Choosing corrugation for a car: instructions for repair and replacement

Corrugation (bellows, vibration compensator, vibration damper) is installed on almost all modern cars. Its main function is to prevent vibration of the car exhaust system. The part also helps prevent the car from overheating. It connects the intake manifold to the muffler pipes. It looks like a tube made of multilayer metal mesh. Replacing the muffler corrugation with your own hands without welding is possible in all cases where the brand of the car being repaired allows it.

The part takes on the main vibration loads and therefore often becomes unusable. But the use of this spare part in the design of the car exhaust system helps other parts to operate longer. Also, replacing a muffler corrugation is much cheaper than repairing an entire section of the car. Many people are interested in how to replace it themselves, without using welding. After all, this part quite often burns out, and there may not be a welding machine in the garage.

Causes of damage

The corrugation can break through from external mechanical influence. The cause of the malfunction may be impacts on hard objects protruding relative to the roadway - stones, bumps, etc. It also becomes less durable due to natural wear and tear.

Another possible cause of damage is the unsatisfactory technical condition of the transmission. Damage to the engine mount and wear of the rubber in the muffler fasteners have a negative impact on the condition of the part. Also, the spare part can quickly become unusable due to improper installation or dismantling of the muffler.

Chemical reagents used to clear roads of snow in winter have a destructive effect on metal parts. A clogged catalyst can also damage the spare part. The integrity of the part may be compromised by the presence of additives that increase the octane number in the fuel consumed by the vehicle.

Advantages of SVS Exhaust car service

Our service center specialists will quickly and efficiently perform complete or partial dismantling of the corrugation, treat the welded parts with a special anti-corrosion solution and install the muffler pipe in the shortest possible time. Among the main advantages of the car service it is worth noting:

• More than 10 years of experience in the market;
• A staff of qualified employees;
• Use of high-quality materials and modern equipment;
• Operational deadlines for order fulfillment;
• Individual form of work;
• Free diagnostics and affordable prices;
• 3 year warranty on all types of services.

Signs of damage

The most important sign of damage to the corrugation is atypical sounds when turning on the ignition and driving.

In addition to the loud roar, the car also gives other malfunction signals:

• car “sneezing”, popping noises;
• engine power decreases;
• the rhythm of the engine becomes unstable;
• exhaust gases penetrate into the car interior;
• soot appears on metal parts.

There are three options for replacing the muffler corrugation without welding. The first two methods imply high-quality repairs with further long-term operation of the part. The third is a temporary replacement in order to get to the nearest service station. We will see that welding mufflers and corrugations, although desirable, is not at all necessary.

What does it represent?

An important component of the exhaust system, it resembles a corrugated metal tube, protected on the outside by a stainless steel braid. A number of models received a similar coating inside. This provides complete protection. The only drawback is the increased cost of the product. On both edges there are tubes necessary for fastening. The corrugation connects the exhaust pipe to the muffler intake pipe. This placement is associated with vulnerability during movement. Any unevenness negatively affects the integrity of the structure. The main advantage is its flexibility. Thanks to this, it connects 2 tubes that do not fit together in the same plane.

The installation location varies depending on the manufacturer:

• in front of the muffler;
• after the manifold (intake pipe);
• to the resonator (replace the catalyst).

Regardless of placement, the role is the same. Only the accent varies. It should be noted that it is tight.

What tasks does it perform?

Corrugation is also called a vibration compensator, flexible connection and corrugated element. It is necessary to dampen the vibrations that accompany the operation of the engine, especially at the moment of start. As a result, the destruction of the exhaust system occurs much more slowly.

The functions boil down to:

• the role of the elastic connection in the exhaust system;
• minimizes the risk of cracks and subsequent destruction of the exhaust tract;
• corrects the engine position in case of strong vibrations and increased torque;
• shifts the receiving and output flanges in space, this reduces the requirements for the accuracy of large parts; the factor has a positive effect on the cost;
• minimizing vibrations that occur when driving over rough terrain or poor-quality road surfaces, especially at speed;
• exhaust gases are safely removed outside, without the risk of entering vulnerable areas;
• turning into a movable system simplifies the installation of a universal exhaust or direct flow;
• extends the service life of parts and elements.

Corrugation is not installed in all cars. A graphite sealing ball ring acts as a substitute. It is tightened with bolts and springs. Before giving preference to one or another element, engineers carefully study the placement of the engine in the engine compartment (longitudinal or transverse), vibration load and the length of the exhaust system. There are old car models that lack both types of dampers. But this is an exception to the rule. Modern vehicles need a muffler corrugation.

What are they?

Products are divided into groups according to several criteria. The first thing to determine before purchasing is the installation method. Highlight:

• Vertical. Located under the exhaust manifold of the exhaust system. The length of the damper does not exceed 15 cm, the internal diameter is no more than 6.5 cm. When the engine is running, it works for compression and straightening.
• Horizontal. Basic bending deformation. It is attached after the receiver pipe from the engine. With a diameter of 6.5 cm, the length reaches 40 cm.

There is a wide range of couplings available on the market from all over the world. The declared category covers all categories of the population. The element is created from stainless wire and molded plates.

