Manifolds and exhaust systems - Td5 (Description): Description and operation (page 2 of 2)

Front pipe assembly The front pipe is of welded and fabricated tubular construction. The front pipe is connected to a flange on the turbocharger and secured with three flanged nuts and sealed with a metal laminated gasket. The front pipe incorporates a flexible pipe near the connection with the turbocharger and terminates in a flanged connection with the intermediate pipe.

The flexible pipe is formed into a concertina shape with woven metal strands around its outer diameter. The flexible pipe allows for ease of exhaust system alignment and also absorbs engine vibration. The woven metal strands also increase the longevity of the flexible pipe.

The front pipe is attached via a bracket and a mounting rubber to the chassis. The mounting rubber allows ease of alignment and vibration absorption.

Intermediate pipe and silencer The intermediate pipe is of welded and fabricated tubular construction. It connects at its forward end to the front pipe flange. Two captive studs on the intermediate pipe flange allow for attachment to the front pipe with locknuts. The rear section of intermediate pipe connects to the tail pipe assembly via a flanged joint, sealed with a metal gasket and secured with locknuts and studs.

The forward and rear sections are joined by a silencer. The silencer is fabricated from stainless steel sheet to form the body of the silencer. An end plate closes each end of the silencer and is attached to the body with seam joints. Perforated baffle tubes, inside the silencer, are connected to the inlet and outlet pipes on each end plate. Internal baffle plates support the baffle tubes and, together with a stainless steel fibre packing, absorb combustion noise as the exhaust gases pass through the silencer.

The intermediate pipe is attached by two brackets, positioned at each end of the silencer, and two mounting rubbers to the chassis. The mounting rubber allows for ease of alignment and vibration absorption.

Tail pipe assembly The tail pipe is of welded and fabricated construction. The tail pipe connects to the intermediate pipe with a flanged joint secured with locknuts and sealed with a metal gasket. The pipe is shaped to locate above the rear axle allowing clearance for axle articulation. The pipe is also curved to clear the left hand side of the fuel tank which has a reflective shield to protect the tank from heat generated from the pipe.

A fabricated silencer is located at the rear of the tail pipe. The silencer is circular in section and is constructed from stainless steel sheet. A baffle tube is located inside the silencer and the space around the baffle tube is packed with a stainless steel fibre. The holes in the baffle tube allow the packing to further reduce combustion noise from the engine. The tail pipe from the silencer is curved downwards at the rear of the vehicle and directs exhaust gases towards the ground. The curved pipe allows the exhaust gases to be dissipated by the airflow under the vehicle and prevents the gases from being drawn behind the vehicle.

The tail pipe is attached by a bracket, positioned forward of the silencer, and a mounting rubber to the chassis. The mounting rubber allows ease of alignment and vibration absorption.