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

10A-95
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
K9K
10A

10A-96
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: 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 air filter unit (see 12A, Fuel mixture,
Air filter unit: Removal - Refitting, page 12A-13) .
aRemove the battery (see Battery: Removal - Refit-
ting) (80A, Battery).
aRemove:
-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 engine undertray,
-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 cooling system (see 19A, Cooling, Cooling
system: Draining - Refilling, page 19A-9) ,
-the engine, if necessary (see 10A, Engine and
cylinder block assembly, Engine oil: Draining -
Refilling, page 10A-22) ,
-the refrigerant circuit using a refrigerant charging
station (see Refrigerant circuit: Draining - Fill-
ing) (62A, Air conditioning).
aAttach the « engine cooling radiator - condenser »
assembly to the front upper cross member.
aRemove:
-the engine tie-bar (see 19D, Engine mounting,
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 radiator mounting cross member (see Radiator
mounting cross member: Removal - Refitting)
(41A, Front lower structure),
-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 seal (see Differential output
seal: Removal - Refitting) (21A, Manual gear-
box).
aRemove the catalytic converter (see 19B, Exhaust,
Catalytic converter: Removal - Refitting, page
19B-12) . Special tooling required
Mot. 1448Remote operation pliers for
hose clips .
Equipment required
refrigerant charging station
Tightening torquesm
rubber pad mounting
bolts for the suspended
engine mounting on the
gearbox21 N.m
bolts of the suspended
mounting r ubber pad62 N.m
suspended engine
mounting shaft nut62 N.m

10A-97
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
K4M
10A
aRemove using the (Mot. 1448) :
-the clip (6) from the top hose on the water cham-
ber,
-the clip (7) from each heater matrix hose.
aDisconnect:
-the top hose on the water chamber,
-the heater matrix hoses.aUnclip:
-the gearbox controls (8) on the gear selectors,
-the gearbox controls on the cable sleeve stops at
(9) ,
-the hydraulic clutch control pipe on the gearbox at
(10) .
aDisconnect the hydraulic clutch control pipe from the
gearbox by pressing on the clip (11) .
aFit blanking plugs on the hydraulic clutch control
pipe openings and on the opening of the clutch
thrust bearing.
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132346131761
121410

10A-98
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
K4M
10A
aDisconnect:
-the fuel vapour absorber bleed solenoid valve pipe
(12) ,
-the fuel vapour absorber bleed solenoid valve con-
nector (13) .aUnclip the fuel supply pipe at (14) .
aDisconnect the fuel supply pipe (15) .
131766131767
WARNING
To prevent impur ities from entering the circuit,
place protective plugs on all fuel circuit compo-
nents exposed to the open air.

10A-99
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
K4M
10A
aDisconnect:
-the engine cooling fan assembly resistor connector
(16) ,
-the engine cooling fan assembly connector (17) .
aUnclip:
-the engine cooling fan assembly wiring at (18) ,
-the cooling radiator top and bottom hose from the
engine cooling fan assembly.aRemove:
-the engine compartment connection unit cover
bolts (19) ,
-the cover of the engine compartment connection
unit.
aDisconnect the connector (20) from the engine com-
partment connection unit.
aRemove the engine compartment connection unit
nuts (21) from the body.
aMove the engine compartment connection unit to
one side.
132336121429
121213

10A-100
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
K4M
10A
aRemove the earth nuts (22) .
aDisconnect the fuses (23) .
aUnclip:
-the fuse-holders,
-the engine compartment connection unit relay
plates (24) .
aRemove the earth nut (25) .aRemove the coolant pump inlet pipe hose clip (26)
using the tool (Mot. 1448).
aDisconnect the hose from the coolant pump inlet
pipe.
132347
121435131781

10A-101
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
K4M
10A
aRemove:
-the bolt (27) from the « compressor - intermediate
pipe » connecting pipe,
-the bolt (28) on the « compressor - condenser »
connecting pipe,
-the bolt (29) from the « compressor - intermediate
pipe » connecting pipe mounting.
aDisconnect:
-the pressure sensor connector (30) ,
-the « compressor - intermediate pipe » connecting
pipe,-the « compressor - condenser » connecting pipe.
aInsert the blanking plugs.
aDisconnect the brake servo vacuum pipe union (31)
.
131782
132335
WARNING
To prevent moisture from entering the system,
place plugs on the cold loop components which
are open to the air.
121348

10A-102
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
K4M
10A
aSupport the engine - gearbox assembly on theat
(32) .II - REMOVAL OPERATION
aRemove:
-the nut (33) from the suspended engine mounting
rubber pad shaft on the gearbox.
-the bolts (34) of the rubber pad of the suspended
engine mounting from the gearbox,
-the suspended engine mounting rubber pad from
the gearbox.
aRemove:
-the rubber pad mounting bolts (35) from the sus-
pended engine mounting on the gearbox,
132348
17765
131760
120310

