees. In addition, holes can be repaired with special sealants. All of these are sold in any specialty store.

Another affordable way to troubleshoot on your own, which even beginners can safely resort to, is to repair the muffler with cold welding. Cold welding is a special adhesive. It can be two-piece or one-piece. The two-part is liquid and similar to plasticine (the one-part has the same consistency). For the car, "cold welding" is produced with a special marking. The bottom line is that this substance is capable of combining almost any material. Breaking force - 120 kilograms per square centimeter. The main disadvantage is that after gluing it is necessary to wait about a day until the composition is completely solidified. And, in addition, this method is inconvenient at temperatures below 5 degrees Celsius, since the plastic-like composition becomes solid and requires additional heating.

Finally, we add that no matter what method of fixing the problem motorists would not resort to, it is necessary to thoroughly inspect the entire part.

However, the owners of old models can turn to the so-called "auto dismantling", where they often bring in old, removed from the register cars for sale for spare parts. Here you can find a completely functional muffler, which usually can be bought at a reasonable price and then installed on the car instead of the failed element.

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The exhaust system of a car performs very important functions to reduce the noise of the engine, reduce the temperature of gases escaping from the cylinders, as well as to partially eliminate the smoke and toxicity of exhaust gases.

The malfunction of the elements of such a system cannot be unnoticed. A muffler breakage is especially evident. When depressurizing, this element immediately loses the function for which it received its name.

Given this feature of the breakdown, it is necessary to restore the working capacity of this part as quickly as possible, otherwise increased attention on the road cannot be avoided not only from motorists moving in the stream, but also from traffic police officers.

The easiest way to remedy the situation is to install a new part, but due to various circumstances, replacing an inoperative muffler may not be possible. Fortunately, it is possible to repair the muffler with your own hands without welding and replacing.

This article will consider simple and effective ways to restore the performance of this element of the exhaust system of a car, but first it should be recalled under what circumstances such a breakdown can occur.

It is easier to prevent a disease than to treat it later. The same is true for car breakdowns.

Of course, all the nuances on the road cannot be avoided. But knowing about the dangers that threaten the elements of the exhaust system of a car, you can try to delay the occurrence of one or another malfunction with preventive measures.

If the car is used constantly, then sooner or later problems with the muffler will arise, regardless of the quality of the material from which this part is made. Located in the lower part of the car, this part is constantly exposed to the abrasive effect of sand and stones falling on its surface. And if, when the car is moving, a sufficiently large solid object turns out to be between the wheels, then the muffler can be completely destroyed from a strong impact.

Therefore, the main rule of extending the life of the unit is to drive the car carefully.

The muffler is connected to the exhaust system by means of threaded connections, so if the nuts are not tightened well enough, this part can be lost while driving. To prevent this from happening, the condition of the threaded connections of this element of the exhaust system should be monitored from time to time.

The muffler often becomes unusable from burning out the metal, but this process cannot be completely stopped. Slightly slowing down the failure of this part as a result of thermal and corrosive effects is possible only when processing the inner surface of this part using graphite impregnation.

If, despite all the preventive measures taken, the muffler burned out or its body was damaged as a result of mechanical stress, then many owners immediately become interested in the question of how to connect the muffler pipes without welding.

Such repairs can be performed at home using a special sealing compound.

Cold welding is a two-part adhesive that can be used to glue metal products. Is it possible to weld a muffler with cold welding, because this part is affected by a very high temperature of the exhaust gases.

The adhesive composition of cold welding tolerates high loads and temperatures well, therefore, when a burnout appears in the muffler, or cracks from mechanical stress, it is necessary to remove the part from the car and perform the following actions:

Clean the damaged area thoroughly. Cleaning is carried out with coarse sandpaper or using attachments for a drill or grinder.
The metal, free from rust and carbon deposits, is thoroughly degreased with a solvent.
Cold welding is applied to the damaged area. Gloves should be used to apply the plastic type of glue.
After applying the composition, it is necessary to wait about an hour, and then polish the layer of hardened glue.
After a day, the part can be installed on the car and operated without any restrictions.

The muffler must be repaired by cold welding in a warm room. Only at temperatures above +5 degrees will the two-component composition of the glue react with the metal surface.

Ceramic tape is a popular and effective remedy for muffler repair.A small hole in the muffler is closed in the following sequence:

The metal is cleaned of rust and carbon deposits.

The ceramic tape is wetted with water.

The hole is closed by repeatedly wrapping the muffler with ceramic tape.

This method is temporary, but during the entire service life of the "bandaged" muffler, its function will not be impaired, and in case of repeated burnout, you can easily wind a new layer of ceramic tape.

The exhaust system is designed to remove exhaust gases from engine cylinders, neutralize nitrogen oxide and carbon monoxide in gasoline engines, and also prevent soot from entering the environment in diesel engines. Modern exhaust systems are quite complex because they contain oxygen sensors, catalytic converters and particulate filters. Particular attention is paid to the suppression of exhaust noise through the installation of resonators.

Exhaust system device

The exhaust system consists of the following elements:

The exhaust system is designed to remove exhaust gases from the engine cylinders.

Exhaust manifold;
Oxygen sensors;
Catalytic converter (muffler catalyst) or a particulate filter;
Exhaust pipeline;
Pipe with vibration-insulating coupling (corrugation);
Resonator or pre-muffler;
Main muffler;
Muffler suspension.

