Manifold & exhaust systems (Tailpipe Assembly): Description and operation

Tailpipe Assembly

The tailpipe assembly is of fabricated and welded construction and comprises a large capacity silencer, a connecting pipe and a tail pipe. The curved connecting pipe is welded to the left hand end of the silencer and connects with the rear pipe section of the centre silencer assembly. The tail pipe is welded to the right hand end of the silencer and directs exhaust emissions downwards from the right hand end of the rear bumper.

The connecting pipe is a sliding fit on the centre silencer. A clamp secures the two pipes together. Attachment bars are welded to each end of the tailpipe assembly and provide attachment points for the tailpipe to the body via mounting rubbers.

The tail pipe silencer is fabricated from a 0.6 mm mild steel outer cover with a 0.5 mm stainless steel inner liner and is oval in section. An end plate is secured to each end of the outer cover with seam joints. The inlet and outlet of the silencer are diametrically opposed at each end of the silencer. The inlet and outlet each incorporate a perforated baffle tube welded to each end plate and retained internally by two baffle plates.

Two perforated balance pipes are located between the two baffle plates and exhaust gases from the inlet is forced to flow through the balance pipes before it reaches the outlet. Two open spaces at each end of the silencer act as expansion chambers to further reduce engine exhaust noise.

The upper surface on the outside diameter of the silencer has an additional plate welded, with an air gap between the plate and the silencer body. The air gap is filled with a heat absorbing ’Fibrax’ insulating pad which reduces heat from the silencer radiating to the floorpan of the vehicle.

’L’ Series Engine

The exhaust system comprises an elbow, downpipe, catalytic converter, centre pipe and a tailpipe. The system is constructed mainly of 60 mm diameter extruded pipe with a 1.5 mm wall thickness.

Elbow

The elbow is made from cast iron and connects the turbocharger to the downpipe of the exhaust system. The elbow is located on four studs on the turbocharger and secured with four nuts. A flanged end with three studs connects with the downpipe and is secured with three nuts. There is a metal gasket between the elbow and the downpipe.

Front Pipe Assembly

The downpipe is of welded and fabricated tubular construction and is connected to the elbow flange with three nuts. The downpipe connects into a flexible pipe and terminates in a flanged connection which mates with the catalytic converter and sealed with a metal gasket.

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 increase the longevity of the flexible pipe.

The downpipe is secured to the to the gearbox via a metal support bracket with 4 bolts and a mounting rubber connected to the body.