engine RENAULT TWINGO RS 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.
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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-12
EXHAUST
Catalytic converter: Removal - Refitting
K9K
19B
PARTS AND CONSUMABLES FOR THE REPAIR
Pièces à remplacer systématiquement :
-air inlet pipe seals,
-the catalytic converter seal on the turbocharger,
-any stud and/or nut on the turbocharger or damaged
catalytic converter,
-The exhaust system sealing ring on the catalytic con-
verter.
Ingrédients :
-ABRASIVE PADS,
-SURFACE CLEANER.
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift ( (see Vehicle:
Towing and lifting) ).
aDisconnect the battery ( (see Battery: Removal -
Refitting) ).
aRemove:
-the windscreen wiper arms ( (see Windscreen
wiper arm: Removal - Refitting) ),
-the scuttle panel grille ( (see Scuttle panel grille:
Removal - Refitting) ),
-the scoop under the scuttle panel grille ( (see
Scoop under the scuttle panel grille: Removal -
Refitting) ),
-the air filter box (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the catalytic converter bolts (1) on the tur-
bocharger.
aRaise the vehicle.
aRemove the engine tie-bar (see 19D, Engine
mounting, Lower engine tie-bar: Removal - Refit-
ting, page 19D-18) . Tightening torquesm
catalytic converter studs
on the turbocharger9 Nm
catalytic converter nuts
on the turbocharger26 Nm
catalytic converter
upstream strut bolts on
the engine44 Nm
catalytic converter
downstream strut bolts
on the gearbox21 Nm
catalytic converter
downstream strut nut on
the gearbox21 Nm
catalytic converter
upstream strut bolts on
the catalytic converter26 Nm
catalytic converter
downstream strut bolt
on the catalytic con-
verter21 Nm
exhaust pipe bolts on
the catalytic converter21 Nm
IMPORTANT
Consult the safety and cleanliness advice and oper-
ation recommendations before carrying out any
repair (see 19B, Exhaust, Exhaust: Precautions
for the repair, page 19B-8) .
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19B-14
EXHAUST
Catalytic converter: Removal - Refitting
K9K
19B
aIf they are replaced, torque tighten the catalytic
converter studs on the turbocharger (9 Nm ).
II - REFITTING OPERATION FOR PART
CONCERNED
aFrom underneath the vehicle, fit:
-the catalytic converter on the turbocharger fitted
with a new seal between the catalytic converter
and the turbocharger,
-one of the catalytic converter nuts on the turbo-
charger.
aIn order, fit (without tightening):
-the catalytic converter upstream strut bolts on the
engine,
-the catalytic converter downstream strut bolt and
nut on the gearbox,
-the catalytic converter upstream strut bolts on the
catalytic converter,
-the catalytic converter downstream strut bolt on the
catalytic converter,
-the catalytic converter nuts on the turbocharger,
aTorque tighten and in order:
-the catalytic converter nuts on the turbocharger
(26 Nm),
-the catalytic converter upstream strut bolts on
the engine (44 Nm),
-the catalytic converter downstream strut bolts
on the gearbox (21 Nm),
-the catalytic converter downstream strut nut on
the gearbox (21 Nm),
-the catalytic converter upstream strut bolts on
the catalytic converter (26 Nm),
-the catalytic converter downstream strut bolt
on the catalytic converter (21 Nm).
aFit in order:
-a new exhaust system sealing ring on the catalytic
converter,
-the exhaust pipe on the catalytic converter,
-the exhaust pipe springs and bolts on the catalytic
converter.aTorque tighten the exhaust pipe bolts on the cata-
lytic converter (21 Nm).
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.
III - FINAL OPERATION.
aRefit:
-the engine tie-bar (see 19D, Engine mounting,
Lower engine tie-bar: Removal - Refitting, page
19D-18) ,
-the air filter box (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the scoop under the scuttle panel grille ( (see
Scoop under the scuttle panel grille: Removal -
Refitting) ),
-the scuttle panel grille ( (see Scuttle panel grille:
Removal - Refitting) ),
-the windscreen wiper arms ( (see Windscreen
wiper arm: Removal - Refitting) ).
aConnect the battery ( (see Battery: Removal - Re-
fitting) ).
aStart the engine.
aCheck that there are no leaks and deal with them if
necessary. Note:
Check that there is no contact between the cata-
lytic conver ter and the turbocharger oil return
pipe during the entire catalytic converter tighten-
ing operation.

19B-16
EXHAUST
Catalytic converter: Removal - Refitting
D4F, and 780 or 782
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).
aDisconnect the battery (see Battery: Removal - Re-
fitting) (MR 411, 80A, Battery).
aRemove:
-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the air filter box strut bolt,-the air filter box strut,
-the upstream oxygen sensor (see 17B, Petrol in-
jection, Oxygen sensors: Removal - Refitting,
page 17B-13) . Tightening torquesm
catalytic converter lower
bracket bolt on the gear-
box44 N.m
bolts of the catalytic
converter lower bracket
on the engine25 N.m
side bracket bolts on the
catalytic converter21 N.m
side bracket bolts on the
engine21 N.m
catalytic converter nuts
on the turbocharger (ini-
tial torque)20 N.m
catalytic converter nuts
on the turbocharger30 N.m
bolts of the catalytic
converter lower bracket
on the catalytic con-
verter (initial torque)20 N.m
bolts of the catalytic
converter lower bracket
on the catalytic con-
verter30 N.m
exhaust downpipe bolts21 N.m
catalytic converter strut
nut21 N.m
catalytic converter strut
bolt on the rocker cover21 N.m

