Muffler for Nissan Sunny FB15: how to choose, replace and upgrade

Nissan Sunny FB15 is a legendary sedan that is still in demand due to its reliability and simplicity of design. However, even such time-tested cars have weak points, and one of them is exhaust system, or rather, its muffler. Over time, corrosion, mechanical damage and natural wear lead to the fact that the standard muffler requires replacement or repair.

In this article we will look at everything the owner needs to know. FB15 about mufflers: from signs of malfunction to the nuances of choosing between the original and analogues, from step-by-step instructions for replacement to tuning options to improve sound and performance. You will also find current prices for 2026, comparison of popular brands and answers to frequently asked questions.

Signs of a muffler malfunction on a Nissan Sunny FB15

A muffler rarely fails suddenly; problems usually accumulate gradually. If you do not pay attention to the first symptoms in time, you may encounter more serious (and expensive) breakdowns. Here are the key signs that you have a muffler FB15 something is wrong:

• 🔊 Increased noise — the muffler begins to “growl” or “shoot”, especially when picking up speed. This is a signal about burnout of internal partitions or corrosion of the housing.
• 💨 Exhaust smell in the cabin - if the seals or corrugations have lost their tightness, gases can penetrate inside the car. Dangerous for health!
• 🔥 Condensation or water droplets from the exhaust pipe - in small quantities this is normal, but if the liquid flows in a stream, cracks or corrosion are possible.
• 🛠️ Visible damage - rust, dents, holes or fallen parts (for example, heat shield).

Particular attention should be paid to muffler corrugation — it is often the first to suffer due to constant vibrations and temperature changes. On Sunny FB15 The corrugation is located closer to the front of the system, and its burning out leads to a characteristic metallic rattling sound when the engine is running.

⚠️ Attention: If black or bluish smoke comes from the exhaust pipe, the problem may not be in the muffler, but in the engine (wear of piston rings, oil seals). In this case, a comprehensive diagnosis is required.

Another warning sign - deterioration in acceleration dynamics. A clogged or damaged muffler creates excess resistance to exhaust gases, which reduces engine power. On FB15 with its modest volume (1.5–1.6 l), this is especially noticeable.

Original muffler vs analogues: what to choose for FB15

When replacing the muffler with Nissan Sunny FB15 The owner is faced with a choice: to install an original part or an analogue. Each option has pros and cons, and the final decision depends on budget, goals (restoration or tuning) and availability of spare parts.

Original muffler for FB15 has a catalog number 20620-4M000 (for 1990–1995 models). Its main advantage is the perfect fit and factory sound quality. However, the high price and difficulties with searching (especially for older versions) force many owners to consider analogues.

Among the alternatives that have proven themselves well:

• 🔧 Bosal (Netherlands) - optimal price/quality ratio, often used in European services.
• 🔧 Walker (USA) - durable, but more expensive than most analogues.
• 🔧 Asam (Türkiye) - a budget option, but the quality of welding is sometimes poor.
• 🔧 SASIC (Korea) - close to the original in terms of characteristics, but 30–40% cheaper.

⚠️ Attention: When purchasing an analogue, be sure to check the car’s VIN code or check the year of manufacture. Silencers for FB15 1990 and 1994 may differ in mounts and length!

Critical nuance: some versions of the Sunny FB15 with the GA15DE engine use a muffler with an additional resonator. If you install a model without a resonator, the sound will become noticeably louder, and at high speeds an unpleasant “metallic” timbre will appear.

Step-by-step instructions for replacing the muffler on a Nissan Sunny FB15

Replacing the muffler with FB15 - a task of medium complexity that requires a minimum set of tools and accuracy. If there is an inspection hole or a lift, the work can be completed independently in 1.5–2 hours. If there is no hole, you will need a jack and reliable stops.

Required tools and materials:

• 🔧 Set of sockets and keys (10, 12, 14 mm).
• 🔧 WD-40 or a similar composition for unscrewing stuck nuts.
• 🔧 New gaskets and clamps (if replacement is required).
• 🔧 Grinder or hacksaw for metal (in case the fastenings do not unscrew).
• 🔧 Gloves and safety glasses.

Work order:

1. Preparation. Stop the engine and allow the system to cool (the exhaust pipe may be hot!). Jack up the rear of the car and install jack stands.
2. Removing the old muffler.
   • Treat all bolted connections with WD-40 (flange in front of the resonator, attachment to the body).
   • Unscrew the nuts of the clamp connecting the muffler to the resonator.
   • Remove the rubber hangers (they can be cut off if they have soured).
   • Carefully remove the muffler by pulling it backwards.
3. Installing a new muffler.
   • Check the condition of the gaskets and replace them if necessary.
   • Install the new muffler in the reverse order, starting with the mounting to the resonator.
   • Tighten the clamps and bolts, but do not overdo it - you may strip the threads.
   • Make sure that the rubber hangers are not twisted or stretched.

