wheel RENAULT TWINGO 2009 2.G Engine And Peripherals Workshop Manual

TWINGO - Chapitre 1
Contents
Pages
TWINGO - Chapitre 1ContentsPages
10AENGINE AND CYLINDER BLOCK
ASSEMBLY
Crankshaft seal on timing
end: Removal - Refitting 10A-1
Crankshaft seal, gearbox
end: Removal - Refitting 10A-3
Lower cover: Removal -
Refitting 10A-6
Engine oil: Draining -
Refilling 10A-22
Oil filter: Removal - Refitting 10A-29
Oil-coolant heat exchanger:
Removal - Refitting 10A-33
Conrod bearing shell:
Removal - Refitting 10A-37
Oil pressure sensor:
Removal - Refitting 10A-45
Oil pump: Removal -
Refitting 10A-50
Oil pressure: Check 10A-59
Multifunction suppor t:
Removal - Refitting 10A-63
Engine - gearbox assembly:
Removal - Refitting 10A-74
Valves: Adjustment 10A-105
Flywheel: Removal - Refitting 10A-10711A TOP AND FRONT OF ENGINE
Pressure at end of
compression: Check 11A-1
Accessories belt: Removal -
Refitting 11A-3
Crankshaft accessories
pulley: Removal - Refitting 11A-20
Timing belt: Removal -
Refitting 11A-27
Rocker cover: Removal -
Refitting 11A-66
Camshaft: Removal -
Refitting 11A-82
Cylinder head: Removal -
Refitting 11A-114
Camshaft dephaser :
Removal - Refitting 11A-135
Camshaft seal, timing end:
Removal - Refitting 11A-138
Oil decanter: Removal -
Refitting 11A-147
12A FUEL MIXTURE
Air inlet: Description 12A-1
Air filter: Removal - Refitting 12A-6
Air filter unit: Removal -
Refitting 12A-13

10A-1
ENGINE AND CYLINDER BLOCK ASSEMBLY
Crankshaft seal on timing end: Removal - Refitting
K4M
10A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aDisconnect the battery (see Battery: Removal - Re-
fitting) (80A, Battery).
aRemove:
-the engine undertray,
-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 front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),
-the headlights (see Halogen headlight: Removal
- Refitting) (80B, Headlights),
-the bonnet catch (see Bonnet lock: Removal -
Refitting) (52A, Non-side opening element mecha-
nisms),
-the front upper cross member (see Front upper
cross member: Removal - Refitting) (42A, Upper
front structure),
-the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-3) ,
-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the throttle valve (see 12A, Fuel mixture, Throttle
valve: Removal - Refitting, page 12A-20) ,
-the windscreen wiper arms (see Windscreen wip-
er arm: Removal - Refitting) (85A, Wiping -
Washing),
-the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),
-the scoop under the scuttle panel grille (see Scoop
under the scuttle panel grille: Removal - Refit-
ting) (56A, Exterior equipment),-the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-13) ,
-the crankshaft accessories pulley (see 11A, Top
and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-20) ,
-the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-27) ,
-the camshaft dephaser (see 11A, Top and front of
engine, Camshaft dephaser: Removal - Refit-
ting, page 11A-135) .
II - REMOVAL OPERATION
aRemove the crankshaft timing end seal (1) .
REFITTING
I - REFITTING PREPARATION OPERATION
aparts always to be replaced: Crankshaft seal on
timing end. Special tooling required
Mot. 1385Tool for fitting the crankshaft
seal, timing end (35 x 47 x 7).
130542