10A-103
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
K4M
10A
-the rubber pad mounting from the suspended en-
gine mounting on the gearbox.
aRemove the right-hand suspended engine mounting
(see 19D, Engine mounting, Right-hand sus-
pended engine mounting: Removal - Refitting,
page 19D-13) .
aLift the vehicle to remove the "engine and gearbox"
assembly.
REFITTING
I - REFITTING PREPARATION OPERATION
aFor standard engine replacement (see Standard re-
placement) (Technical Note 6023A, 10A, Engine
and peripherals).
II - REFITTING OPERATION
aPosition the "engine and gearbox" assembly in the
body.
aRefit the right-hand suspended engine mounting
(see 19D, Engine mounting, Right-hand sus-
pended engine mounting: Removal - Refitting,
page 19D-13) .
aRefit the rubber pad mounting from the suspended
engine mounting on the gearbox.
aTorque tighten the rubber pad mounting bolts for
the suspended engine mounting on the gearbox
(21 N.m).
aRefit the suspended engine mounting rubber pad.
aTorque tighten:
-the bolts of the suspended mounting rubber
pad (62 N.m),
-the suspended engine mounting shaft nut (62
N.m).
III - FINAL OPERATION
aRemove the.
aRemove the blanking plugs.
aConnect:
-the union of the brake servo vacuum pipe,
-the « compressor - condenser » connecting pipe,-the « compressor - intermediate pipe » connecting
pipe,
-the pressure sensor connector,
aConnect the hose on the coolant pump inlet pipe.
aFit the hose clip on the coolant pump inlet pipe using
the (Mot. 1448).
aRefit the earth nuts.
aClip:
-the relay plates on the engine compartment con-
nection unit,
-the fuse holders.
aConnect the fuses.
aRefit the engine compartment connection unit on the
body.
aConnect the connector to the engine compartment
connection unit.
aRefit the engine compartment connection unit cover.
aClip:
-the wiring on the engine cooling fan assembly,
-the cooling radiator top and bottom hoses on the
engine cooling fan assembly.
aConnect:
-the engine cooling fan assembly resistor connec-
tor,
-the engine cooling fan assembly connector.
aRemove the blanking plug from the fuel supply pipe
opening and the injector rail fuel opening.
aReconnect the fuel supply pipe.
aClip the fuel supply pipe in place.
aConnect:
-the fuel vapour absorber bleed solenoid valve con-
nector,
-the fuel vapour absorber bleed solenoid valve pipe.
aFit the gearbox control cables.
aClip the manual gearbox control cables onto:
-the gear selectors,
-the cable sleeve stops.
aRemove the blanking plug from the hydraulic clutch
control pipe opening and the opening of the clutch
thrust bearing.
aConnect the hydraulic clutch control pipe.
aClip the hydraulic clutch control pipe on the gearbox. Note:
Check no component obstructs the movement of
the body around the engine - gearbox assembly.

10A-104
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
K4M
10A
aConnect:
-the top hose on the water chamber,
-the hoses on the heater matrix.
aUsing the (Mot. 1448), fit:
-the clip on the top hose on the water chamber,
-the clip on each hose on the heater matrix.
aRefit the catalytic converter (see 19B, Exhaust,
Catalytic converter: Removal - Refitting, page
19B-12) .
aRefit:
-the differential output seal (see Differential output
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 radiator mounting cross member (see Radiator
mounting cross member: Removal - Refitting)
(41A, Front lower structure),
-the front axle subframe (see Front axle subframe:
Removal - Refitting) (31A, Front axle compo-
nents),
-the strap of the « engine cooling radiator -
condenser » assembly on the front upper cross
member,
-the engine tie-bar (see 19D, Engine mounting,
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 fuel injection computer (see 17B, Petrol injec-
tion, Petrol injection computer: Removal - Refit-
ting, page 17B-20) .
aRefit the battery (see Battery: Removal - Refitting)
(80A, Battery).
aRefit the air filter unit (see 12A, Fuel mixture, Air fil-
ter unit: Removal - Refitting, page 12A-13) .aRefill:
-the gearbox (see Manual gearbox oils: Draining -
Filling) (21A, Manual gearbox),
-and bleed the cooling system (see 19A, Cooling,
Cooling system: Draining - Refilling, page 19A-
9) ,
-the engine if necessary (see 10A, Engine and cyl-
inder block assembly, Engine oil: Draining - Re-
filling, page 10A-22) ,
-the refrigerant circuit using a refrigerant charging
station (see Refrigerant circuit: Draining - Fill-
ing) (62A, Air conditioning).
aBleed the clutch circuit (see Clutch circuit: Bleed)
(37A, Mechanical component controls).
aRefit the engine undertray.