Renault Clio: Catalytic pre-converter: Removal - Refitting

Renault Clio III (2005-2013) Service Manual / Engine And Peripherals / Exhaust / Catalytic pre-converter: Removal - Refitting

K9K, and 772

PARTS AND CONSUMABLES FOR THE REPAIR WORK

• Parts always to be replaced:
  • the seal between the catalytic pre-converter and the turbocharger,
  • the seal between the catalytic pre-converter and the flexible pipe.
• Consumables:
  • abrasive pads,
  • surface cleaner 77 01 404 178,
  • clean cloths.

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 392, 02, Lifting equipment).
• Disconnect the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).
• Remove:
  • the engine cover,
  • the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (MR 393, 56A, Exterior equipment),
  • the scoop under the scuttle panel grille (see Scoop under the scuttle panel grille: Removal - Refitting) (MR 393, 56A, Exterior equipment).
• Disconnect the connector from the turbocharger upstream exhaust gas temperature sensor.
• Detach the turbocharger upstream exhaust gas temperature sensor connector from the timing end lifting eye.
• Remove:
  • the bolts from the lifting eye, timing end,
  • the lifting eye on the timing end.

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove:
  • the catalytic pre-converter nuts on the turbocharger,
  • the engine undertray,
  • the lower engine tie-bar (see 19D, Engine mounting, Lower engine tie-bar: Removal - Refitting, 19D-13).
• Remove:
  • the connecting hose nuts on the catalytic pre-converter,

• Remove the bolt from the downstream stay on the catalytic pre-converter.
• Undo the downstream stay bolts on the cylinder block.
• Remove the catalytic pre-converter downstream stay.
• Remove the catalytic pre-converter upstream stay upper bolts.
• Undo the catalytic pre-converter upstream stay lower bolt.
• Remove the catalytic pre-converter upstream stay.
• Remove the catalytic pre-converter diesel injector cooler nuts.
• Discard the catalytic pre-converter diesel injector cooler seal.
• Remove the catalytic pre-converter by moving it towards the timing end and moving aside the catalytic pre-converter diesel injector cooler.
• Remove the catalytic pre-converter from the engine compartment by moving the engine towards the front of the vehicle.
• Remove:
  • the seal between the catalytic pre-converter and the turbocharger,
  • the seal between the catalytic pre-converter and the flexible pipe.
• Discard:
  • the seal between the catalytic pre-converter and the turbocharger,
  • the seal between the catalytic pre-converter and the flexible pipe.

REFITTING

I - REMOVAL PREPARATION OPERATION

• Using ABRASIVE PADS, clean the pressure faces:
  • of the turbocharger and the catalytic pre-converter,
  • of the catalytic pre-converter and the exhaust pipe.
• Next, degrease these pressure faces using SURFACE CLEANER AND CLEAN CLOTHS 77 01 404 178.
• If replacing, torque tighten:
  • the catalytic pre-converter studs on the turbocharger (7 N.m),
  • the turbocharger studs on the flexible pipe (7 N.m),
  • the catalytic pre-converter diesel injector cooler studs (7 N.m).

II - REFITTING OPERATION FOR PART CONCERNED

• From underneath the vehicle, fit:
  • the catalytic pre-converter fitted with a new seal between the catalytic pre-converter and the turbocharger,
  • one of the catalytic pre-converter nuts on the turbocharger,
  • the diesel injector cooler on the catalytic pre-converter,
  • the diesel injector cooler nuts.

WARNING

Check that there is no contact between the catalytic pre-converter and the turbocharger oil return pipe during the entire catalytic pre-converter tightening operation.

• Torque tighten in order:
  • the catalytic pre-converter upstream stay bolts on the engine,
  • the catalytic pre-converter downstream stay bolt and nut on the gearbox,
  • the catalytic pre-converter upstream stay bolts on the catalytic converter,
  • the catalytic pre-converter downstream stay bolt on the catalytic converter,
  • the catalytic pre-converter nuts on the turbocharger,
  • the diesel injector cooler nuts.
• Torque tighten in order:
  • the catalytic pre-converter nuts on the turbocharger (26 N.m),
  • the catalytic pre-converter upstream stay bolts on the engine (44 N.m),
  • the catalytic pre-converter downstream stay bolt and nut on the gearbox (21 N.m),
  • the catalytic pre-converter upstream stay bolts on the catalytic pre-converter (26 N.m),
  • the catalytic pre-converter downstream stay bolt on the catalytic pre-converter (21 N.m),
  • the diesel injector cooler nuts (25 N.m).
• Refit a new seal between the catalytic pre-converter and the flexible pipe on the catalytic pre-converter.
• Position the connecting hose on the catalytic pre-converter.
• Refit the flexible pipe nuts on the catalytic pre-converter.
• Torque tighten the flexible pipe nuts on the catalytic pre-converter (21 N.m).

III - FINAL OPERATION

• Refit the lower engine tie-bar (see 19D, Engine mounting, Lower engine tie-bar: Removal - Refitting, 19D-13).
• Refit:
  • the lifting eye on the timing end,
  • the timing end lifting eye bolts.
• Clip the turbocharger upstream exhaust gas temperature sensor connector on the timing end lifting eye.
• Connect the turbocharger upstream exhaust gas temperature sensor connector.
• Refit:
  • the scoop under the scuttle panel grille (see Scoop under the scuttle panel grille: Removal - Refitting) (MR 393, 56A, Exterior equipment),
  • the scuttle panel grille (see Scuttle panel grille: Removal - Refitting) (MR 393, 56A, Exterior equipment),
  • the engine cover.
• Connect the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).
• Refit the engine undertray.

D4F, and 784

REMOVAL

REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 392, 02A, Lifting equipment).
• Disconnect the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).
• Remove:
  • the engine protector,
  • the engine cover.
• Drain the gearbox (see Manual gearbox oils: Draining - Filling) (MR 392, 21A, Manual gearbox).

• Remove the nuts (1) from the exhaust bracket at the outlet of the catalytic pre-converter.

• Remove:
  • the front right-hand driveshaft (see 29A, Driveshafts, Front right-hand driveshaft: Removal - Refitting),
  • the front right-hand wheel driveshaft bearing nuts (2),
  • the front right-hand wheel driveshaft bearing.

• Disconnect the catalytic pre-converter upstream oxygen sensor connector (3).
• Unclip the catalytic pre-converter upstream oxygen sensor connector.
• Detach the catalytic pre-converter upstream oxygen sensor wiring harness at (4).
• Remove:
  • the bolts (5) from the turbocharger heat shield,
  • the turbocharger heat shield.

• Disconnect the catalytic pre-converter downstream oxygen sensor connector (6).
• Unclip the catalytic pre-converter downstream oxygen sensor connector.
• Detach the catalytic pre-converter downstream oxygen sensor wiring harness at (7).

• Remove:
  • the nut (8) from the turbocharger strut,
  • the bolt (9) from the turbocharger strut,
  • the turbocharger strut.

• Disconnect the oil pressure sensor connector.
• Undo the bolts (10) on the catalytic pre-converter primary strut.
• Remove:
  • the catalytic pre-converter upstream strut bolts (11),
  • the catalytic pre-converter upstream stay,
  • the bolts (12) from the catalytic pre-converter primary strut,
  • the primary strut on the catalytic pre-converter.

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