10A-2
ENGINE AND CYLINDER BLOCK ASSEMBLY
Crankshaft seal on timing end: Removal - Refitting
K4M
10A
aUse SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consuma-
bles - Products) to clean and degrease:
-the mating face of the crankshaft seal at the timing
end,
-the crankshaft seal housing at the timing end of the
cylinder block.
II - REFITTING OPERATION
aRefit a new crankshaft seal at the timing end, using
the tool (Mot. 1385) (2) .
III - FINAL OPERATION
aRefit:
-the camshaft dephaser (see 11A, Top and front of
engine, Camshaft dephaser: Removal - Refit-
ting, page 11A-135) ,
-the timing belt (see 11A, Top and front of engine,
Timing belt: Removal - Refitting, page 11A-27) ,
-the crankshaft accessories pulley (see 11A, Top
and front of engine, Crankshaft accessories
pulley: Removal - Refitting, page 11A-20) ,
-the right-hand suspended engine mounting (see
19D, Engine mounting, Right-hand suspended
engine mounting: Removal - Refitting, page
19D-13) ,-the scoop under the scuttle panel grille (see Scoop
under the scuttle panel grille: Removal - Refit-
ting) (56A, Exterior equipment),
-the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (56A, Exterior equipment),
-the windscreen wiper arms (see Windscreen wip-
er arm: Removal - Refitting) (85A, Wiping -
Washing),
-the throttle valve (see 12A, Fuel mixture, Throttle
valve: Removal - Refitting, page 12A-20) ,
-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the accessories belt (see 11A, Top and front of
engine, Accessories belt: Removal - Refitting,
page 11A-3) ,
-the front upper cross member (see Front upper
cross member: Removal - Refitting) (42A, Upper
front structure),
-the bonnet catch (see Bonnet lock: Removal -
Refitting) (52A, Non-side opening element mecha-
nisms),
-the headlights (see Halogen headlight: Removal
- Refitting) (80B, Headlights),
-the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),
-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),
-the engine undertray.
aConnect the battery (see Battery: Removal - Refit-
ting) (80A, Battery). WARNING
The joint faces must be clean, dr y and free from
grease (avoid finger marks).
14523

10A-3
ENGINE AND CYLINDER BLOCK ASSEMBLY
Crankshaft seal, gearbox end: Removal - Refitting
K4M
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,
-the battery (see Battery: Removal - Refitting)
(80A, Battery),
-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the petrol injection computer (see 17B, Petrol in-
jection, Petrol injection computer: Removal -
Refitting, page 17B-20) ,
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
-the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion),
-the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection).
aDrain:
-the gearbox (see Manual gearbox oils: Draining -
Filling) (21A, Manual gearbox),
-the engine cooling system (see 19A, Cooling,
Cooling system: Draining - Refilling, page 19A-
9) ,
-the refrigerant circuit using a refrigerant charging
station (see Refrigerant circuit: Draining - Fill-
ing) (62A, Air conditioning).
aRemove:
-the lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-18) ,-the front axle subframe (see Front axle subframe:
Removal - Refitting) (31A, Front axle compo-
nents),
-the front left-hand wheel driveshaft (see Front left-
hand driveshaft: Removal - Refitting) (29A,
Driveshafts),
-the front right-hand wheel driveshaft (see Front
right-hand driveshaft: Removal - Refitting)
(29A, Driveshafts),
-the differential output seals (see Differential out-
put seal: Removal - Refitting) (21A, Manual gear-
box),
-the « engine and gearbox » assembly (see 10A,
Engine and cylinder block assembly, Engine -
gearbox assembly: Removal - Refitting, page
10A-74) ,
-the manual gearbox (see Manual gearbox: Re-
moval - Refitting) (21A, Manual gearbox).
-the « pressure plate - disc » assembly (see Pres-
sure plate - Disc: Removal - Refitting) (20A,
Clutch),
-the flywheel (see 10A, Engine and cylinder block
assembly, Flywheel: Removal - Refitting, page
10A-107) . Special tooling required
Mot. 1129-01Tool for fitting the crankshaft
seal, flywheel end (80 x 100 x
8 seal).
Equipment required
refrigerant charging station