19B-17
EXHAUST
Catalytic converter: Removal - Refitting
D4F, and 780 or 782
19B
aRemove the turbocharger air outlet rigid pipe bolt (1)
from the throttle valve.
aDetach the turbocharger air outlet pipe from the tur-
bocharger in the direction of the arrow (2) .
aDisconnect the turbocharger air outlet pipe from the
turbocharger.aMove aside the turbocharger air outlet pipe.
aRemove:
-the catalytic converter strut nut (4) ,
-the catalytic converter strut bolt (5) from the rocker
cover,
-the turbocharger strut.
-the rear suspended engine mounting (see 19D,
Engine mounting, Lower engine tie-bar: Re-
moval - Refitting, page 19D-18) .
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Note:
Removing the heat-resistance protector clip (3)
requires the turbocharger air outlet pipe to be
replaced.
120959

19B-18
EXHAUST
Catalytic converter: Removal - Refitting
D4F, and 780 or 782
19B
aRemove the exhaust bracket bolts (6) at the catalytic
converter outlet.
aUndo the intermediate pipe clip.
aRemove the intermediate pipe clip.
aRemove the exhaust downpipe.aRemove:
-the side bracket bolts (7) from the engine,
-the side bracket bolts (8) from the catalytic convert-
er,
-the side exhaust bracket from the catalytic convert-
er.
aLoosen the bolts (9) of the catalytic converter lower
bracket on the catalytic converter.
aRemove:
-the bolts (10) of the catalytic converter lower brack-
et on the engine,
-the bolt (11) securing the catalytic converter lower
bracket on the gearbox,
-the catalytic converter lower exhaust bracket.
108817120960

19B-19
EXHAUST
Catalytic converter: Removal - Refitting
D4F, and 780 or 782
19B
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aDisconnect the catalytic converter downstream oxy-
gen sensor connector (12) .
aUnclip the downstream oxygen sensor connector
from the catalytic converter.
aUnpick the catalytic converter downstream oxygen
sensor wiring harness (13) .aRemove:
-the catalytic converter nuts (14) on the turbocharg-
er,
-the catalytic converter by rotating it while tilting the
engine,
-the catalytic converter seal on the turbocharger.
REFITTING
I - REFITTING PREPARATION OPERATION
aAlways replace:
-the catalytic converter seal,
-the catalytic converter nuts on the turbocharger.
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the catalytic converter seal on the turbocharger,
-the catalytic converter by rotating it while tilting the
engine,
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122671
IMPORTANT
Catalytic converters contain cer amic fibres, these
are contained within a closed unit, and cannot
disperse. Drilling or cutting catalytic converters is
prohibited.

19B-20
EXHAUST
Catalytic converter: Removal - Refitting
D4F, and 780 or 782
19B
-the new nuts with the catalytic converter spacers
on the turbocharger.
aAttach the downstream oxygen sensor wiring har-
ness to the catalytic converter.
aClip on the catalytic converter downstream oxygen
sensor connector.
aConnect the catalytic converter downstream oxygen
sensor connector.
III - FINAL OPERATION
aRefit:
-the catalytic converter lower exhaust bracket,
-the bracket bolt on the gearbox,
-the bracket bolts on the engine,
-the catalytic converter side exhaust bracket,
-the catalytic converter side bracket bolts,
-the engine side bracket bolts.
aTorque tighten:
-the catalytic converter lower bracket bolt on the
gearbox (44 N.m),
-the bolts of the catalytic converter lower brack-
et on the engine (25 N.m),
-the side bracket bolts on the catalytic converter
(21 N.m),
-the side bracket bolts on the engine (21 N.m),
-the catalytic converter nuts on the turbocharger
(initial torque) (20 N.m),
-the catalytic converter nuts on the turbocharger
(30 N.m),
-the bolts of the catalytic converter lower brack-
et on the catalytic converter (initial torque) (20
N.m),
-the bolts of the catalytic converter lower brack-
et on the catalytic converter (30 N.m).
aRefit:
-the exhaust downpipe,
-the intermediate pipe clip.
aTighten the intermediate pipe clip.
aRefit the exhaust downpipe bolts on the catalytic
converter.
aTorque tighten the exhaust downpipe bolts (21
N.m).aRefit:
-the rear suspended engine mounting (see 19D,
Engine mounting, Lower engine tie-bar: Re-
moval - Refitting, page 19D-18) ,
-the turbocharger strut.
-the catalytic converter strut bolt on the rocker cov-
er,
-the catalytic converter strut nut.
aTorque tighten:
-the catalytic converter strut nut (21 N.m),
-the catalytic converter strut bolt on the rocker
cover (21 N.m).
aPosition the turbocharger air outlet pipe.
aPush the turbocharger air outlet pipe clip (15) in the
direction of the arrow.
aConnect the turbocharger air outlet pipe onto the tur-
bocharger.
aRefit:
-the turbocharger air outlet rigid pipe bolt on the
throttle valve,
-the upstream oxygen sensor (see 17B, Petrol in-
jection, Oxygen sensors: Removal - Refitting,
page 17B-13) ,
-the air filter box strut,
-the air filter box strut bolt,
-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) .
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