Specifications

THE EXHAUST SYSTEM CLUTCH
A revised front downpipe, centre pipe and tail
silencer have been developed in conjunction with
the engine development programme. The
dimensions selected for the front downpipe and
centre pipe enhance the torque characteristics of
the Group A engine, and the engine management
system has been optimised for this system.
Whilst the total system is considered effective as
a silencing device and meets current U.K. Traffic
Regulations, it is the responsibility of the
competitor to ensure conformity with the traffic
regulations of the countries through which the
event is run.
FITTING GUIDE
Mounting brackets for this exhaust system have
not been attached. Experience has shown that it
is easier to mark the exact position for the
mounting brackets with the system in place.
This allows for some variation between vehicles
and exhaust systems to be catered for.
The chassis mounted rear bracket should first
be removed from the car. Replace with and weld
into place, the modified bracket supplied.The
front bracket should be welded on to the rear
gearbox mounting centre bracket. The position
can be determined by attaching the front
downpipe to the exhaust manifold. The other
part of this bracket can then be tack welded to
the front pipe to line up with it.
Now remove
the front pipe and complete the welding
operation on the bracket.
Refit front pipe and
fully secure to gearbox mounting point. The
centre pipe section and rear silencer box should
now be offered into place. By twisting each
section relative to each other, the optimum
position can be determined giving satisfactory
clearance over the rear axle beam, spare wheel
well etc. Mark position for the rear mounting
bracket and tack weld in place if possible.
Remove from car for final welding operation. It
is suggested that short lengths of small diameter
tubing are welded to the pipes on either side of
the sleeve joints to create a facility for lockwiring
the pipes together rather than using exhaust
clamps. This gives a quick release attachment,
invaluable for on event servicing or replacement
if damaged. The system can then be attached
using the standard exhaust mounting rubbers.
CLUTCH ASSEMBLY
A sachs 190mm diameter, solid disc centreplate
competition clutch with heavy duty diaphragm
cover has been developed. This unit is supplied
in the Clubmans Kit and fits the standard
flywheel without any modifications. However, it
does require a special release bearing which is
supplied complete with a special bearing carrier.
This carrier requires detailed modification for it
to fit the existing gearbox casing, as follows.
One of the three locating flanges must be
reduced in thickness to give clearance against the
gearbox casing at one point. This can be
achieved by carefully grinding away the excess
material thus `thinning' the selected flange
around its outside diameter. The three
attachment holes around the carrier must then be
slotted and elongated to adapt to the smaller
pitch circle radius of the threaded holes in the
casing. Assemble by first fitting the `O' ring seal
followed by the thin spacer ring. Secure in
position by attaching the bearing carrier to the
gearbox casing with the three bolts. Clutch cable
adjustment procedure follows that for the
standard car.