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

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-10
ENGINE AND CYLINDER BLOCK ASSEMBLY
Lower cover: Removal - Refitting
K9K
10A
aRemove the subframe bolts (13) one by one, replac-
ing them in turn with the threaded rods of the tool
(Tav. 1233-01).
aLower the subframe by several centimetres, gradu-
ally loosening the nuts of the (Tav. 1233-01).II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove:
-the bolt (14) from the multifunction support on the
cylinder block,
-the sump bolts (15) on the gearbox casing,
-the sump bolts (16) on the cylinder block,
-the sump, by pivoting and tilting it to remove it from
the oil pump strainer,
-the sump seal.
REFITTING
I - REFITTING PREPARATION OPERATION
aparts always to be replaced: engine oil sump
seal.
aparts always to be replaced: Front sub-frame
bolt
aparts always to be replaced: Steering shaft yoke
bolt
aUse SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consum-
ables - Products) to degrease the joint faces of the
sump on the cylinder block and on the sump.
119336
Note:
Make sure the threaded rod of the (Tav. 1233-01)
is sufficiently screwed into the threaded hole and
that the nut of the tool is properly resting on the
subframe.
20171
Note:
Take care not to pull the sump to prevent damag-
ing the oil pump str ainer.

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-14
ENGINE AND CYLINDER BLOCK ASSEMBLY
Lower cover: Removal - Refitting
D4F or D7F
10A
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (55A, Exterior protec-
tion).
aSet the wheels straight ahead.
aPosition the flywheel immobiliser.
aRemove the cover from the universal joint (do not
keep).
aRemove the universal joint bolt (do not keep).
aRemove the universal joint from the steering box.
aLoosen the tie rod lower bolts.
aRemove the tie rod upper bolts.aRemove:
-the nuts (1) from the track rod ends,
-the track rod ends using the (Tav. 476),
-the bolts (2) from the lower ball joints,
-the lower arm ball joints.
aRemove the lower engine tie-bar (3) (see 19D, En-
gine mounting, Lower engine tie-bar: Removal -
Refitting, page 19D-18) .
aRemove:
-the subframe rear tie rod inner bolts (4) ,
-the subframe rear tie rod outer bolts (5) .
119544
119222
119335

10A-16
ENGINE AND CYLINDER BLOCK ASSEMBLY
Lower cover: Removal - Refitting
D4F or D7F
10A
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the sump fitted with a new seal,
-the sump bolts.
aTighten to torque and in order the sump bolts (10
N.m).
III - FINAL OPERATION
aRefit the engine flywheel guard.aRefit the subframe, gradually tightening the nuts of
the (Tav. 1233-01).
aRemove the threaded rods of the (Tav. 1233-01)
one by one, replacing them with the subframe
mounting bolts.
aTorque tighten:
-the front subframe bolts (62 N.m),
-the rear subframe bolts (105 N.m),
-the front end cross member bolts (21 N.m)
-the subframe rear tie rod inner bolts (21 N.m),
-the subframe rear tie rod outer bolts (90 N.m).
aRefit:
-the lower engine tie-bar (see 19D, Engine mount-
ing, Lower engine tie-bar: Removal - Refitting,
page 19D-18) ,
-the lower arm ball joints,
-the lower ball joint bolts,
-track rod ends,
-the track rod end nuts,
aTorque tighten:
-the lower ball joint bolts (62 N.m),
-the track rod end nuts (37 N.m).
aRefit the subframe tie rod upper bolts.
aTorque tighten the subframe tie rod upper bolts
(21 N.m).
aTorque tighten the subframe tie rod lower bolts
(62 N.m).
aFit the steering box universal joint.
aRefit the universal joint bolt.
aTorque tighten the universal joint (24 N.m).
aRemove the flywheel immobiliser.
aRefit:
-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).
18643
D4F, and 772 – D7F
D4F, and 780 or 782

10A-78
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
D4F or D7F
10A
aDrain the coolant circuit (see Refrigerant circuit:
Draining - Filling) .
aRemove:
-the air conditioning pipe bolts on the compressor,
-the air conditioning pipe bolt on the dehydrator res-
ervoir.
aDisconnect the air conditioning pressostat connec-
tor.
a
aDisconnect the fuel supply pipe union.
aInsert the blanking plugs.
aUnclip the fuel pipe on the upper timing cover.aSet the wheels straight ahead.
aPosition the flywheel immobiliser.
aRemove the cover from the universal joint (do not
keep).
aRemove the universal joint bolt (do not keep).
aRemove the universal joint from the steering box.
aDetach the electrical wiring on the cross member.
aLoosen the tie rod lower bolts.
aRemove:
-the tie rod upper bolts.
-the track rod end nuts,
-the track rod ends using the (Tav. 476),
-the lower guide pin bolts,
-the brake pads,
-the calliper mounting bolts,
-the brake callipers, and attach them to the suspen-
sion springs,
-the ABS sensor bolts (if fitted to the vehicle),
-the ABS sensors,
-the shock absorber base lower bolts, AIR CONDITIONING
WARNING
To prevent moisture from entering the system,
place plugs on the cold loop components which
are open to the air.
IMPORTANT
During this operation, be sure to:
-refrain from smoking or bringing red hot objects
close to the working area,
-be careful of fuel splashes when disconnecting
the union.
IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera-
tion.
WARNING
To avoid any corrosion or damage, protect the
areas on which fuel is likely to run.
119544

