Delivery Programme 2013

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1 Delivery Programme 2013 Catalysts Exhaust-Systems Diesel Particulate Filters Universal Competition Exhaust Parts

2 Motorsport Catalysts Catalytic Converter Technology: HJS offers a universal non-regulated catalytic converter system with 100 cpsi for motor sport applications. For the different cubic capacity classes of racing vehicles, a corresponding catalytic converter with a specifically adapted catalytic converter volume has been developed. New generation of HJS motorsport catalysts with FIA homologation: The new generation of HJS high performance catalysts are characterized by 30 % less weight in relation to the so far used parts. We have reduced the backpressure about another 15%, the exhaust gas pollution reduction is optimised as well. The thickness of the foil (0.11 mm) persists unchanged. For the catalysts with the new developed foil we can guarantee the same durability in relation to our so far offered products. PE Foil less weight and less backpressure up to 180 hp / up to 1300 ccm Weight: 3.5 kg /55 up to 220 hp / up to 2000 ccm Weight: 4.5 kg ST 9074/10 PE WTCC, S2000, WRC up to 180 hp / up to 1200 ccm, up to 360 hp / up to 2000 ccm* Weight: 1.0 kg ST 9074/10 PE WTCC, S2000, WRC up to 180 hp / up to 1200 ccm, up to 360 hp / up to 2000 ccm* Weight: 1.0 kg Size in mm * Two catalytic converters to be mounted parallel 2

3 Motorsport Catalysts F PE Formel 3 up to 240 hp / up to 2000 ccm Weight: 1.6 kg WRC 1112/10 PE WRC, Kit Car, Gr. N/A up to 240 hp / up to 2000 ccm, up to 480 hp / up to 4000 ccm* Weight: 1.8 kg WRC 1112/10 PE WRC, Kit Car, Gr. N/A up to 240 hp / up to 2000 ccm, up to 480 hp / up to 4000 ccm* Weight: 1.6 kg S2 1210/10 PE S2000, WRC up to 280 hp / up to 2000 ccm, up to 560 hp / up to 4000 ccm* Weight: 1.5 kg T PE WRC, WTCC up to 350 hp / up to 1600 ccm Weight: 1.7 kg / PE WRC, Kit Car, Gr. N/A up to 350 hp / up to 2000 ccm, up to 700 hp / 5000 ccm* Weight: 2.0 kg Size in mm * Two catalytic converters to be mounted parallel 3

4 Motorsport Catalysts WRC 1279/10 PE WRC, Kit Car, Gr. N/A up to 350 hp / up to 2000 ccm, up to 700 hp / 5000 ccm* Weight: 2.0 kg GT 1407/10 PE GT, WRC, Kit Car, Gr. N/A up to 400 hp / up to 3000 ccm, up to 800 hp / up to 6000 ccm* Weight: 3.1 kg Size in mm * Two catalytic converters to be mounted parallel Motorsport UL Catalysts Ultra-light catalytic converter reduces weight by up to 30%: With the new ultra-light metal support it was possible to reduce the HJS FIA homologated catalyst s overall weight by up to 30%. The thickness of the catalyst casing can be reduced from 1.5 to 0.5 mm by use of the new three-dimensional bionic structure. In connection with the previously used perforated foil (PE) there is a significant weight reduction of over 50% compared to products of competitors. The smaller difference in thermal capacity of the steel foil matrix and the casing is another advantage of the product. As a result the durability doubles under the extremely high thermal shock loads commonly experienced in motorsport. UL catalyst with bionic 3D structure UL T WRC, WTCC up to 180hp / up to 1200ccm up to 360hp / up to 2000ccm* Weight: 0.8 kg UL 1 T WRC, WTCC up to 350hp / 1600ccm Weight: 1.0 kg 1 available from May 2013 Size in mm * Two catalytic converters to be mounted parallel 4

