Muffler <em>Nissan Terrano 2</em> (R20): how to select, replace and repair

Nissan Terrano 2 (internal designation R20) is a legendary frame SUV that is still in demand due to its reliability and maintainability. However, even such “tanks” have weak points, and one of them is the exhaust system. Muffler Terrano 2 susceptible to corrosion, mechanical damage and wear, especially if the car is operated in difficult conditions. In this article, we will look at how to choose the right spare part, when to change it, and whether it is possible to save on repairs without compromising quality.

Owners Terrano 2 often faced with a dilemma: buy an original muffler from Nissan at a high price or take a chance with an analogue from an unknown manufacturer? We analyzed the market, interviewed service station technicians and collected honest reviews from car owners to help you make an informed decision. And also - detailed replacement instructions with photos and videos, which will save you up to 5,000 rubles on service work.

Signs of a muffler malfunction: when is it time to go to service?

The first symptoms of problems with the muffler Nissan Terrano 2 are often ignored until the situation becomes critical. Meanwhile, early diagnosis allows you to avoid expensive repairs. Pay attention to the following signals:

• 🔊 Increase in noise - a dull rumble or sharp pops during acceleration, especially at low speeds. This is a sign of a burnt-out partition or cracks in the housing.
• 💨 Exhaust smell in the cabin - indicates depressurization of the system. Health hazard: carbon monoxide (CO) is odorless!
• 🔥 Black marks on the body under the muffler - the result of gas leakage through microcracks that “burn out” the paint.
• 🛑 Reduced engine power — a clogged catalyst or resonator creates back pressure, interfering with the normal operation of the engine.

The muffler is especially vulnerable Terrano 2 with a mileage of 150,000 km - it is during this period that active corrosion of welds and fastening points begins. On vehicles with gas-cylinder equipment (LPG), the life of the muffler is reduced by 20–30% due to the higher temperature of the exhaust gases. If you notice at least one of the listed signs, do not delay diagnosis: ignoring the problem can lead to damage to the catalytic converter (the cost of a new one is from 25,000 rubles).

⚠️ Attention: If white smoke with a strong chemical smell comes out of the exhaust pipe, this may be a sign of antifreeze getting into the combustion chamber. Immediately check the cylinder head gasket - the muffler has nothing to do with it!

Original vs analogues: which is better for Nissan Terrano 2?

Choosing a muffler for Terrano 2 Depends on budget and operational goals. Original part from Nissan (article 20680-4M000 for the rear can) guarantees a perfect fit and long service life, but its price is steep - from 12,000 to 18,000 rubles. The alternatives are cheaper, but not all of them are worth considering. Let's look at the pros and cons of each option:

Muffler type	Pros	Cons	Average price, ₽
Original Nissan	Precise geometry, stainless steel, 2 year warranty	High cost, long wait when ordering	12 000–18 000
Premium analogues (Bosal, Walker)	Quality close to the original, wide range	The price is only 20–30% lower, problems with fastenings are possible	8 000–12 000
Budget analogues (Asam, Febi)	Low price, fast delivery	Thin metal, corrosion after 1–2 years, poor sound insulation	3 000–6 000
Universal "banks"	Cheap, suitable for temporary repairs	Requires modification of fastenings, does not comply with environmental standards	1 500–4 000

For Terrano 2 with mileage over 200,000 km, we recommend considering the option with stainless muffler from trusted brands, for example, Remus or Sprint. Yes, the price is higher (from 15,000 rubles), but the service life increases by 2–3 times. If your budget is limited, pay attention to Asam 30526 - this is one of the few budget analogues that does not “rot” within a year.

Step-by-step replacement of the muffler with Nissan Terrano 2: instructions with photos

Replacing the muffler with Terrano 2 - a task of medium complexity that will require an inspection hole or a lift, as well as a set of tools. If you have experience working with an angle grinder and a welding machine, you can do it in 2-3 hours. Otherwise, it is better to contact the service - installation errors can lead to gas leaks or damage to neighboring components.

