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Autopapyrus · Renault Talisman 1.6 TCE 200 (2024)
https://autopapyrus.com/guides/renault/talisman/catalytic-converter-replacement/
Compiled automatically from service literature and owner experience. Specs are for the typical configuration — check them against your exact car before you start.

Renault Talisman 1.6 TCE 200 (2024): Catalytic Converter Replacement

On the 1.6 TCE 200 (M5M) engine, the catalytic converter is located in the downpipe right after the turbocharger. This is known as a close-coupled catalytic converter. Replacing it requires access from underneath. You will need to unbolt it from the turbo and from the mid-section of the exhaust. You may also need to partially lower the subframe for easier access. Exhaust bolts often seize, so treating them with penetrating oil is a must.

Difficulty: Hard Time: 4-6 hours Steps: 13 Tools: lift or inspection pit, socket and ratchet set, extensions, torque wrench, penetrating oil (WD-40 or similar), new exhaust manifold and flange gaskets, heat-resistant thread paste

Part

  • 🔩 catalytic converter (main OE number 208A04660R, also seen as H8201556964, for the 1.6 TCE engine M5M)
There's a full repair manual for this car Every system, wiring diagrams and torque specs — not just this job. Haynes AutoFix (online). See manuals →

Step by step

13 steps
  1. Warm the engine up to operating temperature, shut it off, and let it cool for 20-30 minutes. (Hot bolts come loose more easily after warming up, but it is only safe to work once the parts have cooled down.)
  2. Raise the car on a lift, or position it over a pit with secure supports. Remove the engine undercover (skid plate).
  3. Apply penetrating oil (WD-40 or similar) to all the catalytic converter mounting bolts and let it soak for 15-20 minutes.
  4. Disconnect the oxygen sensor (lambda sensor) connectors: the upstream sensor (before the catalytic converter) and the downstream sensor (after it). Remember the connection order or take a photo.
  5. Remove the fasteners that hold the catalytic converter flange to the turbocharger (usually 3-4 studs with M10 or M12 nuts). Tightening torque at assembly: 25-35 N·m (18-26 lb-ft). Check the exact value in the manufacturer's service manual. Use a socket with an extension and a universal joint because space is limited.
  6. Remove the bolts that hold the catalytic converter to the mid-section of the exhaust system (a flange with 2-3 bolts). Tightening torque at assembly: 20-30 N·m (15-22 lb-ft).
  7. If access is difficult, partially lower the front subframe. Remove the front subframe bolts and lower it by 20-30 mm at the front and 40-50 mm at the rear (using jacks or special supports). This gives you room to maneuver.
  8. Carefully lower the old catalytic converter out from under the car. Check the condition of the gaskets and the studs on the turbo. If necessary, replace the turbo-to-catalytic converter gasket with a new one (a copper or graphite heat-resistant gasket).
  9. Install the new catalytic converter in reverse order. Be sure to use new gaskets on both flanges. Coat the threads of the studs and bolts with heat-resistant copper paste (this prevents seizing).
  10. Tighten the turbo mounting fasteners with a torque wrench (25-35 N·m (18-26 lb-ft)), then the bolts to the mid-section of the exhaust (20-30 N·m (15-22 lb-ft)). Do not overtighten, as this risks stripping the threads or cracking the flanges.
  11. If you lowered the subframe, raise it back into place and tighten the subframe bolts to the torque specified by the manufacturer (usually 80-120 N·m (59-89 lb-ft) for the front subframe bolts, so check the documentation).
  12. Connect the connectors of both oxygen sensors. Reinstall the engine undercover.
  13. Start the engine and listen for exhaust leaks around the flanges. Clear the fault codes with a diagnostic scan tool (codes P0420-P0424 or P0430-P0434 are typical for the catalytic converter). Take a test drive and make sure the Check Engine light does not come back on.

Common mistakes and warnings

  • Before replacing the catalytic converter, be sure to diagnose why it failed (rich mixture, a faulty upstream oxygen sensor, a faulty MAF sensor, worn spark plugs). Otherwise the new catalytic converter will fail quickly. Working on the exhaust system calls for caution: hot parts can cause burns, and seized bolts break easily. If you have no experience working with the subframe and exhaust system, contact a certified Renault service center.