10A-4
ENGINE AND CYLINDER BLOCK ASSEMBLY
Crankshaft seal, gearbox end: Removal - Refitting
K4M
10A
II - REMOVAL OPERATION
aRemove the crankshaft seal (1) at the gearbox end
using a screwdriver.
REFITTING
I - REFITTING PREPARATION OPERATION
aparts always to be replaced: Crankshaft seal on
gearbox end.
aUse SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consuma-
bles - Products) to clean and degrease:
-the mating face of the crankshaft seal at the gear-
box end,
-the crankshaft seal housing at the gearbox end of
the cylinder block.II - REFITTING OPERATION
aRefit a new crankshaft seal at the gearbox end, us-
ing the tool (Mot. 1129-01) (2) .
III - FINAL OPERATION
aRefit:
-the flywheel (see 10A, Engine and cylinder block
assembly, Flywheel: Removal - Refitting, page
10A-107) ,
-the « pressure plate - disc » assembly (see Pres-
sure plate - Disc: Removal - Refitting) (20A,
Clutch),
-the manual gearbox (see Manual gearbox: Re-
moval - Refitting) (21A, Manual gearbox).
-the « engine and gearbox » assembly (see 10A,
Engine and cylinder block assembly, Engine -
gearbox assembly: Removal - Refitting, page
10A-74) ,
-the differential output seals (see Differential out-
put seal: Removal - Refitting) (21A, Manual gear-
box),
-the front right-hand wheel driveshaft (see Front
right-hand driveshaft: Removal - Refitting)
(29A, Driveshafts),
-the front left-hand wheel driveshaft (see Front left-
hand driveshaft: Removal - Refitting) (29A,
Driveshafts),
-the front axle subframe (see Front axle subframe:
Removal - Refitting) (31A, Front axle compo-
nents),
118581
Note:
Take care not to damage the crankshaft mating
face.
WARNING
The joint faces must be clean, dr y and free from
grease (avoid finger marks).
132380

10A-5
ENGINE AND CYLINDER BLOCK ASSEMBLY
Crankshaft seal, gearbox end: Removal - Refitting
K4M
10A
-the lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-18) ,
-the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion),
-the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
-the battery tray (see Battery tray: Removal - Re-
fitting) (80A, Battery),
-the petrol injection computer (see 17B, Petrol in-
jection, Petrol injection computer: Removal -
Refitting, page 17B-20) ,
-the air filter unit (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) ,
-the battery (see Battery: Removal - Refitting)
(80A, Battery).
aRefill:
-and bleed the engine cooling circuit (see 19A,
Cooling, Cooling system: Draining - Refilling,
page 19A-9) ,
-the gearbox (see Manual gearbox oils: Draining -
Filling) (21A, Manual gearbox),
-the refrigerant circuit using a refrigerant charging
station (see Refrigerant circuit: Draining - Fill-
ing) (62A, Air conditioning).
aRefit the engine undertray.

10A-6
ENGINE AND CYLINDER BLOCK ASSEMBLY
Lower cover: 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 front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres),
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion),
-the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection). Special tooling required
Tav. 476Ball joint extractor.
Tav. 1233-01Tooling for carrying out opera-
tions on the axle subframe.
Equipment required
flywheel immobiliser
safety strap(s)
Tightening torquesm
lowe r cylinder block
bolts14 Nm
multifunction support
bolt on the sump25 N.m
sump bolts on the gear-
box casing44 Nm
subframe front bolts62 N.m
subframe rear bolts105 Nm
subframe rear tie rod
inner bolts21 N.m
subframe rear tie rod
outer bolts90 N.m
lower ball joint bolts62 N.m
track rod end nuts37 N.m
subframe tie-rod upper
bolts21 N.m
subframe tie-rod lower
bolts62 N.m
bolts of the front right-
hand driveshaft relay
bearing44 N.m
bolt of the front right-
hand driveshaft relay
bearing bracket21 N.m
relay bearing bolts on
the front right-hand
driveshaft44 N.m
right-hand driveshaft
relay bearing closure
panel bolts21 Nm
catalytic converter
upstream stay bolt on
the cylinder block44 N.m
catalytic converter
downstream stay bolt on
the sump44 Nm
catalytic converter
downstream stay bolts
on the catalytic con-
verter26 Nm
universal joint bolt24 N.m Tightening torquesm

10A-7
ENGINE AND CYLINDER BLOCK ASSEMBLY
Lower cover: Removal - Refitting
K9K
10A
aSet the wheels straight ahead.
aPosition the flywheel immobiliser.
aRemove the cover from the universal joint (do not
keep).
aRemove the bolt (1) from the universal joint (do not
keep).
aRemove the universal joint from the steering box.
aDrain the engine oil (see 10A, Engine and cylinder
block assembly, Engine oil: Draining - Refilling,
page 10A-22) .
aRemove the lower engine tie-bar (see 19D, Engine
mounting, Lower engine tie-bar: Removal - Refit-
ting, page 19D-18) .aUndo the catalytic converter upstream stay bolt (2)
on the sump by a few turns.
aRemove:
-the three catalytic converter upstream stay bolts (3)
,
-the catalytic converter upstream stay, by sliding it
in relation to the bolt remaining on the sump.
119544112328