5 Motorsport Cup series Catalysts For all Cup series and standard motorsport cars with exhaust temperature not over 950 degrees centigrade, HJS offers a special 100 cpsi catalyst which combines the high quality of HJS products with a best price calculation. The target group are production-based F / Gr. N / R (non-turbocharged) cars. The catalyst R Cup is the right choice for all cars up to 1600 ccm/ 180 hp, the catalyst WRC CUP for all cars up to 2000 ccm/ 240 hp and the catalyst WRC Cup for all cars up to 2000 ccm / 300 hp. The Cup catalysts are based on the well known HJS product line of motorsport catalysts, that guarantees best quality and durability for years Cup R up to 180hp / up to 1600ccm up to 360hp / up to 3600ccm* Weight: 1.75 kg Cup WRC up to 240 hp / up to 2000 ccm Weight: 2.2 kg Cup WRC up to 240 hp / up to 2000 ccm Weight: 2.1 kg Cup WRC up to 300 hp / up to 2000 ccm, up to 600 hp / up to 4000 ccm* Weight: 2.9 kg Size in mm * Two catalytic converters to be mounted parallel 5

6 Motorsport Exhaust Systems HJS has developed an exhaust system for Mitsubishi EVO VII up to X including FIA homologated catalytic converters. The exhaust systems are made of stainless steel. We also offer an optimized front pipe for the Mitsubishi VII / VIII / IX / X. The Gr. R4 exhaust systems have been adapted to the specific capabilities of the technical regulations. Mitsubishi Motorsport Exhaust System Mitsubishi EVO X 3 2 Exhaust Systems Mitsubishi Car Exhaust System Purchased Catalytic Converter parts package EVO VII / VIII / IX Front Pipe Gr. N EVO X Front Pipe Gr. N EVO X Front Pipe Gr. A EVO VII / VIII / IX Exhaust System Gr. N - WRC 1279/10 PE EVO X Exhaust System Gr. N 1, 4, 5, 6 WRC 1279/10 PE EVO X Exhaust System Gr. N 2, 3, 5, 6 WRC 1279/10 PE EVO X Exhaust System Gr. A 1, 4, 5, 6 WRC 1279/10 PE EVO X Exhaust System Gr. R4 2, 3, 5, 7 GT1407/10 PE EVO X Turbo Front Pipe Gr. N & R4 2, EVO X Turbo Header Pipe Gr. N & R EVO X Middle Section Gr. N & R EVO X Middle Section with Flange Gr. N EVO X Rear Section Gr. N & R EVO X Retail Catalytic Converter Gr. N 6 WRC PE EVO X Retail Catalytic Converter Gr. R4 7 GT1407/10 PE 6

7 Motorsport Exhaust Systems HJS has developed a complete exhaust system for the Subaru WRX STI Gr. N and R4 including FIA homologated catalytic converters. The exhaust systems are made of stainless steel. The Gr. R4 exhaust systems have been adapted to the specific capabilities of the technical regulations. Our exclusive partner for the Gr. R4 exhaust systems is Tommi Mäkinen Racing: Subaru Motorsport Exhaust System Subaru WRX STI Exhaust Systems Subaru Car Exhaust System Purchased Catalytic Converter parts package WRX STI N15 Exhaust System Gr. N - left side 1, 2, 3, 5 WRC 1279/10 PE WRX STI N15 Exhaust System Gr. N - right side 1, 2, 4, 6 WRC 1279/10 PE WRX STI N15 Turbo Header Pipe Gr. N - left & right side WRX STI N15 Middle Section Gr. N - left & right side WRX STI N15 Middle Section Gr. N - right side WRX STI N15 Retail Catalytic Converter Gr. N - right side 6 WRC 1279/10 PE WRX STI N15 Middle Section Gr. N - left side WRX STI N15 Retail Catalytic Converter Gr. N - left side 5 WRC 1279/10 PE 7

