RENAULT TWINGO 2009 2.G Engine And Peripherals Service Manual

10A-35
ENGINE AND CYLINDER BLOCK ASSEMBLY
Oil-coolant heat exchanger: Removal - Refitting
D4F, and 780 or 782
10A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove:
-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, Ex-
terior protection),
-the oil filter (see 10A, Engine and cylinder block
assembly, Oil filter: Removal - Refitting, page
10A-29) .II - OPERATION FOR REMOVAL OF PART
CONCERNED
aFit the tool (Ms. 583) onto the oil-coolant heat ex-
changer hoses (1) .
aRelease the clips (2) using the (Mot. 1448).
aConnect the oil-coolant heat exchanger hoses.
aRemove:
-the nipple (3) from the oil-coolant heat exchanger,
-the oil-water heat exchanger. Special tooling required
Ms. 583Pipe clamps .
Mot. 1448Remote operation pliers for
hose clips .
Tightening torquesm
oil-coolant heat
exchanger nipple30 N.m
IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera-
tion.121726
121402

10A-36
ENGINE AND CYLINDER BLOCK ASSEMBLY
Oil-coolant heat exchanger: Removal - Refitting
D4F, and 780 or 782
10A
REFITTING
I - REFITTING PREPARATION OPERATION
aparts always to be replaced: coolant-engine oil
heat exchanger seal on the cylinder block.
aUse a GREY ABRASIVE PAD (see Vehicle: Parts
and consumables for the repair) (04B, Consum-
ables - Products) to clean the bearing faces of the
oil-coolant heat exchanger and the cylinder block.
II - REFITTING OPERATION FOR PART
CONCERNED
aCoat the nipple with HIGH STRENGTH THREAD-
LOCK (see Vehicle: Parts and consumables for
the repair) (04B, Consumables - Products).
aRefit:
-the oil-coolant heat exchanger,
-the oil-coolant heat exchanger nipple.
aTorque tighten the oil-coolant heat exchanger nip-
ple (30 N.m).
aConnect the oil-coolant heat exchanger hoses.
aRefit the clips using the (Mot. 1448).
aRemove the tools (Ms. 583).
III - FINAL OPERATION
aRefit:
-the oil filter (see 10A, Engine and cylinder block
assembly, Oil filter: Removal - Refitting, page
10A-29) ,
-the front right-hand wheel arch liner (see Front
wheel arch liner: Removal - Refitting) (55A, Ex-
terior protection),
-the front right-hand wheel (see Wheel: Removal -
Refitting) (35A, Wheels and tyres).
aFill and bleed the cooling system (see 19A, Cool-
ing, Cooling system: Draining - Refilling, page
19A-9) . WARNING
To ensure proper sealing, the gasket surfaces
must be clean, dry and not greasy (avoid any fin-
ger marks).

10A-37
ENGINE AND CYLINDER BLOCK ASSEMBLY
Conrod bearing shell: Removal - Refitting
K9K
10A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aRemove the engine undertray.
aDrain the oil from the engine (see 10A, Engine and
cylinder block assembly, Engine oil: Draining -
Refilling, page 10A-22) .
aRemove the oil filter (see 10A, Engine and cylinder
block assembly, Oil filter: Removal - Refitting,
page 10A-29) .
aRemove the lower engine tie-bar (see 19D, Engine
mounting, Lower engine tie-bar: Removal - Refit-
ting, page 19D-18) .
aStrap the radiator to the vehicle using safety
strap(s).
aRemove the front axle subframe (see Front axle
subframe: Removal - Refitting) (31A, Front axle
components).
aRemove the relay bearing of the front right-hand
wheel driveshaft. Special tooling required
Mot. 1914Tool for fitting G9 con rod
bear ing shells
Mot. 1920Tool for fitting F9 / K9 con rod
bear ing shells
Equipment required
safety strap(s)
component jack
indelible pencil
torque wrench
Diagnostic tool
Tightening torquesm
con rod cap bolts20 N.m + 45˚ ±± ± ±
6˚
oil pump bolts25 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 Vehicle: Precautions for the repair) .
IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera-
tion.
123838

10A-38
ENGINE AND CYLINDER BLOCK ASSEMBLY
Conrod bearing shell: Removal - Refitting
K9K
10A
aDisconnect the oil level sensor connector (if
equipped) (2) .
aRemove the catalytic converter upstream stay (3) .a
Undo the bolts of the engine oil sump.
aFit a component jack to support the engine oil
sump.
aRemove the bolts from the engine oil sump.
aDetach the engine oil sump, while supporting it with
the component jack.
123834
112328
140940
WARNING
Failure to observe the following procedure may
damage the oil pump strainer.