Check. Start the engine and check the connections for leaks. Listen to the sound - there should be no extraneous noise or rattling.

Cool the exhaust system

Prepare new gaskets and clamps

Treat all threaded connections with WD-40

Check the condition of the rubber hangers

Make sure there are no cracks on the new muffler -->

The hardest part is unscrewing the stuck nuts. If they do not give in, you should not use excessive force - it is better to cut them off with a grinder and replace the fasteners with new ones. Also note corrugation: if it burns out, it is better to replace it at the same time as the muffler.

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Before installing a new muffler, apply graphite lubricant to the threaded connections - this will facilitate future replacement and protect against corrosion.

Muffler Tuning: How to Improve Sound and Performance

Many owners Nissan Sunny FB15 want to give their car a sportier character, and modifying the exhaust system is one of the most affordable ways to do this. However, it is important to understand that the muffler affects not only the sound, but also the engine performance.

Tuning options:

• 🔥 "Forward flow" — replacing the standard muffler with a model with minimal resistance. Gives a louder and lower sound, but may impair traction at low speeds.
• 🔥 Sports muffler (For example, Remus or Sprint) - maintains an acceptable noise level, but improves gas removal.
• 🔥 Resonator installation - if it was not included as standard, this will help smooth out the sound and reduce rattling.
• 🔥 Replacing corrugation with a flexible metal hose — increases reliability and reduces vibrations.

On FB15 with engine GA16DE (1.6 l) popular scheme: standard manifold → flame arrester → straight-through muffler. This gives a nice bass sound without losing power. However, it is important to remember:

• ⚠️ Installing forward flow without modifying the ECU may cause an error P0420 (low catalyst efficiency).
• ⚠️ A muffler that is too short impairs low-end traction - this is critical for city driving.
• ⚠️ In some regions of Russia, loud exhaust may cause a fine (exceeding noise standards).

If the goal is not only sound, but also an increase in power, it is worth considering replacing the entire exhaust to the 4-2-1 system (for example, from Nismo or HKS). However, this is already a serious modification that requires adjusting the fuel map.

What does installing a flame arrester provide?

The flame arrester (or “stronger”) is installed instead of the catalyst and performs two functions:

1. Reduces the temperature of exhaust gases, protecting the muffler from burning out.

2. Reduces flow resistance, which can give an increase of 3-5 hp. at high speeds.

However, its installation requires flashing the ECU or using a decoy lambda probe, otherwise the “Check Engine” will light up.

Prices for mufflers for Nissan Sunny FB15 in 2026

Muffler cost for FB15 depends on the type (original/analog), material (stainless steel/aluminized steel) and region of purchase. Below is the current price list for Moscow and the regions (prices are in rubles, including delivery).

Muffler type	Brand	Price, ₽ (Moscow)	Price, ₽ (regions)	Notes
Original (20620-4M000)	Nissan	15 000–18 000	16 500–19 000	Long delivery time (2–4 weeks)
Analogue (stainless steel)	Bosal	7 500–9 000	8 000–9 500	2 year warranty
Analogue (aluminum steel)	Asam	4 500–6 000	5 000–6 500	Service life 3–4 years
Direct flow (stainless steel)	Fox	12 000–14 000	13 000–15 000	Noise level ~95 dB
Sports (with resonator)	Remus	22 000–25 000	23 000–26 000	Suitable for tuning

Prices in regions may differ by 10–15% depending on logistics. It is also worth considering the cost of replacement work:

• 💰 Replacement of the muffler in the service: 1,500–2,500 ₽.
• 💰 Replacement of corrugation: 800–1,200 ₽.
• 💰 Welding cracks: 500–1,000 ₽.

When purchasing through online stores (for example, Exist.ru, Autodoc) pay attention to reviews about the seller - you often come across counterfeits of well-known brands. Original mufflers Nissan must have an engraving with a catalog number and a hologram.

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Saving on a muffler is more expensive: cheap analogs made of thin steel burn out in 1–2 years, and replacing them, including labor, costs the same amount as buying a high-quality part.