8 Motorsport Catalyst Muffler Systems The developed Motorsport catalyst muffler system from HJS provides many advantages. The compact construction permits the installation also in vehicles with little ground clearance. The combination of muffler and catalyst effects a clear weight reduction. The exchangeable catalyst unit guarantees a cost-effective replacement. The system is certified for all vehicles up to 2000 ccm capacity. Catalyst Muffler Systems Diameter x Length Pipe Diameter FIA Homologation x 425 mm 63,5 mm WRC 1112/10 PE Spare Part Catalyst 63,5 mm WRC 1112/10 PE x 425 mm 70 mm WRC 1112/10 PE Spare Part Catalyst 70 mm WRC 1112/10 PE Diesel Particulate Filters for Motorsport The German Motorsportbund (DMSB) regulates for diesel powered vehicles the usage of a particulate filter. HJS developed a high-performance particulate filter for diesel powered vehicles in the context of the Alfa 147 Cup. This particulate filter meets all essential Motorsport requirements. HJS also offers diesel particulate filters for up to date Race-Trucks of the FIA European Truck Racing Championship. Diesel Particulate Filter Homologation Vehicle Classification MS DPF 1.8/0.87 Up to 2000 ccm / 210 hp front-wheel drive MS DPF 2.4/1.3 Up to 2000 ccm / 280 hp front-wheel drive MS DPF 2.5/1.3 Up to 3000 ccm / 300 hp rear-wheel drive MS DPF 1.7/0.87 BMW 120 D exhaust-system Gr. N MS DPF 1.7/0.87 Up to 2000 ccm / 210 hp rear-wheel drive MS DPF 1.7/0.87 Subaru Impreza Boxer Diesel Race Trucks Up to ccm / Version Additive F 51 1 Liter 8

9 Universal Competition Exhaust Parts Universal competition exhaust parts: A complete program of universal parts for the self-construction of exhaust systems is offered by the company HJS. With this delivery program, each passionate motor sport fan has now the opportunity of designing his exhaust system individually. It is also extremely helpful for the reconstruction or replacement of original parts which are no longer available. All parts are manufactured in stainless steel. The HJS silencers reduce the noise by absorption through centre perforated tubes and high temperature proof fibreglass. Accordingly, there is less gas flow restriction and hence back pressure is reduced and engine performance is optimised. The pipe ends are expanded to a length of 30 mm. Outside-Ø 45 mm - Universal Competition Pipes and Bends Description Length Wall Thickness Straight Pipe 1000 mm 1,5 mm Degree Bend 125 mm 1,5 mm Degree Bend 135 mm 1,5 mm Degree Bend 160 mm 1,5 mm Degree Bend 220 mm 1,5 mm Outside-Ø 60 mm - Universal Competition Pipes and Bends Description Length Wall Thickness Straight Pipe 1000 mm 1,5 mm Degree Bend 120 mm 1,5 mm Degree Bend 145 mm 1,5 mm Degree Bend 160 mm 1,5 mm Degree Bend 220 mm 1,5 mm Outside-Ø 48 mm - Universal Competition Pipes and Bends Description Length Wall Thickness Straight Pipe 1000 mm 1,5 mm Degree Bend 125 mm 1,5 mm Degree Bend 135 mm 1,5 mm Degree Bend 160 mm 1,5 mm Degree Bend 220 mm 1,5 mm Outside-Ø 65 mm - Universal Competition Pipes and Bends Description Length Wall Thickness Straight Pipe 1000 mm 1,2 mm Degree Bend 120 mm 1,2 mm Degree Bend 145 mm 1,2 mm Degree Bend 190 mm 1,2 mm Degree Bend 220 mm 1,2 mm Outside-Ø 50 mm - Universal Competition Pipes and Bends Description Length Wall Thickness Straight Pipe 1000 mm 1,5 mm Degree Bend 120 mm 1,5 mm Degree Bend 140 mm 1,5 mm Degree Bend 140 mm 1,5 mm Degree Bend 220 mm 1,5 mm Outside-Ø 70 mm - Universal Competition Pipes and Bends Description Length Wall Thickness Straight Pipe 1000 mm 1,5 mm Degree Bend 120 mm 1,5 mm Degree Bend 145 mm 1,5 mm Degree Bend 190 mm 1,5 mm Degree Bend 240 mm 1,5 mm Outside-Ø 55 mm - Universal Competition Pipes and Bends Description Length Wall Thickness Straight Pipe 1000 mm 1,5 mm Degree Bend 120 mm 1,5 mm Degree Bend 160 mm 1,5 mm Degree Bend 165 mm 1,5 mm Degree Bend 220 mm 1,5 mm Outside-Ø 76 mm - Universal Competition Pipes and Bends Description Length Wall Thickness Straight Pipe 1000 mm 1,5 mm Degree Bend 130 mm 1,5 mm Degree Bend 150 mm 1,5 mm Degree Bend 190 mm 1,5 mm Degree Bend 250 mm 1,5 mm 9