10A-39
ENGINE AND CYLINDER BLOCK ASSEMBLY
Conrod bearing shell: Removal - Refitting
K9K
10A
aTilt the engine oil sump forwards in order to access
the oil pump bolts.
aPartially loosen the oil pump bolts 3 mm to 5 mm.
aDetach the oil pump from its position in order to re-
move the engine oil sump.
aRemove:
-the engine oil sump,
-the engine oil sump seal,
-the oil pump.II - REMOVAL OPERATION FOR THE CON ROD
BEARING SHELLS NO.2
aUse SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consum-
ables - Products) to clean the big ends.
aMark the position of the con rod cap in relation to the
con rod body using a indelible pencil.
aPosition the crankshaft at Top Dead Centre.
140917
139306

10A-40
ENGINE AND CYLINDER BLOCK ASSEMBLY
Conrod bearing shell: Removal - Refitting
K9K
10A
aRemove:
-the con rod bolts,
-the con rod cap,
-the lower con rod bearing shell.
aUse SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consum-
ables - products) to clean the bearing mating face on
the con rod cap.aFit the tie rod of the tool (Mot. 1914) on the con rod
body.
aPush the con rod upwards to release the con rod
from the crankpin.
aTurn the crankshaft 90˚ clockwise (timing end).
139300
Note:
If reusing the con rod bearing shells, mark the
position of the lower con rod bearing shell in rela-
tion to the con rod cap.
139310

10A-41
ENGINE AND CYLINDER BLOCK ASSEMBLY
Conrod bearing shell: Removal - Refitting
K9K
10A
a
Pull the con rod - piston assembly using the tie rod of
the tool (Mot. 1914), taking care not to allow the pis-
ton to touch the piston base cooling jets.
aRemove the upper con rod bearing shell.
aUse SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consum-
ables - products) to clean the bearing mating face on
the con rod body.
REFITTING
I - REFITTING OPERATION FOR THE CON ROD
BEARING SHELLS ON CYLINDER NO.2
aparts always to be replaced: con rod cap boltsa
Fit the head of the tool (Mot. 1920) with the marking
" K9K INF " on the threaded sleeve of the tool (Mot.
1914).
aPosition the lower con rod bearing shell on the tool
(Mot. 1920).
139315
WARNING
Failure to observe the following procedure may
damage the piston base cooling jets.
Note:
If reusing the con rod bearing shells, mark the
position of the upper con rod bearing shell in
relation to the con rod body.
Note:
Always replace con rod bearing shells with a
width of 20 mm by con rod bearing shells with a
width of 18 mm.
If the set of con rod bearing shells only includes
con rod bearing shells which are 18mm wide,
only use the head of the tool (Mot. 1920) with the
mar king " K9K SUP ".

10A-42
ENGINE AND CYLINDER BLOCK ASSEMBLY
Conrod bearing shell: Removal - Refitting
K9K
10A
a
Fit the lower con rod bearing shell on the con rod
cap using the tool (Mot. 1920).
aPosition the lower con rod bearing shell so that the
ends do not protrude beyond the con rod cap.
aLubricate the surface of the con rod bearing shell
(crankshaft end) using new engine oil.aRemove the tool head with the marking " K9K INF "
and fit the head with the marking " K9K SUP ".
aPosition the upper con rod bearing shell on the tool
(Mot. 1920).
aFit the upper con rod bearing shell on the con rod
body using the tool (Mot. 1920).
aPosition the upper con rod bearing shell so that the
ends do not protrude beyond the con rod body.
aLubricate the surface of the con rod bearing shell
(crankshaft end) using new engine oil.
aPush the con rod - piston assembly back up into
place.
aTurn the crankshaft 90˚ anticlockwise.
aLubricate the crankpin with new engine oil.
aPull the con rod - piston assembly to position the con
rod on the crankshaft.
a
Refit:
-the con rod cap according to the mark made during
removal,
-the new con rod bolts.
aTorque and angle tighten the con rod cap bolts (20
N.m + 45˚ ±± ± ±
6˚).
133814
133815
Note:
The contact surface between the bearing shell
and the con rod must be dry and free of grease.
139318
Note:
Before refitting the con rod cap, ensure that there
are no impurities (filings, cloth lint, etc.) on the
con rod body or cap surfaces.

