exhaust RENAULT TWINGO RS 2009 2.G Engine And Peripherals Owners Manual

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.
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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.
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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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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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19B-21
EXHAUST
Catalytic converter: Removal - Refitting
D4F, and 780 or 782
19B
aConnect the battery (see Battery: Removal - Refit-
ting) (MR 411, 80A, Battery).

19B-22
EXHAUST
Catalytic converter: Removal - Refitting
K4M
19B
aThe catalytic converter cannot be separated from
the exhaust manifold.
Replace the "exhaust manifold - catalytic converter"
assembly if the catalytic converter is faulty (see 12A,
Fuel mixture, Exhaust manifold: Removal - Refit-
ting, page 12A-48) .

19B-23
EXHAUST
Expansion chamber: Removal - Refitting
D4F, and 780 or 782
19B
REMOVING THE FRONT SECTION OF THE
EXPANSION CHAMBER
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 clip (1) between the front section of the expan-
sion chamber and the expansion chamber,
-the bolts (2) and the springs from the front section
of the expansion chamber on the catalytic convert-
er,-the front section of the expansion chamber,
-the exhaust downpipe sealing ring from the catalyt-
ic converter and discard it.
REFITTING THE FRONT SECTION OF THE
EXPANSION CHAMBER
aParts always to be replaced:
-any stud and/or nut from the damaged catalytic
converter,
-the exhaust system sealing ring on the catalytic
converter,
-clip.
I - REFITTING PREPARATIONS OPERATION
aUsing RUBBING PADS clean the bearing faces of:
-on the catalytic converter,
-on the exhaust system.
aThen, degrease the bearing faces with SURFACE
CLEANER (see Vehicle: Parts and consumables
for the repair) (MR 411, 04B, Consumables - Prod-
ucts).
II - REFITTING OPERATION FOR PART
CONCERNED
aPlace the front section of the expansion chamber on
the catalytic converter fitted with a new sealing ring.
aRefit:
-the expansion chamber front section bolts and
springs on the catalytic converter,
-a new clip between the front section of the expan-
sion chamber and the expansion chamber,
aTorque tighten the expansion chamber front sec-
tion bolts on the catalytic converter (21 Nm).
REMOVING THE EXPANSION CHAMBER
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 clip between the front section of the ex-
pansion chamber and the expansion chamber.
aRemove the expansion chamber. Tightening torquesm
expansion chamber
front section 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-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-25
EXHAUST
Expansion chamber: Removal - Refitting
K4M
19B
REMOVING THE EXHAUST PIPE FRONT
EXPANSION CHAMBER
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-the engine undertray bolts,
-the engine undertray.II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the expansion chamber clip (1) .
aRemove:
-the nuts (2) on the catalytic converter bracket,
-the expansion chamber,
-the catalytic converter seal,
-the catalytic converter studs using a roller-type
stud removal tool. Equipment required
roller-type stud removal tool
Tightening torquesm
catalytic converter studs7 N.m
catalytic converter
bracket nuts21 N.m
IMPORTANT
To avoid all risk of damage to the systems, apply
the safety and cleanliness instructions and opera-
tion recommendations before carrying out any
repair (see 19B, Exhaust, Exhaust: Precautions
for the repair, page 19B-8) .
IMPORTANT
Wear protective gloves during the operation.
IMPORTANT
Wear heat protective gloves during the operation.
WARNING
To prevent the surrounding components from over-
heating, do not damage (tear, pierce bend etc.) a
heat shield.
All damaged heat shields must be replaced.
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19B-26
EXHAUST
Expansion chamber: Removal - Refitting
K4M
19B
REMOVING THE EXHAUST PIPE REAR
EXPANSION CHAMBER
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aCut the exhaust pipe (see 19B, Exhaust, Exhaust:
Precautions for the repair, page 19B-8) in the des-
ignated cutting area downstream from the expan-
sion chamber (see ) .
aRemove:
-the rubber mounting bush bolt (3) ,
-the clip (4) from the expansion chamber,
-the expansion chamber.
REFITTING THE EXHAUST PIPE FRONT
EXPANSION CHAMBER
I - REFITTING PREPARATION OPERATION
aUse ABRASIVE PADS to clean the bearing faces of
the expansion chamber on the catalytic converter
(see Vehicle: Parts and consumables for the re-
pair) (04B, Consumables - Products).aNext, degrease these bearing faces using SUR-
FACE CLEANER and clean cloths (see Vehicle:
Parts and consumables for the repair) (04B, Con-
sumables - Products).
aAlways replace:
-the catalytic converter seal,
-the expansion chamber clip,
-the catalytic converter studs.
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit new studs on the catalytic converter.
aTorque tighten the catalytic converter studs (7
N.m).
aRefit:
-a new catalytic converter seal,
-the expansion chamber,
-the clip on the expansion chamber.
aTorque tighten the catalytic converter bracket
nuts (21 N.m).
aTighten the clip bolt while guiding the exhaust pipe
to ensure correct alignment.
aCheck:
-that all the exhaust pipe heat shields are in place
and properly attached.
-that there is no contact with the underbody,
-that there are no leaks.
III - FINAL OPERATION.
aRefit the engine undertray.
REFITTING THE EXHAUST PIPE REAR
EXPANSION CHAMBER
I - REFITTING PREPARATION OPERATION
aAlways replace the expansion chamber clip.
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the expansion chamber,
-an expansion chamber clip.
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