trunk RENAULT TWINGO 2009 2.G Engine And Peripherals Workshop Manual

19B-8
EXHAUST
Exhaust: Precautions for the repair
19B
I - PARTS AND CONSUMABLES FOR THE REPAIR
1 - Parts always to be replaced:
- the exhaust trunking (if fitted)
- the seal or sealing ring on the connection between the
catalytic converter or catalytic pre-converter and the
rest of the exhaust system
- the exhaust clip(s) (if fitted)
2 - Consumables (see part no. in Technical Note
5068, 04B, Consumables - Products):
- exhaust mastic
- surface cleaner
- abrasive pads
II - ADVICE TO OBSERVE
1 - During removal and refitting, the catalytic converter
or catalytic pre-converter must not receive any knocks
or impacts as this could damage it.
2 - The whole exhaust pipe is made of stainless steel.
3 - After working on the bracket between the catalytic
converter or catalytic pre-converter and the rest of the
exhaust system, ensure that the connection is perfectly
sealed.
To do this:
-clean the pressure faces of the connection using the
ABRASIVE PADS,-degrease the pressure faces of the connection using
SURFACE CLEANER and clean cloths,
-always replace the seal or sealing ring on the connec-
tion.
III - SPECIAL NOTES ON THE SINGLE UNIT
EXHAUST PIPE
1 - Cutting the single unit exhaust pipe
The exhaust pipe is a « single unit type » .
To replace different parts of the exhaust system it must
be cut.
To do this be sure to carry out these precautions in the
following order:
-correctly identify the area to be cut, as explained be-
low,
-use the cutting tool correctly (Mot. 1199-01),
-position the exhaust trunking correctly.
2 - Identifying the area of the exhaust system to be
cut
Two marks made on the exhaust system define the
area to be cut (see Exhaust: Parts and consumables
for the repair) (see MR for vehicle concerned, 19B,
Exhaust).
Example of cutting area Special tooling required
Mot. 1199-01Exhaust pipe cutter (diame-
ter 35/50 mm and diameter
50/65mm). Complete kit in a
case.
IMPORTANT
Do not park and run the engine in a place where
combustible substances and materials such as
grass or leaves can come into contact with the hot
exhaust system.
IMPORTANT
Catalytic converters contain ceramic fibres , these
are contained within a closed unit, and cannot dis-
perse. Drilling or cutting catalytic converters is pro-
hibited.
99226

19B-9
EXHAUST
Exhaust: Precautions for the repair
19B
Before cutting the exhaust system, draw a line (D) be-
tween the two marks (P1) and (P2) .
The distance between the two marks on the exhaust
pipe is (X1) : 90 mm (all types except RENAULT
SPORT).
The distance between the two marks on the exhaust
pipe is (X1) : 80 mm (RENAULT SPORT).
3 - Operate tool Mot. 1199-01Fit the (Mot. 1199-01) (1) on the exhaust pipe.
Tighten the two bolts on the tool until they touch the
pipe in order to clamp the tool onto the pipe.
Turn the cutting tool using the handle and pressing it
against the pipe (as indicated in the diagram above).
Tighten the two bolts on the tool whilst cutting, until the
pipe is completely cut.
Once the pipe is cut, file and deburr the end of the pipe
to be used on the vehicle again.
4 - Positioning the exhaust trunking
100649
Note:
For CLIO II RENAULT SPORT with F4R*730,
F4R*732 and F4R*736 engines, the cutting area is
shown by a single mark on the exhaust pipe.
Cut the exhaust pipe by placing the (Mot. 1199-01)
on the mark.
14747
102118
Note:
Do not over-tighten the tool onto the pipe to avoid
deforming it.
WARNING
Do not reuse an old exhaust trunking.

19B-10
EXHAUST
Exhaust: Precautions for the repair
19B
Exhaust trunking with 1 bolt
Exhaust trunking with 2 bolts
Fit the exhaust trunking onto the part of the exhaust
system fitted to the vehicle.
Position the pipe onto the lugs (2) inside the exhaust
trunking.
Tighten the exhaust trunking bolt(s) slightly (depending
on the version).
Position the second part of the exhaust system under
the vehicle, fitting it in the exhaust trunking.Position the second exhaust pipe onto the lugs inside
the exhaust trunking.
Check that the two cut marks (3) are aligned (if applica-
ble).
Position the trunking so that there is no risk of contact
between its bolt or bolts and the heat shields.
Torque tighten
-the exhaust trunking nut with 1 bolt (25 N.m) (if fit-
ted),
-the exhaust trunking nuts with 2 bolts (18 N.m) (if
fitted).
Check the following and deal with if necessary:
-no underbody contact between the exhaust system
and the heat shields,
-all of the heat shields are present and secure.
Start the engine.
Check that there are no leaks: deal with any leaks.
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119681
Note:
If necessary, use a workshop jack to lift and hold
the heavy and bulky components of the exhaust
system.
99227
Note:
Any damaged heat shields must be replaced.