10 Universal Competition Exhaust Parts A = Outside-Ø mm B = Outside-Ø mm C = Inside-Ø mm Stepped Connection Pipes, Stainless Steel A B C Length mm 48 mm 50 mm 170 mm mm 50 mm 55 mm 170 mm mm 55 mm 60 mm 170 mm mm 60 mm 70 mm 170 mm mm 70 mm 76 mm 170 mm Flexible-pipe coupling, 3-thick walled, Heavy Duty, gas-tight (*2-thick walled) Inside-Ø Outside-Ø Length mm 70 mm 94 mm mm 75 mm 100 mm mm 80 mm 105 mm mm 90 mm 120 mm * 64 mm 86 mm 200 mm mm 95 mm 150 mm mm 101 mm 150 mm L2 L1 Stepped flexible-tube, gas-tight Inside-Ø Outside-Ø L1 L /48/50 mm 76 mm 100 mm 400 mm /50/55 mm 85 mm 105 mm 400 mm /55/60 mm 90 mm 120 mm 400 mm /60/70 mm 95 mm 150 mm 400 mm /70/76 mm 101 mm 150 mm 400 mm Bellow, gas-tight Inside-Ø Outside-Ø Length ,5 mm 85,5 mm 70 mm Y-Pipes Outside-Ø Pipe Distance Total Length x 50 mm / 2 x 50 mm 70 mm 200 mm x 55 mm / 2 x 50 mm 70 mm 200 mm x 60 mm / 2 x 55 mm 75 mm 200 mm x 60 mm / 2 x 60 mm 80 mm 200 mm x 70 mm / 2 x 60 mm 80 mm 200 mm x 76 mm / 2 x 60 mm 80 mm 200 mm Compensators / Connection adaptors Inside-Ø Total Length mm 155 mm mm 155 mm mm 155 mm mm 155 mm mm 155 mm mm 155 mm mm 155 mm 10

11 Universal Competition Exhaust Parts Connection adaptors Description Inside-Ø Length with λ plug 45 mm 75 mm mm 75 mm with λ plug 50 mm 75 mm mm 75 mm with λ plug 55 mm 75 mm mm 75 mm with λ plug 60 mm 75 mm mm 75 mm with λ plug 70 mm 75 mm mm 75 mm with λ plug 76 mm 75 mm mm 75 mm Competition Boxes, Absorption principle (*stainless steel) Tube Ø Box dimensions Total Length Ø x l / h x w x l mm 100 x 400 mm 650 mm mm 125 x 400 mm 650 mm mm 125 x 450 mm 700 mm * 60 mm 110 x 350 mm 450 mm mm 125 x 450 mm 700 mm * 60 mm 150 x 430 mm 650 mm * 70 mm 125 x 450 mm 650 mm * 76 mm 125 x 400 mm 600 mm mm 150 x 225 x 450 mm 700 mm mm 150 x 225 x 450 mm 700 mm * 60 mm 120 x 160 x 350 mm 450 mm Three-hole flanges, Steel Ø Bolt Circle Bore mm 76 mm 9 mm mm 91 mm 9 mm mm 116 mm 11 mm Packing ring / Packing ring for Connection adaptors, Steel Ø /48/50 mm /60 mm /76 mm Exhaust System consisting of Universal Competition Parts Example for application 11

