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

19A-54
COOLING
Engine cooling fan assembly: Removal - Refitting
D4F, and 780 or 782
19A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 411, 02A, Lifting equip-
ment).
aDisconnect the battery (see ) (MR 411, 80A, Bat-
tery).
aRemove:
-the front wheels (see Wheel: Removal - Refitting)
(MR 411, 35A, Wheels and tyres),
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (MR 412, 55A, Exterior
protection),
-the front bumper (see Front bumper: Removal -
Refitting) (MR 412, 55A, Exterior protection).
aDisconnect the air filter unit air inlet pipe (1) from the
air filter unit cover.
aRemove:
-the air filter unit air inlet pipe bolt (2) from the cross
member,
-the air filter unit air inlet pipe.
aDrain the cooling system (see 19A, Cooling, Cool-
ing system: Draining - Refilling, page 19A-9) .aRemove using the (Mot. 1448) :
-the radiator top hose clip,
-the radiator degassing hose clip.
aDisconnect:
-the radiator top hose,
-the radiator degassing hose.
aUnclip:
-the lower hose from the engine cooling fan assem-
bly,
-the wiring harness from the engine cooling fan as-
sembly.
aDisconnect the engine cooling fan assembly con-
nectors.
II - REMOVAL OPERATION FOR PART
CONCERNED
a
aRemove:
-the radiator mounting cross member (see Radiator
mounting cross member: Removal - Refitting)
(MR 412, 41A, Front lower structure),
-the « radiator / engine cooling fan assembly » unit. Special tooling required
Mot. 1448Remote operation pliers for
hose clips .
122833
Note:
Hold the radiator during the removal of the radia-
tor lo wer cross member.

19A-56
COOLING
Engine cooling fan assembly: Removal - Refitting
K4M
19A
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 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),
-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).
aRemove the air inlet pipe scoop (1) .II - REMOVAL OPERATION
aDisconnect:
-the engine cooling fan assembly resistor connector
(2) ,
-the engine cooling fan assembly connector (3) .
aUnclip:
-the engine cooling fan assembly wiring at (4) ,
-the cooling radiator top and bottom hose from the
engine cooling fan assembly.
aUnclip the engine cooling fan assembly from the ra-
diator at (5) by pushing it upwards to detach the
brackets holding it.
aRemove the engine cooling fan assembly upwards.
REFITTING
I - REFITTING OPERATION
aFit the engine cooling fan assembly:
aClip the engine cooling fan assembly to the cooling
radiator.
aClip:
-the cooling radiator top and bottom hose on the en-
gine cooling fan assembly,
-the engine cooling fan assembly wiring.
aConnect:
-the engine cooling fan assembly connector,
145934
132336

19A-58
COOLING
Coolant pump inlet pipe: Removal - Refitting
K9K
19A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 411, 02A, Lifting equip-
ment).
aDisconnect the battery (see ) (MR 411, 80A, Bat-
tery).
aRemove:
-the engine cover,
-the windscreen wiper arms (see Windscreen wip-
er arm: Removal - Refitting) (MR 411, 85A, Wip-
ers - Washers),
-the scuttle panel grille (see Scuttle panel grille:
Removal - Refitting) (MR 412, 56A, Exterior
equipment),
-the scoop under the scuttle panel grille (see Scoop
under the scuttle panel grille: Removal - Refit-
ting) (MR 412, 56A, Exterior equipment),
-the front wheels (see Wheel: Removal - Refitting)
(MR 411, 35A, Wheels and tyres),
-the front wheel arch liners (see Front wheel arch
liner: Removal - Refitting) (MR 412, 55A, Exterior
protection),
-the front bumper (see Front bumper: Removal -
Refitting) (MR 412, 55A, Exterior protection),
-the headlights (see Halogen headlight: Removal
- Refitting) (MR 411, 80B, Headlights),
-the front upper cross member (see Front upper
cross member: Removal - Refitting) (MR 412,
42A, Upper front structure).
aDrain the cooling system (see 19A, Cooling, Cool-
ing system: Draining - Refilling, page 19A-9) .
aRemove the engine tie-bar (see 19D, Engine
mounting, Lower engine tie-bar: Removal - Refit-
ting, page 19D-18) . Special tooling required
Mot. 1672Low er engine support.
Mot. 1448Remote operation pliers for
hose clips .
Tightening torquesm
subfame front bolt62 Nm
subframe rear bolt105 Nm
IMPORTANT
Consult the safety and cleanliness advice and oper-
ation recommendations before carrying out any
repair (see ) .
IMPORTANT
When working in the engine compartment, take
care as the radiator fan(s) may start up unexpect-
edly (risk of being cut).
To avoid any risk of serious burns when the engine
is hot:
-do not open the expansion bottle cap,
-do not drain the cooling system,
-do not open the bleed screw(s).
WARNING
Before the operation, protect the electrical accesso-
ries to prevent any risk of shor t circuiting and pro-
tect the belts to avoid damaging them.
WARNING
When carr ying out a repair that requires a complete
change, it is essential to flush the circuit with clean
water, blast compressed air through the circuit to
drive out the water, fill and bleed the circuit and
then measure the effective protection.
The cr iteria to be met are:
-protection down to -25˚C ±± ± ±
2 for cold and temper-
ate countries,
-protection down to -40˚C ±± ± ±
2 for "extreme cold"
countries.
WARNING
The coolant helps to keep the engine running prop-
erly (heat exchange).
The system must not operate using pure water.