10A-83
ENGINE AND CYLINDER BLOCK ASSEMBLY
Engine - gearbox assembly: Removal - Refitting
D4F or D7F
10A
aTorque tighten:
-the front subframe bolts (62 N.m),
-the rear subframe bolts (105 N.m),
-the subframe rear tie rod inner bolts (21 N.m),
-the subframe rear tie rod outer bolts (90 N.m),
-the engine tie-bar bolts on the gearbox (105
N.m),
-the engine tie-bar bolt on the subframe (105
N.m).
aRefit the control cables onto the gearbox.
aRemove the blanking plugs from the openings.
aClip the clutch pipe onto the gearbox.
aConnect the clutch slave cylinder.
aRemove the hose clamp (Ms. 583).
aBleed the clutch circuit (see Clutch circuit: Bleed) .
aRefit the gear control linkage.
aAttach the gear control linkage to:
-the gear lever,
-the control lever on the gearbox.
aRefit:
-the heat shield,
-the heat shield bolts.
aRefit the clutch control cable on the manual gearbox.
aRefit the catalytic converter (see 19B, Exhaust,
Catalytic converter: Removal - Refitting, page
19B-12) .aRefit the exhaust downpipe.
aFit the clip.
aTighten the intermediate pipe clip.
aRefit the exhaust downpipe bolts.
aTorque tighten the exhaust downpipe bolts (9
N.m).
aRefit:
-the shock absorber base lower bolts,
-the ABS sensors,
-the ABS sensor bolts (if fitted to the vehicle),
-the brake callipers,
-the calliper mounting bolts,
-the brake pads,
-the lower guide pin bolts,
-track rod ends,
-the track rod end nuts,
-the tie rod upper bolts.
aTorque tighten:
-the shock absorber base lower bolts (105 N.m ),
-the calliper mounting bolts (105 N.m),
-the lower guide pin bolts (34 N.m),
-the track rod end nuts (37 N.m),
-the tie rod upper bolts (21 N.m),
-the tie rod lower bolts (62 N.m).
aClip the electrical wiring on to the cross member.
aFit the steering box universal joint.
aRefit the universal joint bolt.
aTorque tighten the universal joint (24 N.m).
aRemove the flywheel immobiliser.
aClip the fuel pipe on to the upper timing cover.
aConnect the fuel supply pipe union.
aConnect the air conditioning pressostat connector. JH3
JB1 or JH1
D4F, and 772 – D7F
D4F, and 780 or 782
AIR CONDITIONING

13B-2
DIESEL INJECTION
Diesel injection: Precautions for the repair
K9K
13B
II - ADVICE TO BE FOLLOWED BEFORE ANY
OPERATION
1) Carry out the work in a clean working area and take
care to protect removed components from dust using
plastic bags which are hermetically-resealable, for ex-
ample.
2) Always order the following from the Parts Depart-
ment before carrying out work:
-a new set of blanking plugs, specific to the engine,
-enough lint-free cleaning cloths.
-one of the two cleaning products for fuel pipe
unions,
-the parts that are always to be replaced after each
removal operation, mentioned in the operational pro-
cedures specific to the vehicle (see related Workshop
Repair Manual).
3) Wear safety goggles fitted with side shields to pre-
vent the cleaning product from splashing the eyes.
4) Wear leaktight protective gloves (Nitrile type) to
avoid prolonged contact with the skin.
5) Before carrying out work on the injection system,
use plastic bags or clean rags, for example, to protect:
-the accessories and timing belts,
-the electrical accessories (starter, alternator, power-
assisted steering pump, sensors and electrical con-
nectors),
-the flywheel face.
III - INSTRUCTIONS TO BE FOLLOWED DURING
THE OPERATION
Wash your hands before and while carrying out the
work.
Replace leaktight protective gloves (Nitrile type) when
they are soiled or damaged.
All components removed from the injection system
must be stored in a hermetically sealed plastic bag
once they have been capped.
Reseal the bag hermetically, for example using adhe-
sive tape, even if the bag must be opened shortly after-
wards: ambient air can be a source of impurities.After opening the fuel circuit, the use of brushes, clean-
ing agents, air blow guns, rifle-type brushes or stan-
dard cloths is strictly prohibited: these items are likely
to allow impurities to enter the system.
When replacing a component with a new one or when
refitting it after storing it in a plastic bag, do not unpack
it until it is time to fit it on the vehicle.
IV - CLEANING
There are currently two procedures for cleaning the
fuel circuit before opening it in order to carry out work in
the workshop.
These procedures enable the fuel circuit to be cleaned
to prevent contamination from entering: they both have
the same end result and neither is preferred over the
other.
1 - Cleaning using injector cleaner
Clear the access to the unions that need opening, fol-
lowing the work procedures specific to the vehicle (see
the relevant Workshop Repair Manual).
Protect sections which are sensitive to fuel leaks.
Pour the injector cleaning agent into a container which
is free from impurities.
Dip a clean brush, which is not shedding bristles, into
the container of injector cleaning agent.
Clean the unions carefully using the brush and the in-
jector cleaning agent.
Blast the components that have been cleaned with
compressed air (tools, workbench, and also parts,
unions and around the injection system). Check that no
bristles from the brush have come away and that the
area is clean.
Wipe the sections that were cleaned with fresh clean-
ing cloths.
Open the circuit at the unions and immediately fit the
relevant blanking plugs. Note:
When using leather protective gloves, wear a pair of
leaktight protective gloves (Nitrile type) over the top.
IMPORTANT
Wear leaktight gloves (Nitrile type) for this opera-
tion.
IMPORTANT
Wear goggles with side protectors for this opera-
tion.