Depending on the structure there are:

• Single layer. Consists of a metal sleeve and outer braid.
• Double layer. An internal braid was added to the design described above. The dense wire coating retains exhaust gases more effectively. It is not possible to ensure complete tightness. The main advantage is the affordable price. Due to flexibility, they dampen vibrations.
• Three-layer. Includes a double corrugated metal sleeve and outer protective braid, as well as an additional internal rolled sleeve. Popular category.
• Multilayer. Distinctive features in comparison with competitors are visible to the naked eye. It is enough to study the internal coating. Braided wire has been replaced by stainless steel sheets. Molding gave the material the necessary flexibility. Among the design features, flexibility is noted, which is inferior to other groups. This does not prevent the coupling from functioning and coping with its tasks, since the exhaust system fasteners provide for this. The only thing you should pay attention to before purchasing is the mutual movement of the flanges (twisting). To do this, examine the fasteners of the installed repair insert.

The corrugations, where chainmail mesh was used as the outer braid, deserve special mention. The solution significantly increased protection from negative external influences, which had a positive effect on the service life of the part.

Video about types of corrugations:

The first method is corrugation on clamps

In order to repair the corrugation, it can be installed on metal clamps.

Suitable parts for 48 mm Lada cars.

To replace you need to do the following:

• Jack up the car from the rear right;
• Remove the engine crankcase protection;
• Remove the exhaust manifold;
• Saw off the old part with a grinder;
• On the new corrugation, make short longitudinal cuts along the pipes welded to it, this will ensure a tight fit of the part to the exhaust pipe;
• We seal the corrugation and crimp its edges with clamps;
• We install the part in its original place.

After such repairs, the corrugation will not need repairs for a year or a year and a half.

Correct selection

In order for the muffler corrugation to reliably protect the exhaust system of the car, and at the same time the body, you need to know some of its features. This will help you choose the best option without overpaying.

Before you go to the auto parts store, you need to determine the type of old element. It is usually located in two positions:

• horizontally;
• vertically.

In a horizontal position, the corrugation can be seen, if viewed from the side of the power unit, then after the first bend of the exhaust pipe. In this case, it bends under load. As for the length, it can reach up to 400 mm with a diameter of 65 mm. When choosing a new part, you need to focus on the dimensions of the old one.

In a vertical position, the corrugation, under the influence of the load from engine operation, first compresses and then straightens. Typically, such elements have a reinforced design. At the same time, the dimensions are limited: the length is no more than 150 mm, and the internal diameter is 65 mm. When choosing this part, it is important to consider how the old corrugation is welded.

Any type of elastic element is placed on the exhaust system pipe using the overlap method. The main thing is to take into account the following nuance: if it is not possible to remove the welds, excluding damage to the exhaust system pipe, you should choose a corrugation of the same length as the old part. If they can be cut, then the corrugation needs to be selected 20 or 30 mm longer.

In addition to the two main criteria for choosing a corrugation (length, internal diameter), it is also important to take into account its quality, which always depends on the manufacturer. Common brands in the automotive market are the German company Ehler and the Italian manufacturer Hydra. The cost of parts can vary from 800 to 1500 rubles. There are cheaper options, but if you want to save money, you should remember that it is not always justified.

Threaded connection

For repairs, you will need high-temperature sealant and eight M5 threaded bolts.

The old spare part is still cut off with a grinder. In order to install a new part, you must do the following:

• On the rings and exhaust pipe, drill eight holes with a diameter of 4-6 mm around the circumference at the points of contact;
• Using an M5 tap, cut threads in the drilled holes;
• Treat all structural parts with sealant;
• Screw the bolts into the holes;
• Install corrugation.

The use of high-temperature sealant will ensure the reliability of the connection. After completing these steps, you will receive a fairly high-quality and sealed car exhaust system assembly.

Varieties in detail

These products are categorized according to several properties. First, you need to find out the product placement option; there are the following types:

1. Vertical type installation. Length up to 150mm, diameter up to 65mm.
2. Horizontal type installation. Length up to 400mm, diameter up to 65mm.

The modern market offers an abundance of models of these parts from manufacturers from different countries. The product is made from stainless steel wire and specialized plates.

Most common configurations:

1. Instances in 1 layer. Simple sleeve and external protection.
2. Instances from 2 layers. Identical to the above configuration, the difference is additional internal protection. This option shows better (compared to point 1) results in tightness, although it is far from ideal. Has an attractive price tag.
3. Instances from 3 layers. Unlike the 2nd position, it is equipped with an additional sleeve, which makes the product reliable and tight. Popular among car owners.
4. The copies are multi-layered. The strongest representatives in the field of such spare parts. Instead of braiding, sheet steel is used for internal protection. In addition, the product has the necessary flexibility with the strength of protective materials. It is important to know that the flexibility in these products is only nominal due to the amount of additional materials that are used to enhance the seal. The lack of flexibility is compensated by the specificity of the fastening elements. Before purchasing a copy of this category, you should familiarize yourself with the twisting capabilities.

It is also important to take into account configurations that are equipped with protection in the form of a mesh, such as chain mail. Users note that such braiding is most effective in protecting properties and extending the service life of machine spare parts.

Important nuances

As we have seen, welding the muffler and corrugation for repair is not at all necessary. But there are some nuances in the above types of repairs.

The corrugation must be installed evenly, without distortions. At the end of the work, make sure that all brackets and hangers for attaching the muffler are intact and ensure its stability and immobility.

All three options for replacing corrugations will take no more than an hour. The part must be repaired at the first sign of a malfunction. Do not forget that timely replacement of the part is necessary for the further safe operation of the car.