10A-12
ENGINE AND CYLINDER BLOCK ASSEMBLY
Lower cover: Removal - Refitting
K9K
10A
-the subframe rear bolts (105 Nm),
-the subframe rear tie rod inner bolts (21 N.m),
-the subframe rear tie rod outer bolts (90 N.m).
aRefit the radiator mounting cross member (see Ra-
diator mounting cross member: Removal - Refit-
ting) (41A, Front lower structure).
aDetach the radiator and the intercooler from the up-
per cross member using a safety strap(s).
aDetach the radiator from the upper cross member
using a safety strap(s).
aRefit:
-the rear engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-18) ,
-the lower ball joints,
-the track rod ends.
aTighten to torque:
-the lower ball joint bolts (62 N.m),
-the track rod end nuts (37 N.m).
aRefit the subframe tie rod upper bolts.
aTighten to torque:
-the subframe tie-rod upper bolts (21 N.m),
-the subframe tie-rod lower bolts (62 N.m).
aRefit the front right-hand driveshaft relay bearing
aTighten to torque:
-the bolts of the front right-hand driveshaft relay
bearing (44 N.m),
-the bolt of the front right-hand driveshaft relay
bearing bracket (21 N.m).aFit the relay bearing on its bearing on the front right-
hand driveshaft.
aTorque tighten the relay bearing bolts on the front
right-hand driveshaft (44 N.m).
aRefit the closure panel of the front right-hand drive-
shaft relay bearing
aTorque tighten the right-hand driveshaft relay
bearing closure panel bolts (21 Nm).
aRefit the catalytic converter upstream stay, by slid-
ing it in relation to the bolt remaining on the sump.
aTighten the following until contact is made and to tor-
que:
-the catalytic converter upstream stay bolt on
the cylinder block (44 N.m),
-the catalytic converter downstream stay bolt on
the sump (44 Nm),
-the catalytic converter downstream stay bolts
on the catalytic converter (26 Nm).
aFit the steering box universal joint equipped with a
new bolt.
aTorque tighten the universal joint bolt (24 N.m).
aRemove the flywheel immobiliser.
aRefit:
-the front bumper (see Front bumper: Removal -
Refitting) (55A, Exterior protection),
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion),
-the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres).
aFill up the engine oil (see 10A, Engine and cylinder
block assembly, Engine oil: Draining - Refilling,
page 10A-22) . K9K, and 718
K9K, and 740
K9K, and 718
K9K, and 740
Note:
Ensure that the right-hand dr iveshaft relay bear-
ing closure panel is refi tted the right way round.

10A-13
ENGINE AND CYLINDER BLOCK ASSEMBLY
Lower cover: Removal - Refitting
D4F or D7F
10A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aDrain the engine oil (see 10A, Engine and cylinder
block assembly, Engine oil: Draining - Refilling,
page 10A-22) .
aRemove the engine undertray.
aRemove the engine flywheel guard
aRemove:
-the front wheels (see Wheel: Removal - Refitting)
(35A, Wheels and tyres), Special tooling required
Tav. 476Ball joint extractor.
Tav. 1233-01Tooling for carrying out opera-
tions on the axle subframe.
Mot. 1716Removes housing with sili-
cone seals.
Equipment required
flywheel immobiliser
Tightening torquesm
sump bolts10 N.m
front subframe bolts62 N.m
rear subframe bolts105 N.m
front end cross member
bolts21 N.m
subframe rear tie rod
inner bolts21 N.m
subframe rear tie rod
outer bolts90 N.m
lower ball joint bolts62 N.m
track rod end nuts37 N.m
subframe tie rod upper
bolts21 N.m
subframe tie rod lower
bolts62 N.m
universal joint24 N.m
IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera-
tion.
Note:
The sump is sealed in the factory using silicone
adhesive sealant.
When removing the sump in a workshop, it is
essential to use the After-Sales seal available from
the Parts Department.
D4F, and 772 – D7F
120407
D4F, and 780 or 782