19A-61
COOLING
Coolant pump inlet pipe: Removal - Refitting
D4F, and 780 or 782
19A
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 ) (80A, Battery).
aRemove the engine undertray.
aDrain the cooling system (see 19A, Cooling, Cool-
ing system: Draining - Refilling, page 19A-9) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aSeparate the clips on the coolant pump inlet pipe
hoses using the tool (Mot. 1448).
aDisconnect the coolant pump inlet pipe hoses.
aRemove:
-the bolts (1) from the coolant pump inlet pipe,
-the coolant pump inlet pipe,-the coolant pump inlet pipe seal.
REFITTING
I - REFITTING PREPARATION OPERATION
aparts always to be replaced: seal between cool-
ant pump inlet pipe and coolant pump.
aUse SURFACE CLEANER (see Vehicle: Parts
and consumables for the repair) (04B, Consum-
ables - Products) to clean the bearing surfaces of
the coolant pump inlet pipe.
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-a new seal on the coolant pump inlet pipe,
-the coolant pump inlet pipe,
-the coolant pump inlet pipe bolts.
aTorque tighten the coolant pump inlet pipe bolts
(10 N.m).
aConnect the hoses to the coolant pump inlet pipe.
aRefit the clips on the coolant pump inlet pipe hoses
using the tool (Mot. 1448).
III - FINAL OPERATION
aFill and bleed the cooling system (see 19A, Cool-
ing, Cooling system: Draining - Refilling, page
19A-9) .
aRefit the engine undertray.
aConnect the battery (see ) (80A, Battery). Special tooling required
Mot. 1448Remote operation pliers for
hose clips .
Tightening torquesm
coolant pump inlet pipe
bolts10 N.m
120956

19A-62
COOLING
Coolant pump inlet pipe: Removal - Refitting
K4M
19A
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 ) (80A, Battery).
aRemove the engine undertray.
aDrain the cooling system (see 19A, Cooling, Cool-
ing system: Draining - Refilling, page 19A-9) .
aRemove:
-the dipstick,
-the bolts (1) from the dipstick guide,
-the dipstick guide.aDisconnect:
-the pinking sensor connector (2) ,
-the oil pressure sensor connector (3) . Special tooling required
Mot. 1448Remote operation pliers for
hose clips .
Tightening torquesm
coolant pump inlet pipe
bolts25 N.m
132368
132374

19A-64
COOLING
Expansion bottle: Removal - Refitting
D4F or D7F or K4M or K9K
19A
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).
aRemove the front engine cover.
aRemove the oil filler neck.II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the bolts (1) from the expansion bottle.
aMove the expansion bottle aside following the ar-
rows (2) and (3) .
aFit the tool (Ms. 583) on the expansion bottle hoses.
aUsing the (Mot. 1448) or (Mot. 1202-01) or (Mot.
1202-02) remove:
-the clip of the expansion bottle top hose,
-the clip of the expansion bottle bottom hose.
aDisconnect:
-the expansion bottle top hose,
-the expansion bottle bottom hose.
aRemove the expansion bottle.
REFITTING
I - REFITTING OPERATION FOR PART
CONCERNED
aConnect:
-the expansion bottle bottom hose,
-the expansion bottle top hose.
aUsing the (Mot. 1448) or (Mot. 1202-01) or (Mot.
1202-02) fit:
-the clip of the expansion bottle bottom hose,
-the clip of the expansion bottle top hose. Special tooling required
Ms. 583Pipe clamps .
Mot. 1448Remote operation pliers for
hose clips .
Mot. 1202-01Clip pliers for hose clips
(large size).
Mot. 1202-02Clip pliers for hose clips
(small size)
K9K
D4F
120514

19A-67
COOLING
Coolant temperature sensor: Removal - Refitting
K9K
19A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 411, 02A, Lifting equip-
ment).
aRemove the front engine cover.
aUnclip the neck on the gearbox.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aDisconnect the coolant temperature sensor connec-
tor.
aRemove:
-the coolant temperature sensor clip,
-the coolant temperature sensor,
-the coolant temperature sensor seal.
REFITTING
I - REFITTING PREPARATIONS OPERATION
a
II - REFITTING OPERATION FOR PART
CONCERNED
aRefit:
-the new seal on the coolant temperature sensor,
-the coolant temperature sensor,
-the coolant temperature sensor clip.
aConnect the coolant temperature sensor connector.
III - FINAL OPERATION.
aClip the channel to the gearbox.
aFill the cooling system (see 19A, Cooling, Cooling
system: Draining - Refilling, page 19A-9) .
aRefit the engine cover. IMPORTANT
When working in the engine compartment, take
care as the radiator fan(s) may start up unexpect-
edly (risk of being cut).
To avoid any risk of serious burns when the engine
is hot:
-do not open the expansion bottle cap,
-do not drain the cooling system,
-do not open the bleed screw(s).
WARNING
Before the operation, protect the electrical accesso-
ries to prevent any risk of shor t circuiting and pro-
tect the belts to avoid damaging them.
WARNING
The coolant helps to keep the engine running prop-
erly (heat exchange).
The system does not operate using pure water.
WARNING
The seals m ust always be replaced.