To work you will need:

• 🔧 Set of sockets and keys (especially for “14” and “17”)
• 🔥 Grinder with a cutting wheel (if the nuts are stuck)
• 🔩 New clamps and gaskets (item no. 11385-4M000)
• 🧲 Sealant for the exhaust system (for example, Liqui Moly Auspuff-Montage-Paste)
• 🛠️ Jack and stops (if there is no hole)

Procedure:

1. Treat all threaded connections with a penetrating lubricant (e.g. WD-40) 1–2 hours before the start of work.
2. Disconnect the muffler from the resonator by unscrewing the clamp or bolts (depending on the modification).
3. Remove the muffler mountings to the body (usually 2-3 rubber hangers).
4. If the nuts are stuck, carefully cut them off with a grinder, leaving a reserve for new fasteners.
5. Install the new muffler, first applying sealant to the joints.
6. Tighten the clamps and check the system for leaks (start the engine and inspect for leaks).

Buy a new muffler and consumables (clamp, gaskets, sealant)

Treat threads with WD-40 in advance

Prepare tools (heads, grinder, jack)

Provide access to the lower part of the car (pit/lift)

Check the availability of a fire extinguisher (working with an angle grinder is a fire hazard!) -->

Pay special attention alignment pipes when joining. If the muffler is installed crookedly, vibrations during movement will quickly destroy the welds. After replacement, check the operation of the system at idle and during acceleration - there should be no popping or rattling noises.

⚠️ Attention: When cutting stuck nuts with a grinder, follow safety precautions! Sparks can ignite dry grass or spilled oil. Wear safety glasses and gloves and place a metal sheet under the machine.

Muffler repair Nissan Terrano 2: when can you do without replacement?

A crack or corrosion of a muffler is not always a death sentence. If the damage is not critical, you can try to repair the part and extend its life by 1–2 years. Here are some proven methods:

• 🔥 Welding — suitable for cracks up to 5 cm long. Use a semi-automatic machine with stainless steel wire. After welding, be sure to clean the seam and paint it with heat-resistant paint.
• 🧲 Bandage clamps - temporary solution for small holes. Select a clamp with a rubber gasket (for example, ABRO ES-3) and tighten it on the damaged area.
• 🎨 Heat resistant sealant - for microcracks. Apply the composition (for example, Permatex Muffler & Tailpipe Sealer) onto the cleaned surface and allow to dry for 24 hours.
• 🔩 Replacing individual sections — if only the rear “can” burns out, you can cut it off and weld a new one without touching the resonator.

However, repairs make sense only in three cases:

1. The mileage of the car is more than 300,000 km, and you are planning to sell the car soon.
2. The damage is local (for example, one fastener burned out), but the rest of the muffler is in good condition.
3. You do not have the opportunity to buy a new muffler here and now (for example, on a business trip).

According to service station statistics, 80% of “repaired” mufflers on Terrano 2 fail within 6–12 months. If you are not ready for repeated work, it is better to immediately install a new part.

What happens if you drive with a leaky muffler?

In addition to noise discomfort, there are three serious problems:

1. Carbon monoxide (CO) can penetrate into the cabin through body leaks, causing headaches and nausea.

2. Increased engine load due to a violation of back pressure leads to an increase in fuel consumption by 5–10%.

3. Risk of fire — sparks from a burnt-out muffler can set fire to dry grass or leaves under the car, especially in hot weather.

How to extend the life of a muffler: prevention and care

Muffler service life Nissan Terrano 2 depends not only on the quality of the part, but also on the operating conditions. By following simple recommendations, you can delay replacement by 30–50%:

• 🚿 Washing in winter - salt and reagents destroy the metal. Wash the underbody (including the muffler) once every 2 weeks with warm water.
• 🛣️ Avoid deep puddles — sudden cooling of hot metal leads to microcracks.
• 🔧 Regular inspection — check the muffler every six months for rust and burnouts, especially after off-road trips.
• 💨 Exhaust system control — if the engine begins to “trouble”, check the tightness of the pipes. Faulty spark plugs or injectors increase the load on the muffler.

The muffler can be treated for additional protection heat-resistant composition (For example, CRC Muffler Paint or VHT FlameProof). These paints can withstand temperatures up to 650°C and slow down corrosion. Apply them to a clean, grease-free surface in 2-3 layers, drying between layers.