10A-43
ENGINE AND CYLINDER BLOCK ASSEMBLY
Conrod bearing shell: Removal - Refitting
K9K
10A
II - REMOVAL - REFITTING OPERATIONS FOR THE
CON ROD BEARING SHELLS ON CYLINDERS
NO.3, 1 AND 4
aPerform the same removal - refitting operations as
for the con rod bearing shells on cylinder no. 2.
III - FINAL OPERATION
aparts always to be replaced: engine oil sump
seal
parts always to be replaced: Oil filter
parts always to be replaced: Drain plug seal on
engine oil sump
aUse a wooden spatula or an ABRASIVE PAD to
clean the joint face of the cylinder block and engine
oil sump.
aRefit the oil pump.
aFit without tightening the oil pump bolts, while keep-
ing a clearance of 3 mm to 5 mm.
aFit the engine oil sump seal.aApply SILICONE ADHESIVE SEALANT (see Vehi-
cle: Parts and consumables for the repair) :
-four beads with a diameter of 5 mm at (A) ,
-two drops with a diameter of 5 mm at (B) .
aFit the engine oil sump while supporting it using a
component jack. Note:
For removing and refitting the con rod bearing
shells on cylinders no. 1 and no. 4, position the
pistons at Bottom Dead Centre before performing
the same removal and refitting operations as for
the con rod bearing shells on cylinder no. 2.
WARNING
Do not scrape the joint faces of the aluminium,
any damage caused to the joint face will result in
a risk of leaks.
WARNING
To ensure proper sealing, the gasket surfaces
must be clean, dry and not greasy (avoid any fin-
ger marks).
WARNING
Applying excess sealant could cause it to be
squeezed out when parts are tightened. A mix-
ture of sealant and fluid could damage certain
components (engine, radiator, etc.).
20166
20167

10A-44
ENGINE AND CYLINDER BLOCK ASSEMBLY
Conrod bearing shell: Removal - Refitting
K9K
10A
aTilt the engine oil sump forwards in order to access
the oil pump bolts.
aTorque tighten the oil pump bolts (25 N.m) using
the torque wrench PROSTEEL, part number 77 11
226 888 starting with the 13 mm bolt.
a
aRefit the engine oil sump bolts.
aTorque tighten in order the engine oil sump bolts
(see 10A, Engine and cylinder block assembly,
Lower cover: Removal - Refitting, page 10A-6) .
aRefit the catalytic converter upstream stay (see 19B,
Exhaust, Catalytic converter: Removal - Refit-
ting, page 19B-12) .
aConnect the connector to the oil level sensor.
aRefit the relay bearing of the front right-hand wheel
driveshaft (see Front right-hand driveshaft: Re-
moval - Refitting) .
aRefit the front axle subframe (see Front axle sub-
frame: Removal - Refitting) (31A, Front axle com-
ponents).
aRemove the safety strap(s) from the radiator.
aRefit the lower engine tie-bar (see 19D, Engine
mounting, Lower engine tie-bar: Removal - Refit-
ting, page 19D-18) .aDisconnect the crankshaft position sensor (4) to pre-
vent the engine from starting.
aRefit the oil filter (see 10A, Engine and cylinder
block assembly, Oil filter: Removal - Refitting,
page 10A-29)
aFill up the engine oil (see 10A, Engine and cylinder
block assembly, Engine oil: Draining - Refilling,
page 10A-22) .
aStart the engine using the starter until the engine oil
warning light goes out.
aConnect the crankshaft position sensor.
aRefit the engine undertray.
aClear the present faults using the Diagnostic tool.
140918
Note:
Check that the engine oil sump seal is definitely
in place before tightening the engine oil sump
bolts.
123824