12 Universal Competition Exhaust Parts The vacuum (pneumatic) operated exhaust valve consists of a double supported pressure plate, a housing with an integrated plate stop and a metal vacuum actuator. The double supported pressure plate and the patented axle suspension allows a noncontact positioning of the pressure plate in the housing. The special design of the exhaust valve ensures a very high tightness and compared to conventional exhaust valves, the vibration noise is reduced best possible. The pneumatic activation of the exhaust valve can be performed directly on the intake manifold, an additional "vacuum storage" is not needed. The exhaust valve is opened in the pressure-less situation and the opening angle can be adjusted manually. Exhaust Valves Ø mm mm mm mm mm λ - sensor plug and rings (*Stainless Steel) Description Screw Thread * Screwed Sealing Plug M 14 x 1, * CO - Sensor Threaded Ring M 14 x 1, * Temperatur PT - Threaded Ring M 14 x 1, λ - Sensor Screwed Sealing Plug M 18 x 1, * λ - Sensor Threaded Ring with Bevel M 18 x 1, * λ - Sensor Threaded Ring, Straight M 18 x 1, * λ - Sensor Threaded Ring, 45 Angle M 18 x 1, * NOx - Sensor Screwed Sealing Pluge M 20 x 1,5-6H * NOx - Sensor Threaded Ring M 20 x 1,5-6H A 0.5 mm thick aluminum blank is used as support material and guarantees the necessary stability for the mounting on the vehicle A 2.0 mm thick ceramics fleece material is used as a heat shield, which is heat resistance up to C. floor. Heat shields, heat resistance up to C Thickness W x L ,5 mm 330 x 330 mm ,5 mm 330 x 500 mm ,5 mm 330 x 660 mm Straight Holder, Stainless Steel Ø Length mm 220 mm mm 250 mm Locking spring & Bracket Description Ø x L Locking spring 8 x 80 mm Bracket Stainless Steel 12

13 Universal Competition Exhaust Parts Pipe Coupling Ø Length ,0 mm 90 mm ,0 mm 90 mm ,0 mm 70 mm ,0 mm 90 mm ,0 mm 70 mm ,0 mm 90 mm ,0 mm 70 mm ,0 mm 90 mm ,0 mm 70 mm ,0 mm 90 mm ,0 mm 70 mm U-clamp M8, zinc coated (Packing unit 10 pieces) Ø ,0 mm ,0 mm ,0 mm ,0 mm ,0 mm ,0 mm ,0 mm Pipe Clamp (VW/Audi), zinc coated (Packing unit 10 pieces) Ø ,5 mm ,5 mm ,5 mm ,5 mm ,5 mm ,5 mm Silent Blocks Dimensions Total Length Outside-ø M6 x 10,0 mm 35,0 mm 20,0 mm M6 x 11,5 mm 48,0 mm 25,0 mm M8 x 14,0 mm 45,0 mm 30,0 mm M8 x 15,0 mm 60,0 mm 40,0 mm M8 x 20,0 mm 61,0 mm 25,0 mm M8 x 21,0 mm 70,0 mm 42,0 mm M10 x 17,5 mm 63,0 mm 42,0 mm /16 UNF x 16,9 mm 54,4 mm 33,0 mm Ø 30,5 mm Ø 57 mm Clip on tips Ø Length , mm 118 mm , mm 118 mm , mm 118 mm Rubber ring Rubber thickness mm 13

14 Universal Competition Exhaust Parts Ø 10 mm 68 mm 68 mm 31,5 mm 102,5 mm 53,5 mm Rubber pad Rubber pad Rubber thickness Rubber thickness ,2 mm ,8 mm 72 mm Ø 11,5 mm 15 mm 53,5 mm 51 mm 38 mm Rubber pad Rubber thickness mm Rubber pad Rubber thickness ,5 mm 46 mm 68 mm 70 mm Ø 11 mm 89 mm 35 mm Rubber-metal element Rubber thickness mm Rubber pad HD Rubber thickness mm 14

15 Quality characteristic Mechanical decoupling function Prevents stresses in the exhaust system Compensation of thermal expansion Can also be put to versatile use with front pipes Vibration damping/noise reduction Improves comfort levels in the passenger compartment Flexible-pipe coupling Excellent gas tightness Corrosion resistance Compact design Cost-efficient repair solution Optimised connection fit thanks to modified screw head (carriage bolt) Overlapping screw guides (from Ø 50 mm) Use of washers 4 Dimensional stability thanks to extra beads Pipe Clamp 1 1 Overlapping screw guides ensure excellent gas tightness. 2 2 Reinforcing beads guarantee high dimensional stability and good clamping. 3 Unambiguous assignment ensured by markings 3 Pipe Coupling Diameter and length Tightening torque (Nm) Article number 15

16 > Download of certifications > Information all-around motor sports > HJS Motorsport -- supply sources HJS 2012 Last update Subject to change without notice HJS Emission Technology Dieselweg 12 Phone GmbH & Co. KG D Menden/Sauerland Fax Internet

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