If your Terrano 2 equipped gas cylinder equipment (GBO), pay attention to setting up the system. A mixture that is too lean (high oxygen content in the exhaust) accelerates corrosion of the muffler. Optimal air/gas ratio for Terrano 2 with motor TD27 — 14,5:1.

Exhaust system tuning: is it worth the trouble?

Many owners Nissan Terrano 2 are thinking about tuning the exhaust system - be it installing a “forward flow” for better sound or replacing it with a stainless muffler for durability. But before spending money, weigh the pros and cons:

Type of tuning	Pros	Cons	Cost, ₽
Direct flow muffler	Sports sound, slight increase in power (3–5 hp)	Increased noise (may fail inspection), rapid wear	8 000–15 000
Stainless muffler	Service life 10+ years, corrosion resistance	High price, does not always improve sound	15 000–25 000
Removing the catalyst	Reducing the cost of repairs, improving exhaust flow	Not environmentally friendly, the "Check Engine" may light up, problems with technical inspection	3 000–7 000

For Terrano 2 with diesel engine TD27 Tuning the exhaust system makes sense only in two cases:

1. You plan to participate in off-road competitions where maximum cross-country ability is important (for example, installing a “snorkel” for deep fording).
2. Your muffler is completely rusted out and you want to install a durable stainless alternative.

In other cases, tuning is more of a fashion statement than a practical necessity. Remember that modification of the exhaust system design may lead to:

• 🚨 Problems with passing technical inspection (especially after removing the catalyst).
• 📉 Increased fuel consumption due to back pressure violation.
• 🔊 Conflicts with the law - exhaust noise should not exceed 96 dB (GOST R 52231-2004).

FAQ: Frequently asked questions about the muffler Nissan Terrano 2

Is it possible to drive without a muffler if it is completely rusty?

Technically possible, but highly undesirable. Without muffler:

• The noise will exceed all permissible standards (risk of a fine from the traffic police).
• Exhaust gases will enter the cabin, which is hazardous to health.
• The load on the engine will increase, which will lead to increased wear.

If the muffler falls off on the road, you can temporarily secure the pipe with wire or a clamp, but do not delay repairs for long.

Which muffler is best for Terrano 2 with LPG?

For cars with gas cylinder equipment we recommend:

1. Stainless silencers (For example, Remus or Sprint) - they can withstand higher temperatures.
2. Models with reinforced welds — gas burns slower than gasoline, which increases the heat load.
3. Silencers with additional thermal insulation (for example, thermal tape wrapping).

Suitable for budget options Asam 30526, but it will have to be changed more often (every 1–2 years).

How much does it cost to replace a muffler on a Terrano 2 at a service center?

The cost of work depends on the region and complexity:

• Replacing the rear "can" — 1,500–2,500 rubles.
• Complete replacement of the system (from the collector) — 4,000–7,000 rubles.
• Welding cracks — 800–1,500 rubles.

In Moscow services, prices are 20–30% higher than in the regions. Replacing it yourself will save you 30-50% of the cost.

Why did the smell of exhaust gases appear in the cabin after replacing the muffler?

The reasons may be as follows:

1. Leaky joint between the muffler and the resonator - check the clamps and gaskets.
2. Cracks in floor insulation — gases penetrate through cracks in the body.
3. Clogged crankcase breather — creates excess pressure, squeezing gases through leaks.

To diagnose, start the engine, close the windows and check where exactly the smell is coming from. Most often, the problem is solved by tightening the clamps or replacing the gasket.

Which muffler is suitable for Terrano 2 with TD27T engine (turbo)?

For turbodiesel TD27T a muffler with a reinforced design is needed, since the temperature and pressure of the exhaust gases are higher than atmospheric TD27. Suitable options:

• Original Nissan - article number 20680-4M010 (with turbo cutout).
• Bosal 234-141 — a reinforced analogue for turbodiesels.
• Remus — stainless steel, suitable for harsh conditions.

Do not install mufflers from atmospheric versions - they burn out quickly!