Almost all elements, except for the exhaust manifold and sensors, are made of stainless steel. The experience of operating a car shows that even such steel can rot under the influence of chemicals and temperature changes. The places of the welded seams are also susceptible to corrosion, because during the welding process, under the influence of high temperature, the parts to be welded are connected to each other with a fusible electrode, which does not carry protective properties, the temperature of the stainless steel changes and passes into another state of aggregation: austenite or ferrite, which is allowed it is good for it to oxidize with air and rust. Impact loads that appear from uneven roads have a negative effect. Often, mechanical damage appears on the muffler and resonator, which reduces the flow area, and this slows down the rate of exhaust gas removal, that is, the cylinders are poorly cleaned, and this leads to a loss of engine power, a decrease in efficiency and an increase in fuel consumption. You can often find a simply burnt out muffler.This happens when the fuel mixture does not completely burn out in the engine cylinder, but burns out in the exhaust system. All malfunctions of the exhaust system can be quickly eliminated and on their own.

Car muffler device

The exhaust gases pass first through the resonator, where their speed and noise level are reduced.

Exhaust gases travel through the exhaust system under high pressure, and their movement is accompanied by a sound wave that travels faster than gases. The muffler consists of pipes of various diameters not connected to each other, and a steel mesh and sound-absorbing material are installed in the muffler body. Mostly fiberglass is used as such a material.
When driving, the exhaust gases pass first through a resonator, in which their speed decreases, and hence the noise level. Then they move to the main muffler, where they pass a system of pipes, in which a final reduction in speed and noise still occurs. A different number of mufflers is installed on vehicles: from 2 to 5.

The muffler corrugation is designed to reduce vibration loads on welded seams and suspension system elements. However, such an element is exposed to high temperatures and mechanical damage. The corrugation is a small elastic element, which is covered with a metal protective mesh and installed in the exhaust pipe. The corrugation is not repaired, but entirely changed, especially since the price of the muffler corrugation is low. But if there is no welding machine at hand or it is impossible to get to a car service, then it can still be repaired. The most common phenomenon in which a muffler corrugation is repaired is a violation of the integrity of the weld. In the case of do-it-yourself repair of the corrugation, you need to purchase a repair kit for the exhaust system or cold welding, fiberglass and epoxy. A "tourniquet" can be applied in the seam area, but it is worth remembering that this operation is temporary, so it would be most optimal to buy a new corrugation and weld it into place.
The order of applying the harness is as follows:

It is necessary to clean the right place on the weld with coarse sandpaper;
Degrease the repair area;
Prepare the composition for repair according to the instructions on the package;
Apply the mixture liberally to the weld seam and allow to dry.
Saturate the fiberglass with epoxy and screw it tightly in the diameter of the weld;
Over the fiberglass, coat with cold welding another layer in a circle and let cool.

In this way, the weld seam rupture can be temporarily repaired. Often, when repairing a muffler, the corrugation is also replaced.

Replacing rubber hangers for a car muffler

Rubber suspensions are easy to change - you need a little oil and a long screwdriver.

This system is a set of rubber cuffs that are installed between the body and the metal muffler. They wear out mainly from impacts, and rubber is also susceptible to aging from high temperatures. The number of such elements is calculated during the design of the exhaust system, therefore, one torn fastening elastic will lead to the breakage of the rest. They are easy to change, and for this you need a little engine oil and a long screwdriver. Oil is needed to lubricate the hinges with a screwdriver to remove the rubber mounts, and then install new muffler hangers.

The muffler pipe is welded to the corrugation on one side, and connected to the resonator pipe through a clamp on the other. It changes in case of burnout or shock. To replace it, it is necessary to cut off the corrugation with a grinder at the place of the weld seam and remove the clamp. Usually it is very strongly "welded" with the resonator receiving tube, so it must be knocked out through the spacer with a hammer. Next, install a new downpipe and weld on the corrugation.

This element most often burns out. Holes are formed on its body, through which the exhaust gases come out very noisily.The resonator changes in aggregate, because its cost is not very high. However, if a quick repair is needed, you can use the replacement method using cold welding, epoxy resin and fiberglass. In this case, it is necessary to apply a tourniquet impregnated with epoxy resin over the layer of cold welding, and then coat the entire fiberglass with another layer of welding. It must be remembered that such an operation is temporary.

Car muffler repair without welding

Cracks that form at the weld can be sealed with muffler sealant.

Clamp on the pipe of the muffler of the car

The resonator outlet pipe and the silencer inlet pipe will be connected in two ways:

Through the tie with a clamp;
Through the flange.

The most cost-effective way to repair a muffler can be the use of cold welding.

In the first case, the diameter of the resonator hole is larger than that of the muffler. They are joined to each other and tightened with a clamp. In the case of a flange connection, the pipe diameters are the same, therefore it is necessary to install a heat-resistant gasket between the connection of the muffler to the resonator.
The most inexpensive repair method is to use cold welding to repair the muffler, which will help to close up small holes. What to make a muffler gasket? It is necessary to prepare the composition and use fiberglass or fiberglass as the material. Apply another layer of cold welding on top of the fiberglass spacer.
To protect the muffler from rust formation, it is possible to cover its body with heat-resistant spray paint for the muffler before the beginning of the winter season, which will serve as an obstacle for salts and aggressive environmental factors. This material should be used before the beginning of each winter. Also, when repairing, it is necessary to replace the muffler ring.

Video (click to play).