19B-11
EXHAUST
Exhaust: Precautions for the repair
19B
Note:
If there are leaks from the EXHAUST TRUNKING
WITH 1 BOLT, apply EXHAUST MASTIC to the
trunking (see par t no. in Technical Note 5068, 04B,
Consumables - Products).
If the application of exhaust mastic does not fix the
leak:
-remove and replace the used exhaust trunking,
-check the condition of the exhaust pipes (condition
of the pipe surface, deburring of the area cut,
damage to the pipes).
-fit the new trunking in accordance with the instruc-
tions given before.

19B-24
EXHAUST
Expansion chamber: Removal - Refitting
D4F, and 780 or 782
19B
aCut the exhaust pipe (see 19B, Exhaust, Exhaust:
Precautions for the repair, page 19B-8) in the area
designated to be cut (see ) .
aRemove:
-the expansion chamber rubber mounting bush bolt
from the body,
-the expansion chamber,
-the rubber mounting bush bolt from the expansion
chamber,
-the expansion chamber rubber mounting bush.
REFITTING THE EXPANSION CHAMBER
I - REMOVAL OPERATION FOR PART
CONCERNED
aRefit:
-the expansion chamber rubber mounting bush,
-the expansion chamber rubber mounting bush bolt.
aFit the expansion chamber.
aAttach the expansion chamber to the vehicle using
the expansion chamber rubber mounting bush bolt.
aFit a new After-Sales sleeve (see 19B, Exhaust, Ex-
haust: Precautions for the repair, page 19B-8) .
aTighten the exhaust trunking.
aTighten the expansion chamber rubber mounting
bush bolt on the body.
aRefit a new clip between the front section of the ex-
pansion chamber and the expansion chamber.
aTighten the clip between the front section of the ex-
pansion chamber and the expansion chamber.II - FINAL OPERATION
aCheck the following and deal with if necessary:
-that there is no contact with the underbody,
-the presence and correct positioning of all the ex-
haust pipe heat shields.
aStart the vehicle.
aCheck that there are no leaks and deal with them if
necessary.
Note:
If the rubber mounting bushes are damaged,
mark the position of the support on the body,
then replace the « support - rubber mounting
bush » assembly.
Note:
If replacing the rubber mounting bush, spray the
inside of the rubber mounting bush with BRAKE
CLEANER (see Vehicle: Parts and consum-
ables for the repair) (MR 411, 04B, Consum-
ables - Products) to facilitate fitting.

19B-31
EXHAUST
Silencer: Removal - Refitting
D4F or D7F or K9K
19B
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 411, 02A, Lifting equip-
ment).
II - REMOVAL OPERATION FOR PART
CONCERNED
aRemove the expansion chamber rubber mounting
bush bolt from the body.
aCut the exhaust pipe (see 19B, Exhaust, Exhaust:
Precautions for the repair, page 19B-8) in the des-
ignated area to be cut (see ) .
aDetach the rubber mounting bush rear silencer.
aRemove the rear silencer.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
a
aFit:
-the rear silencer,
-the new After-Sales sleeve (see 19B, Exhaust,
Exhaust: Precautions for the repair, page 19B-
8) .
aTighten the exhaust trunking.
aRefit the expansion chamber rubber mounting bush
bolt on the body.II - FINAL OPERATION
aCheck (and correct if necessary):
-that there is no contact with the underbody,
-the presence and correct positioning of all the ex-
haust pipe heat shields.
aStart the vehicle.
aCheck that there are no leaks and deal with them if
necessary.
D4F, and 780
Note:
If replacing the rubber mounting bush, spray the
inside of the rubber mounting bush with brake
cleaner (see Vehicle: Parts and consumables
for the repair) (MR 411, 04B, Consumables -
products) to facilitate fitting.
D4F, and 780