Renault Clio: Exhaust manifold: Removal - Refitting

Renault Clio III (2005-2013) Service Manual / Engine And Peripherals / Fuel Mixture / Exhaust manifold: Removal - Refitting

D4F, and 740 or 742 or 764

REMOVAL

I - 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) (MR392, 80A, Battery).
• Remove:
  • the air filter box (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, 12A-17),
  • the engine undertray.
• Unclip the wiring harness from the downstream oxygen sensor.
• Disconnect the connector from the downstream oxygen sensor.

• Remove:
  • the exhaust manifold retaining strut mounting bolt (1),
  • the exhaust bracket mounting bolts (2).
• Remove the exhaust pipe towards the rear of the vehicle.

• Unclip the upstream oxygen sensor electrical wiring harness at the cylinder head.
• Disconnect the upstream oxygen sensor connector (3).

• Remove:
  • the heat shield mounting bolts (4),
  • heat shield.

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove:
  • the exhaust manifold mounting nuts,
  • the exhaust manifold,
  • the exhaust manifold gasket.

REFITTING

I - REFITTING PREPARATION OPERATION

• Always replace:
  • the sealing ring (6) between the exhaust manifold and the catalytic converter,
  • the exhaust manifold seal.

Note: If a stud becomes loose during this operation, coat it with LOCTITE FRENBLOC.

Torque tighten the manifold mounting stud (9 N.m).

II - REFITTING OPERATION FOR PART CONCERNED

• Pre-tighten to torque and in order the exhaust manifold mounting nuts (10 N.m).
• Tighten to torque and in order the exhaust manifold mounting nuts (25 N.m).

III - FINAL OPERATION.

• Refit:
  • heat shield.
  • the heat shield mounting bolts.

WARNING

Any damaged heat shields must be replaced.

• Clip the wiring harness to the downstream oxygen sensor.
• Connect the downstream oxygen sensor connector.
• Refit the exhaust manifold retaining strut bolt.
• Torque tighten the exhaust bracket mounting bolts (25 N.m).
• Connect the upstream oxygen sensor connector.
• Clip the upstream oxygen sensor wiring harness into place at the cylinder head.
• Refit:
  • the engine undertray,
  • the air filter box (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, 12A-17).
• Connect the battery (see Battery: Removal - Refitting) (MR392, 80A, Battery).

K9K

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (MR 392, 02A, Lifting equipment).
• Remove the engine undertray.

• Remove:
  • the exhaust downpipe bolts,
  • the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting, 19B- 29),
  • the turbocharger (see 12B, Turbocharging, Turbocharger: Removal - Refitting, 12B-4),

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove:
  • the exhaust manifold mounting nuts,
  • the exhaust manifold.

REFITTING

I - REFITTING PREPARATION OPERATION

• Clean the joint faces.

WARNING

It is essential to replace the seal with a new one.

II - REFITTING OPERATION FOR PART CONCERNED

• If replacing, torque tighten the exhaust manifold studs (10 Nm)
• refit:
  • the exhaust manifold,
  • the exhaust manifold mounting nuts.
• Torque tighten in order the exhaust manifold mounting nuts (26 Nm).

III - FINAL OPERATION.

• refit:
  • the turbocharger (see 12B, Turbocharging, Turbocharger: Removal - Refitting, 12B-4),
  • the catalytic converter (see 19B, Exhaust, Catalytic converter: Removal - Refitting, 19B- 29),
  • the exhaust downpipe,
  • the engine undertray.

K4J or K4M

IMPORTANT

Wear protective gloves during the operation.

WARNING

To prevent the surrounding components from overheating, do not damage (tear, pierce, bend, etc.) a heat shield.

Any damaged heat shields must be replaced.

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
• Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery).

K4M, and 862

• Remove:
  • the front right-hand wheel (see Wheel: Removal - Refitting) (35A, Wheels and tyres),
  • the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection).