Frequent mistakes when replacing and operating a muffler

Even experienced car owners sometimes make mistakes that lead to premature failure of the muffler or deterioration in its performance. Here are the most common mistakes:

1. Ignoring rubber hangers. Over time, rubber loses elasticity and breaks. If you do not replace the hangers, the muffler will dangle, hit the body and burn out faster.
2. Tightening the nuts. Excessive tightening force will cause stripping of threads or deformation of flanges. Optimal tightening torque for FB15 — 25–30 Nm.
3. No anti-corrosion treatment. After replacing the muffler, it is worth treating it with heat-resistant paint or anti-corrosion agent (for example, Dinitrol 479). This will extend the service life by 20–30%.
4. Installation of incompatible corrugation. The corrugation must correspond to the diameter of the pipe (usually 50–55 mm for FB15). Too narrow will create excess resistance, too wide - it will rattle.
5. Saving on gaskets. Old or cheap gaskets quickly become tanned and begin to leak gases, which leads to loss of power and an unpleasant odor.

Another common mistake is an attempt to repair a burnt-out muffler by welding. In most cases, this has a temporary effect (1-3 months) as the corrosion continues to spread. The exception is small cracks that can be sealed with argon and then treated with a heat-resistant sealant.

⚠️ Attention: If after replacing the muffler the engine becomes unstable or the "Check Engine" light comes on, check the system for leaks. Even a small leak of exhaust gases to the lambda probe will lead to an error P0171 (lean mixture).

Muffler maintenance: how to extend its service life

Muffler on Nissan Sunny FB15 can last 5-7 years with proper care. Here are the key preventive measures:

• 🛠️ Regular washing in winter. Salt and reagents accelerate corrosion. Wash the underbody (including the muffler) at least once every 2 weeks.
• 🛠️ Anti-corrosion treatment. Once a year, apply a heat-resistant coating to the muffler (e.g. Liqui Moly Auspuff-Spray).
• 🛠️ Gimbal control. Check the condition of the rubber suspensions every 20,000 km. If they are cracked, replace them.
• 🛠️ Avoid overheating. Do not accelerate on a cold engine - condensation inside the muffler during sudden heating accelerates corrosion.
• 🛠️ Checking fastenings. Tighten the clamps and bolts every six months (especially after off-road driving).

If you often drive on dirt roads or gravel, install protective screen under the muffler. It will prevent mechanical damage from stones and branches. Also useful once a year clean drain holes in the muffler (they are located in the lower part) - this will prevent condensation from accumulating.

For owners FB15For those who store their car in the garage in winter, there is a simple life hack: before parking, start the engine and let it idle for 2-3 minutes. This will dry out the condensation inside the muffler and reduce the risk of corrosion.

FAQ: Frequently asked questions about Nissan Sunny FB15 mufflers

Is it possible to drive with a burnt out muffler?

Technically possible, but not advisable. A burnt-out muffler not only affects sound and comfort, but can also lead to:

• Exhaust gases entering the cabin (risk of carbon monoxide poisoning).
• Overheating of exhaust system elements and fire.
• Deterioration of dynamics and increased fuel consumption.

If the damage is minor (such as a crack), you can temporarily seal it with heat-resistant sealant (Abro ES-332), but this is a solution for 1–2 months.

Which muffler is better for a quiet ride: original or Bosal?

In terms of noise level, the original muffler and Bosal almost identical. However, there are nuances:

• The original is guaranteed to fit the mounts and give a “native” sound.
• Bosal cheaper, but in some batches there are problems with the quality of welding (a whistle may appear at high speeds).

If your priority is silence, choose the original or Walker (they use thicker metal and better sound insulation).

Do I need to change the corrugation along with the muffler?

Not required, but recommended if:

• The corrugation has visible cracks or rust.
• When the engine is running, a metallic rattling sound is heard.
• Reliability is important to you - the new corrugation will last longer than the old one, even if it is still intact.

The cost of corrugation for FB15 — 1,500–2,500 ₽, replacement takes 30–40 minutes.

Is it possible to install a muffler from Nissan Almera N15 on Sunny FB15?

Theoretically it is possible, but some modifications will be required:

• The fasteners do not match - you will have to re-weld the flanges.
• The length of the pipes may vary, which will affect the ground clearance.
• The sound will become louder (by Almera N15 muffler is shorter and has fewer chambers).

If you need a direct analogue without modifications, look for a muffler specifically for Sunny FB15.

How to check the muffler for leaks without removing it?

There are two simple ways:

1. Visual inspection. Start the engine and inspect the muffler for smoke or fumes coming from cracks. It is better to do this in the dark - leaks will be more visible.
2. Hand check. Carefully (so as not to get burned!) run your hand along the seams of the muffler while the engine is running. A flow of gases will be felt at the leak points.

You can also use a soap solution: apply it to the seams - if there is a leak, bubbles will appear.