Before starting the engine for the first time, I wanted to fit the exhaust to have some silencing. Without an exhaust being fitted, running the engine for extended periods of time while diagnosing faults just isn’t going to be possible, without annoying everyone around me.

The heat shield is the first thing to fit. It’s held onto the collector using large hose clamps. The kit supplied clamps are standard zinc plated clamps, so I have upgraded to full stainless genuine Jublee hose clamps. After all, the entire exhaust system is stainless steel. To fit them, open up the clamps and thread them through the brackets on the underside of the heat shield, then slide the heat shield onto the collector.

Heat shield fitted to collector – note the clamp position

A little care needs to be taken to align the heat shield clamps on the collector and to make sure the clamp bolt are low and out of harms way. I am sure if the IVA inspector wasn’t happy with the location, they would give you time to re-arrange them there and then, but you might as well get it right before the test.

I was expecting this next problem: the thread in the chassis for the exhaust mounting bracket has some paint that needed cleaning out. So, out comes a tap. Unfortunately I didn’t have the correct sized tap handle, so a small adjustable spanner became a impromptu handle.

Once the mount was bolted to the chassis, I slid the exhaust onto the collector. A little WD40 helps the exhaust slip into the collector. The exhaust has slots cut into end which joins with the collector. These slots should have no holes visible when the exhaust is fitted, but only just, so don’t slide the exhaust too far onto the collector, or the rear mounting brackets won’t align. The kit-supplied Mikalor clamp is stainless steel, but doesn’t have stainless fixings, so I will upgrade this later. The clamp should be fitted over the slots, covering them. Finally, the exhaust is fitted to the mount using the bobbin and the whole assembly can be tightened up.

The exhaust will need tightening several times when it’s hot to stop the tip from dropping. You don’t want it to drop too much or you will start scraping it on the ground.

Now, the observant reader might have noticed I used the wrong size washers on the exhaust mount. The new manual shows washers and spring washers, but the fixings kit only supplied spring washers. I found a few “that will do” washers that were not going to be used anywhere else. Obviously that’s not what you expect me to do, and you’re correct, but I have a feeling that I will be revisiting the exhaust at some stage before the IVA test.

Tool Used

  • 10mm ring spanner
  • 13mm combination spanner
  • 13mm semi deep 3/8” drive socket
  • 13mm shallow 3/8” drive socket
  • 3/8” drive ratchet
  • 10mm 1/4” drive socket
  • 1/4” drive ratchet
  • M10 tap
  • Small adjustable spanner