• Remove the intake distributor (see 12A, Fuel mixture, Inlet distributor: Removal - Refitting, 12A-45).

• Remove the bolts (1) from the exhaust bracket.

K4J - K4M, and 800 or 801 or 804

• Remove the exhaust pipe rubber mounting bush support bolt on the body.

Note: Mark with a pen the position of the exhaust silentbloc supports on the vehicle body.

• Disconnect the downstream oxygen sensor connector at (2).
• Withdraw the exhaust pipe towards the rear of the vehicle.

• Disconnect the upstream oxygen sensor connector.
• Remove:
  • the upstream oxygen sensor (3),
  • the upper heat shield from the exhaust manifold.

K4M, and 862

• Drain the gearbox (see Manual gearbox oils: Draining - Filling) (21A, Manual gearbox).
• Remove:
  • the front right-hand wheel driveshaft (see Front right-hand driveshaft: Removal - Refitting) (29A, Driveshafts),
  • the differential output seal (see Differential output seal: Removal - Refitting) (21A, Manual gearbox).
  • the lower engine tie-bar (see 19D, Engine mounting, Lower engine tie-bar: Removal - Refitting, 19D-13).

• Remove:
  • the bolts (4) from the front right-hand wheel driveshaft relay bearing,
  • the front right-hand wheel driveshaft relay bearing.

• Disconnect the oxygen sensor connectors (5).
• Unclip the oxygen sensor wiring (6).

II - OPERATION FOR REMOVAL OF PART CONCERNED

K4J - K4M, and 800 or 801 or 804

• Remove:
  • the nuts (7) from the exhaust manifold,
  • the exhaust manifold.

• Using the workbench, remove:
  • the lower heat shield bolts,
  • the lower heat shield.

K4M, and 862

• Remove the exhaust manifold nuts (9).

• Remove:
  • the downstream stay bolts (10) of the exhaust manifold,
  • the upstream stay bolts (11) of the exhaust manifold,
  • the exhaust manifold,
  • the exhaust manifold gasket.

REFITTING

I - REFITTING PREPARATION OPERATION

• parts always to be replaced: exhaust manifold seal
• Part always to be replaced: Exhaust bracket seal.
• Use SURFACE CLEANER (see ) (04B, Consumables - Products) to clean and degrease:
  • the exhaust manifold joint face if it is to be re-used,
  • the cylinder head joint face.

Note: If a stud becomes loose during this operation, coat the stud with LOCTITE HIGH STRENGTH THREAD LOCK (see ) (04B, Consumables - Products). Torque tighten the exhaust manifold stud (8 N.m).

K4J - K4M, and 800 or 801 or 804

• Refit the lower heat shield.
• Torque tighten the lower heat shield bolts (12 N.m).

II - REFITTING OPERATION FOR PART CONCERNED

• Refit the exhaust manifold with a new seal.

K4J - K4M, and 800 or 801 or 804

• Torque tighten in order the exhaust manifold nuts (26 N.m).

K4M, and 862

• Tighten to torque and in order:
  • the exhaust manifold nuts (26 N.m),
  • the bolts of the exhaust manifold upstream and downstream stays (44 N.m).

III - FINAL OPERATION

K4M, and 862

• Clip on the oxygen sensor wiring.
• Connect the oxygen sensor connectors.
• Refit:
  • the front right-hand wheel driveshaft relay bearing,
  • the lower engine tie-bar (see 19D, Engine mounting, Lower engine tie-bar: Removal - Refitting, 19D-13),
  • the differential output seal (see Differential output seal: Removal - Refitting) (21A, Manual gearbox),
  • the front right-hand wheel driveshaft (see Front right-hand driveshaft: Removal - Refitting) (29A, Driveshafts).
• Fill the manual gearbox (see Manual gearbox oils: Draining - Filling) (21A, Manual gearbox).