19A-68
COOLING
Coolant temperature sensor: Removal - Refitting
D4F, and 780
19A
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (MR 411, 02A, Lifting equip-
ment).Tightening torquesm
coolant temperature
sensor23 Nm

19B-12
EXHAUST
Catalytic converter: Removal - Refitting
K9K
19B
PARTS AND CONSUMABLES FOR THE REPAIR
Pièces à remplacer systématiquement :
-air inlet pipe seals,
-the catalytic converter seal on the turbocharger,
-any stud and/or nut on the turbocharger or damaged
catalytic converter,
-The exhaust system sealing ring on the catalytic con-
verter.
Ingrédients :
-ABRASIVE PADS,
-SURFACE CLEANER.
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift ( (see Vehicle:
Towing and lifting) ).
aDisconnect the battery ( (see Battery: Removal -
Refitting) ).
aRemove:
-the windscreen wiper arms ( (see Windscreen
wiper arm: Removal - Refitting) ),
-the scuttle panel grille ( (see Scuttle panel grille:
Removal - Refitting) ),
-the scoop under the scuttle panel grille ( (see
Scoop under the scuttle panel grille: Removal -
Refitting) ),
-the air filter box (see 12A, Fuel mixture, Air filter
unit: Removal - Refitting, page 12A-13) .
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove the catalytic converter bolts (1) on the tur-
bocharger.
aRaise the vehicle.
aRemove the engine tie-bar (see 19D, Engine
mounting, Lower engine tie-bar: Removal - Refit-
ting, page 19D-18) . Tightening torquesm
catalytic converter studs
on the turbocharger9 Nm
catalytic converter nuts
on the turbocharger26 Nm
catalytic converter
upstream strut bolts on
the engine44 Nm
catalytic converter
downstream strut bolts
on the gearbox21 Nm
catalytic converter
downstream strut nut on
the gearbox21 Nm
catalytic converter
upstream strut bolts on
the catalytic converter26 Nm
catalytic converter
downstream strut bolt
on the catalytic con-
verter21 Nm
exhaust pipe bolts on
the catalytic converter21 Nm
IMPORTANT
Consult the safety and cleanliness advice and oper-
ation recommendations before carrying out any
repair (see 19B, Exhaust, Exhaust: Precautions
for the repair, page 19B-8) .
112328

19B-15
EXHAUST
Catalytic converter: Removal - Refitting
D4F, and 772 – D7F
19B
REMOVAL
I - REMOVAL PREPARATION OPERATION
aPosition the vehicle on a two-post lift (see Vehicle:
Towing and lifting) (02A, Lifting equipment).
aDisconnect the downstream oxygen sensor connec-
tor.
aUnclip the wiring harness from the downstream oxy-
gen sensor.
aDisconnect the upstream oxygen sensor connector.
aUnpick the wiring harness from the upstream oxy-
gen sensor.
II - OPERATION FOR REMOVAL OF PART
CONCERNED
aRemove:
-the clip (1) between the catalytic converter and the
intermediate pipe,
-the bolts (2) from the exhaust flange,
-the catalytic converter,
-the exhaust pipe sealing ring on the catalytic con-
verter.
Dismantling the catalytic converter
aUsing the (Mot. 1495-01), remove:
-the downstream oxygen sensor,
-the upstream oxygen sensor.
REFITTING
I - REFITTING PREPARATION OPERATION
Reassembling the catalytic converter
aUsing the (Mot. 1495-01), refit:
-the upstream oxygen sensor,
-the downstream oxygen sensor.
II - REFITTING OPERATION FOR PART
CONCERNED
a
aRefit:
-the catalytic converter,
-the exhaust bracket bolts,
-the clip between the catalytic converter and the in-
termediate pipe.
aTighten:
-the exhaust bracket bolts,
-the clip between the catalytic converter and the in-
termediate pipe.
III - FINAL OPERATION
aClip the upstream oxygen sensor wiring harness into
place.
aConnect the upstream oxygen sensor connector.
aAttach the downstream oxygen sensor wiring har-
ness.
aConnect the downstream oxygen sensor connector. Special tooling required
Mot. 1495-0122 mm socket for removal -
refitting of oxygen sensors.
121731
WARNING
Always replace the sealing ring between the cat-
alytic con verter and the exhaust pipe with a new
component.