The UK automotive aftermarket’s dirty secret…

Non-type approved exhausts and catalytic converters that pollute and damage both cars and fuel efficiency are routinely being supplied in the UK aftermarket, and at the moment it is still legal to do so.

A recent test carried out for replacement exhaust manufacturer Klarius at the NAC UK’s Emissions Laboratory (Long-bridge) showed that the common practice of fitting non-type approved exhausts and catalytic converters in the UK is leading to poor fuel economy and increased pollution. Even more shocking results were found when a range of aftermarket catalytic converters were independently tested and found to be virtually useless.

UK type approval for replacement exhausts, or more accurately the lack of it, is set to become a more serious issue in the not too distant future. UK manufacturer Klarius producer of the TIMAX brand has always gained full type approval for its replacement exhaust and catalytic products, and is ready to fight the corner for a better quality product even in recessionary times, claiming that the end user is loosing out at the moment and pollution is far higher than in should or needs to be. And that government legislation needs to follow.

The main drive of the argument is that a cheaper exhaust, only by a few pounds per unit at trade prices, would not pass a UK type approval test (or an EU equivalent, on which it is based) for back pressure. Cheaper internals in a silencer can make a non-type approved exhaust quieter, in order to pass a noise test, but at the expense of higher back pressure than that of an OE part. The result is poorer fuel economy, worse by 3% according to independently audited figures, equivalent to roughly 3p per litre at current pump prices.

Doesn’t sound like much, but over an average 10,000 miles per year usage pattern it equates to the equivalent of £50 per year fuel saving, higher mileage obviously increasing the saving, not only that but the life of the engine is also going to suffer with not having the correct back pressure.

Klarius International Business Development Director, Paul Hannah comments, “Tesco and other large supermarket chains have shown that a saving of 3p per litre at the pumps can be a tremendous motivator to change buying habits with the average motorist, very few people realise that the decision they make (or is made for them) when buying a replacement exhaust can have the same impact on fuel economy for the life of the vehicle.”

 “Choosing a type-approved exhaust or insisting on one being fitted solves the problem immediately, and the purchase cost difference can be negligible. Some household name service chains are starting to use type approved products as the norm, but they are not doing enough at the moment to promote the difference, simply because the general public are not aware enough on the issues right now. That is job we have to educate the market, both the fitters and the end user.” 

When is the law going to change?

Across Western Europe this is not allowed to happen, all replacement exhaust and catalyst products have to be type approved before they can be sold and fitted to a car. The UK however is different, and here’s the rub, there is a consultation document in circulation right now prior to the law changing on catalytic converters, making it a legal requirement to fit only type approved CATs in the UK, it is due to be passed and could be in full effect before the end of the year.

This will address a serious concern over pollution, as some cheaper replacement products commonly being used at the moment have been analysed and found to contain none of the precious metals required to ensure the conversion process happens at all. UK MOT tests are being singled out as the reason why this practice is able to continue, some vehicles with petrol engines in good tune and with a short, straight-through exhaust will pass a standard UK emissions test, so one with an ineffectual CAT can also get through.

With some manufacturers already applying pressure on the Department of Transport to slate the changes for replacement exhaust systems, (Klarius exports a large number of systems across Europe, France, Germany, Spain, Scandinavia… for example and so has to comply already), how long is it before the UK is brought into line with the rest of Europe, the customer and the environment will ultimately benefit.

The fuel test:

A Vauxhall Astra 1.6L petrol, 1998 car was tested in a range of driving conditions using a standard replacement fit Klarius exhaust, designed, manufactured and fully type approved in the UK, against a non-type approved product from another manufacturer, on the urban cycle where the difference was most pronounced, the Astra used 3% more fuel.

 Doug Bentley, R & D Manager at the Klarius factory and test centre in Stoke arranged the test.

“We wanted to understand the financial impact of choosing a non-approved exhaust. We chose an average family car, with an exhaust taken directly off-the-shelf, and subjected the vehicle to the fuel consumption drive cycles tests, just as car manufacturers do. This was done independently at NAC UK’s Emissions Laboratory (Long-bridge). The tests were repeated, with competitors (none type approved) parts for comparison, we then analysed the results. The results showed that in all 3 drive cycle tests conditions, a non-approved part used more fuel.

“This was just one example, and I am sure it’s not the worst. If you were to select the very worst quality replacement exhaust and happened to find a model where the gap in engineering between ours and the alternative was wider, it is easy to see how purchasing or supplying the wrong exhaust could be costing a driver hundreds of pounds a year in fuel expenditure and maintenance.”

What is the type approval test for exhausts?

1. News from garages that a particular model is going to require a replacement, as well as an assessment of the age reached by a particular model (usually four or five years from the start of production) signals the need to develop a replacement. The team at Klarius will source a car and order an OEM replacement system for testing. The development team will then engineer a replacement system to match or exceed the performance of the original.

2. Using the test track at the Stoke plant, there are three tests carried out to confirm the replacement performs ideally. Drive by noise test, noise at the pipe exit, and the crucial back pressure.

3. Back pressure is measured very precisely on the OE system, and is matched to very close tolerances by the replacement. The tests on the replacement are repeated until the design passes testing, while still matching OE noise figures. The VCA then visit the Klarius test track and independently audit the test, issuing a conformity certificate for every single design.

The entire process takes as little as three weeks from demand to finished product being available from stock, next-day anywhere in the country. The fact that no other UK manufacturer bothers with the admittedly involved type approval procedure means that customers are not guaranteed to receive a replacement that matches their cars original design specification.

………………Ends……………….

Today, the Klarius exhaust range includes over 5,500 references and covers 97% of the European car park, and includes production and distribution across Europe. In addition, the past year has seen over £1million invested in the UK manufacturing sites, including the introduction of an advanced Technical Centre, designed to improve the quality and delivery of Klarius Group products.

Contact Details

For reader enquiries contact: Véronique Auger, Marketing Coordinator, Europe, Klarius group Ltd. Squires Gate Lane, Squires Gate Ind. Estate. Blackpool, Lancashire, England FY4 3RN. United Kingdom
Tel: + 44 1253 400 400 Fax: + 44 1253 406 475
Email: Veronique.Auger@Klarius.eu Web: www.klarius.eu

 

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