• Refit the exhaust manifold upper heat shield.
• Torque tighten the exhaust manifold upper heat shield bolts (12 N.m).
• Refit the upstream oxygen sensor.
• Torque tighten the upstream oxygen sensor (44 N.m).
• Connect the oxygen sensors.

K4J - K4M, and 800 or 801 or 804

• Refit the exhaust pipe rubber mounting bush support bolt on the body.
• Torque tighten the exhaust pipe support bolt on the body (21 N.m).

• Refit a new exhaust flange.
• Torque tighten the exhaust flange bolts (21 N.m).
• Refit the inlet distributor (see 12A, Fuel mixture, Inlet distributor: Removal - Refitting, 12A-45)

K4M, and 862

• Refit:
  • the front right-hand wheel arch liner (see Front wheel arch liner: Removal - Refitting) (55A, Exterior protection),
  • the front right-hand wheel (see Wheel: Removal - Refitting) (35A, Wheels and tyres).

• Connect the battery (see Battery: Removal - Refitting) (80A, Battery).

M4R

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Remove the engine cover.
• Disconnect the battery.
• Remove the inlet manifold (see 12A, Fuel mixture, Inlet distributor: Removal - Refitting, 12A- 45).

• Remove:
  • the exhaust manifold stay mounting bolts (1),
  • the exhaust manifold stay.

• Remove the mounting bolts (2) from the exhaust bracket.

• Remove:
  • the mounting bolts from the exhaust manifold heat shield (3),
  • the exhaust manifold heat shield.

II - REMOVAL OF PART CONCERNED

• Remove:
  • the exhaust manifold mounting nuts, in order,
  • the exhaust manifold,
  • the exhaust manifold seal.

REFITTING

I - REFITTING PREPARATION OPERATION

• Always replace:
  • the sealing ring (4) between the exhaust manifold and the catalytic converter,
  • the exhaust manifold seal.

Note: If a stud loosens during this operation, it should be coated with LOCTITE FRENBLOC.

• Tighten to torque the exhaust manifold mounting studs (8 Nm).

II - REFITTING THE PART CONCERNED

• Finger tighten the mounting nuts until they are in contact with the exhaust manifold.
• Tighten to torque and in order the exhaust manifold mounting nuts (33 Nm).

III - FINAL OPERATION

• Refit the exhaust manifold heat shield.
• Tighten to torque the exhaust manifold heat shield mounting bolts (6 Nm).
• Refit the exhaust manifold stay.
• Tighten to torque:
  • the exhaust manifold stay mounting bolts (43 Nm),
  • the exhaust bracket mounting bolts (21 Nm).
• Refit the inlet manifold (see 12A, Fuel mixture, Inlet distributor: Removal - Refitting, 12A-45).
• Connect the battery.
• Refit the engine cover.

F4R

Note: When removing and refitting the exhaust manifold, remove the " manifold - catalytic converter " assembly.

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
• Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery).
• Remove the front axle sub-frame (see Front axle sub-frame: Removal - Refitting) (31A, Front axle components).

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove the exhaust manifold nuts.
• Disconnect the upstream oxygen sensor connector.

• Remove:
  • the clip connecting the catalytic converter and the expansion chamber,
  • the " manifold - catalytic converter " assembly.

When replacing the exhaust manifold

• On the workbench:
  • clamp the " manifold - catalytic converter " assembly in a vice to hold it in place,
  • remove the upstream oxygen sensor.

REFITTING

I - REFITTING PREPARATION OPERATION

• parts always to be replaced: exhaust manifold seal.
• parts always to be replaced: Catalytic converter clip.
• Use SURFACE CLEANER (see ) (04B, Consumables - Products) to clean and degrease:
  • the joint faces of the manifold if it is being reused,
  • the cylinder head joint faces.

Note: If a stud is loosened during this operation, coat the stud with HIGH STRENGTH BOLT LOCKING PRODUCT.

Torque tighten the exhaust manifold stud (9 N.m).

When replacing the exhaust manifold

• On the workbench:
  • clamp the " manifold - catalytic converter " assembly in a vice to hold it in place.
  • refit the upstream oxygen sensor.

Note: Be careful not to damage the " manifold - catalytic converter " pipes during this operation.

• Torque tighten the upstream oxygen sensor (44 N.m).

II - REFITTING OPERATION FOR PART CONCERNED

• Fit the new exhaust manifold gasket.
• Refit:
  • the " manifold - catalytic converter " assembly.
  • the exhaust manifold nuts.

• Torque tighten in order the exhaust manifold nuts (30 N.m).
• Refit the new clip connecting the catalytic converter and the expansion chamber.
• Connect the upstream oxygen sensor connector.

III - FINAL OPERATION

• Refit the front axle sub-frame (see Front axle sub-frame: Removal - Refitting) (31A, Front axle components).
• Connect the battery (see Battery: Removal - Refitting) (80A, Battery).
• Check that there are no exhaust gas leaks.
• Check the axle assembly values (see Front axle assembly: Adjustment values) (30A, General information).

D4F, and 784 or 786

IMPORTANT

Wear protective gloves during the operation.

REMOVAL

I - 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 undertray,
  • the engine cover.
• Drain the gearbox (see Manual gearbox oils: Draining - Filling) (MR 392, 21A, Manual gearbox).
• Remove:
  • the front right-hand driveshaft (see Front right-hand driveshaft: Removal - Refitting) (MR 392, 29A, Driveshafts),
  • the catalytic pre-converter (see 19B, Exhaust, Catalytic pre-converter: Removal - Refitting, 19B-23),
  • the turbocharger (see 12B, Turbocharging, Turbocharger: Removal - Refitting, 12B-4).

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove the exhaust manifold nuts (1).

• Remove:
  • the exhaust manifold by holding the centre stud with a male torx socket and removing the manifold with a larger screwdriver as shown at (2),
  • the exhaust manifold heat shield bolts,
  • the exhaust manifold heat shield.

REFITTING

I - REFITTING PREPARATION OPERATION

• Use abrasive pads to clean the bearing faces of:
  • the exhaust manifold - cylinder head,
  • the exhaust manifold - turbocharger.
• Use SURFACE CLEANER (see Vehicle: Parts and consumables for the repair) (MR 398, 04B, Consumables - Products) and clean cloths to degrease the bearing faces:
  • the exhaust manifold - cylinder head,
  • the exhaust manifold - turbocharger.

WARNING

The joint faces must be clean, dry and free from grease (avoid finger marks).

• Be sure to replace the exhaust manifold gasket.

WARNING

Any damaged heat shields must be replaced.

The catalytic converter must not be subjected to mechanical impacts during removal or refitting, as this could damage it.

II - REFITTING OPERATION FOR PART CONCERNED

• Refit:
  • the exhaust manifold heat shield,
  • the exhaust manifold heat shield bolts.

IMPORTANT

Wear protective gloves during the operation.

• Torque tighten the exhaust manifold heat shield bolts (18 Nm).
• Refit:
  • the new exhaust manifold gasket,
  • the exhaust manifold,
  • the exhaust manifold nuts.
• Pretighten to torque the exhaust manifold nuts (initial torque) (20 Nm).
• Torque tighten the exhaust manifold nuts (30 Nm).

III - FINAL OPERATION.

• Refit:
  • the turbocharger (see 12B, Turbocharging, Turbocharger: Removal - Refitting, 12B-4),
  • the catalytic pre-converter (see 19B, Exhaust, Catalytic pre-converter: Removal - Refitting, 19B-23),
  • the front right-hand driveshaft (see Front right-hand driveshaft: Removal - Refitting) (MR 392, 29A, Driveshafts).
• Fill the gearbox with oil (see Manual gearbox oils: Draining - Filling) (MR 392, 21A, Manual gearbox).
• Refit:
  • the engine undertray,
  • the engine cover.
• Connect the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).

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